Hochschule Esslingen - Hydrosmart. Presentation held by Prof. Dr. on October 26th, 2011 at the E-Mobility Symposium organized by the German State of Baden-Wuerttemberg at the W-Hotel in Los Angeles.

1. Project: Hydro smart
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 1

2. Project: Hydro smart
IBZ - Overview of past projects
Projects 2003-2011
- Fuel Cell Test Bench 2kW
- Natural Gas Reformer
- Methanol Reformer
- Fuel Cell Air Conditioning System
- Portable Hybrid Fuel Cell Systems
- Electric Two Wheelers
- “Hydrofight“ Fuel Cell Scooter
- “Simson“ Experimental Fuel Cell Trike
- “Hydrotrailer“ Fuel Cell Range Extender
- “Hysun3000“ World Record Vehicle
- “Elektro Seven“ Electric Sports Car
- “F-Cell Roadster“ Daimler Design Study
- “Hydrosmart“ Fuel Cell Hybrid City Car
- “Hydroboat“ Fuel Cell Hybrid Boat
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 2

3. Project: Hydro smart
Hydrogen Powered Electric Plug-in Hybrid Car
A University Project - Sponsored by Daimler
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 3

4. Project: Hydro smart
Schematic interconnection between all components
H2 39L/350bar Touch LCD Smart CPU ITX PC PC Display
FC 48V/2,5kW FC CPU Charger 3kW CAN CPU
DC-DC 360V Bat 20kWh DMC 100kW HSM 70kW 2.Gear 1:8,4
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 4

5. Project: Hydro smart
Packaging – Fuel cell stack
n Fuel Cell
Ballard Mark 1020
n Power: 2,5 kW
n Air cooled system
n Positioned in front
of cooler
n Air cooling
supplied by fan
(not on the picture)
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 5

6. Project: Hydro smart
Packaging – Fuel cell system
n Fuel Cell
Ballard Mark 1020
n Power: 2,5 kW
n Air cooled system
n Positioned in front
of cooler
n Air cooling
supplied by fan
(not on the picture)
frame fuel cell filter grill
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 6

7. Project: Hydro smart
Packaging – Hydrogen supply system
n Hydrogen storage:
F-Cell Bottle from A-Klasse
(350bar / 297 mm dia)
n Modifications of the underfloor
and rear axle
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 7

8. Project: Hydro smart
Packaging – Interior
n Touchscreen-
Display [1]
(System-
display)
2
n Car-PC [2]
(Measuring
system and
CAN-Bus) 1
n On bord 3
Battery-
charger [3]
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 8

9. Project: Hydro smart
Packaging – Electric drive system
n Original gearbox
(fixed 2. gear
1:8,4)
n Brusa Motor 70kW
HSM 6.17.12
n Adaptor plate
n Engine mounting
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 9

10. Project: Hydro smart
Packaging – Battery System
n Battery system :
704 Li-Po Cells
n Capacity: 20 kWh
n Voltage (nom.): 320 V
n Current (max.): 300 A (10s)
n Total weight: 135 Kg
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 10

11. Project: Hydro smart
Packaging – whole underfloor design
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 11

12. Project: Hydro smart
Comparison – Smart production car and Hydro smart
Smart Pulse Hydro Smart
- Engine 3-cyl. 4-Stroke - E-Motor Brusa HSM 6.17.12
999 ccm water cooled water cooled
- Torque 92 Nm - Torque >200 Nm
- Total weight ca. 860 kg - Total weight ca. 960 kg
- Top speed 130km/h - Top speed 130km/h (limited)
- Price 11.440 EURO - Price 100.000 EURO
(listed dealer price) (prototype)
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 12

13. Project: Hydro smart
Participation Challenge Bibendum 2010 in Rio de Janeiro
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 13

14. Project: Hydro smart
Challenge Bibendum 2010 in Rio de Janeiro
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 14

15. Project: Hydro smart
Impressions - Challenge Bibendum 2010 in Rio de Janeiro
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 15

16. Project: Hydro smart
Impressions - Challenge Bibendum 2010 in Rio de Janeiro
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 16

17. Project: Hydro smart
Challenge Bibendum 2010 – Award Ceremony
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 17

18. Project: Hydro smart
Awards for the Hochschule Esslingen
1.Place – winner of the rally
1.Place – best acceleration
1.Place – best handling
1.Place – best CO2-emission
Special Design Award
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 18

19. Project: Hydro smart
Impressions - Challenge Bibendum 2010 in Rio de Janeiro
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 19

20. Project: Hydro smart
Impressions - Challenge Bibendum 2010 in Rio de Janeiro
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 20

21. Project: Hydro smart
We want to thank our sponsors ….
www.ibz-es.de
www.hs-esslingen.de
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 21

22. Project: Hydro smart
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 22

23. Project: Hydro smart
Tourism at Lake Constance
The Idea: Tourism at the Lake Constance without emissions
The Urban Buggy is a project of the Fuel Cell Institute at
the University of Applied Science Esslingen. The idea was
to build an electric powered buggy for the region of Lake
Constance to show up electric vehicles in a touristic
surrounding.
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 23

24. Project: Hydro smart
Overview conventional buggys
Price > 10.000.- Price ~ 18.000.-
cost 2.790.- 3.999.- 5.399.- 3.999.- ?
performance 10,5 kW 13 kW 12,4 kW 8 kW 8 kW
weight 385 kg 290 kg 318 kg ? 230 kg
manufacturer Kinroad Epella PGO PGO Tank
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 24

25. Project: Hydro smart
System Components
Fuel Cell
2-3 kW
Hydrogen Tank
350 bar
Electric-Motor
10 kW
Battery
8 kWh
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 25

26. Project: Hydro smart
System-Integration
Electr. storage Energy-Management
(Hybrid-System)
Individual
packaging for
chosen basic model
H2 - storage Fuel cell Electric buggy
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 26

27. Project: Hydro smart
Packaging Investigation
Hydrogen tank
Charger
Battery
Fuel Cell
Battery management system
E-motor
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 27

28. Project: Hydro smart
Conversion
Combustion
Engine
Electric Motor
CVT-Gearbox
Inverter
Fuel-Tank
Battery
Oil-Tank
E-Gas
Radiator
Exhaust
Catalyst
Removal Integration
The integration of the Fuel Cell System will be done in near future.
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 28

29. Project: Hydro smart
Comparison – Eppella 250 II vs. Urban Buggy
Eppella 250 II Urban Buggy
- Engine 1-Zyl. 4-stroke 250 ccm - E-Motor Perm PMS 156
water-cooled air-cooled
- Power 13 kW - Power 14,5 kW
- Torque 17 Nm - Torque 23 Nm (60 Nm peak)
- Fuel tank 10l Super - Battery 5,6 kWh
- Weight ~ 300 kg - Weight ~ 320 kg
- Top speed 75 km/h - Top speed 95 km/h
- Price 5.129.- EURO - Price Prototype ~ 20.000.- EURO
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 29

30. Project: Hydro smart
Challenge Bibendum Berlin 2011
3.Place – Rally
Innercity Quadricycles
1.Place – Best Acceleration
Innercity Quadricycles
CO2 Emissions Award
Lokal Zero Emissions Award
Award Ceremony with Klaus Wowereit (Major
of Berlin)
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 30

31. Project: Hydro smart
Vision
the Vision: tourism with no emission
• rental stations and tours
• fast change batterie for shorter standing time
Thank you very much
• eco-friendly and near to nature
for you attention!
• quiet and emissionfree
Prof. Dr.-Ing. Hugo Gabele www. ibz-es.de 31