Journal of Jilin University(Engineering and Technology Edition) ›› 2022, Vol. 52 ›› Issue (9): 2044-2054.doi: 10.13229/j.cnki.jdxbgxb20220215

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Matching，simulation and optimization for 2.5 ton fuel cell/battery hybrid forklift

Feng-xiang CHEN1(),Qi WU1,Yuan-song LI2,Tian-de MO3,Yu LI3,Li-ping HUANG4,Jian-hong SU4,Wei-dong ZHANG5   

  1. 1.College of Automotive Studies，Tongji University，Shanghai 201804，China
    2.Technical Center，Zhejiang Hangcha Group Co. ，Ltd. ，Hangzhou 311305，China
    3.Smart City Division，Hong Kong Productivity Council，Hong Kong 999077，China
    4.Electric Forklift Research Institute，JAC Heavy-Duty Construction Machine Co. ，Ltd. ，Hefei 230051，China
    5.School of Information and Communication Engineering，Hainan University，Haikou 570228，China
  • Received:2022-03-06 Online:2022-09-01 Published:2022-09-13

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Abstract:

A kind of propulsion system of a 2.5-ton fuel cell hybrid forklift was matched， which mainly consists of a 10 kW fuel cell system and a 25 A·h lithium battery pack （2 kW·h）. And a power following energy management strategy of state recognition was established. The forklift model was created and simulated to verify the system and strategy. The results show that decreasing the keeping state of charge could improve the fuel economy and a reasonable switching state of charge could improve the stability of the system. The rated power of fuel cell system should be at least 15% higher than the average power under working conditions. During the dynamic process of state of charge decline after startup， the large capacity of battery could reduce the average power of the fuel cell system then improve the fuel economy. On the contrary， it wouldn't support the system to work a long time and could lead to an extreme state of charge volatility which would shorten its service life.

Key words: vehicle engineering, fuel cell hybrid forklift, forklift model, energy management strategy, degree of hybridization

CLC Number: 

  • U469.72

Fig.1

Fuel cell hybrid system structure"

Fig.2

Fuel cell hybrid forklift structure"

Table 1

Target parameters of fuel cell hybrid forklift"

参数单位数值
自重kg4100
额定载荷kg2500
起升高度mm3000
最大行驶速度km/h13
最大起升速度mm/s280
最大下降速度mm/s430
最大爬坡能力%15

Table 2

Basic parameters of fuel cell system"

参数单位数值
额定功率kW10
输出电压V30~52
最高效率%59
环境温度℃-30~55

Fig.3

Assembly model of fuel cell hybrid system"

Fig.4

Polarization curve"

Fig.5

Power and efficiency of fuel cell system"

Fig.6

First-order Li-Ion battery cell model"

Fig.7

Working mode recognition"

Fig.8

Power following control strategy"

Fig.9

Test cycle path"

Fig.10

Forklift moving and working velocity"

Fig.11

Changes of SOC under different SOCinitial"

Fig.12

Power demand and distribution offorklift under SOCinitial=0.8"

Fig.13

Changes of SOC under different SOCopt"

Table 3

Performances of working 3600 s under different SOCopt"

性能指标SOCopt
0.70.60.5
燃料电池系统平均效率/%54.7855.1155.44
耗氢量/g379.34364.26349.78
总等效耗氢量/g380.50375.03371.95
燃料电池系统平均功率/W6533.906304.106075.30
锂电池组平均功率/W-19.80186.40385.10

Fig.14

Changes of SOC under different SOCset"

Table 4

Performances of working 1500 s under different SOCset"

性能指标SOCset
0.80.70.6
燃料电池系统平均效率/%56.0456.0356.02
耗氢量/g133.99134.04134.13
总等效耗氢量/g152.12152.19152.25
燃料电池系统平均功率/W5651.705658.705661.60
锂电池组平均功率/W766.30765.90763.50

Fig.15

Changes of SOC under differentFCS rated power"

Fig.16

Changes of SOC under different battery capacity"

Fig.17

Changes of volatility and total equivalent consumption under different battery capacity"

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