The concept is to take a Zero Motorcycle preferably the Zero S 2013 model and add a Hydrogen Fuel Cell from Horizon Fuel Cell and extend the range of the motorcycle. How much is anybody’s guess but I’m thinking that it depends on the fuel cell wattage as well as how much hydrogen you can store on the motorcycle. Since a fuel cell is not limit like a battery to its charge but by the supply of hydrogen it can theoretically supply the necessary power indefinitely. But the fuel cell cannot output the high currents needed (unless it is a very large fuel cell) for the motor thus a hybrid of battery/fuel cell is an ideal solution. I don’t have the motorcycle or the fuel cell yet I just would like an idea of how to proceed so I’m confident that I have the right parts. Also since the fuel cell and the motorcycle cost a lot I will have to get the setup in pieces.
The initial approach was to add the fuel cell on the motorcycle and charge while it was parked but thinking about it a little I came to the conclusion that that is no different than charging at a wall outlet, so charging on the go should be used, more on that later.
Horizon offers a 1000W and a 3000W that would go well with the motorcycle being light weight fuel cells (11lbs and 45lbs w/o the hydrogen storage, valves and tubing). The 1000W is a model H1000XP
http://www.horizonfuelcell.com/usermanual/h-series/h-1000.pdf#!h-series-10w-5kw/c1cb8 used in SHELL Eco-marathon competition for lightweight and high efficiently, it should output about 100VDC@10A about the same as the on-board charger of the Zero S 2013 model. The 3000W is a model H3000 “Autopak"
http://www.horizonfuelcell.com/usermanual/h-series/h-1000.pdf#!autopak-/cpor used in trial runs on small two door vehicles in UK with the added benefit of nitrogen purging that should extend the lifetime of the fuel cell by 2 to 3 times according to Horizon/Arcola. Similarly the H3000 should output about 100VDC@30A which would give a higher charge rate but also increase the weight about 35lbs. Both of these fuel cells come with a DC/DC converter that will output 100VDC regardless of the output of the fuel cells and also about 90% efficient converter.
Here comes the tinkering/assumptions and suggestions are more than welcome. As far as I can see the integration of the fuel cells on the on the motorcycle will require mounting of the fuel cell stack and its components on the motorcycle and the electrical interface to the battery pack. There is also the required 12VDC power supply for the fuel cell controls but I’m assuming that is an easy fix by tapping into the 12VDC source of the motorcycle.
There should be enough room to mount the fuel cell stack in the “gas tank†or maybe further modification is required to fit the fuel cell there. The hydrogen tank can sit behind the rider on a rack. I’m planning on using a metal hydride storage tank
http://www.hydrogencomponents.com/BL-740.htm that measures about 5 inches in diameter and 8 inches in length about 12lb. That leaves the two other main components which are the DC/DC converter and the stack controller/command module, hopefully there is enough area around the gas tank to the seat to the battery pack, and this should also be the area to mount the hydrogen tubing and valves. The fuel cell needs to breath to convert the hydrogen to electricity so a mesh might have to be used in the gas tank area. These are the places I’m thinking of but suggestions are welcomed.
The big unknown for me is how to work the output of the fuel cell to battery interface. According to Horizon/Arcola I can customize the output voltage of the DC/DC converter I think close to 100VDC is what they can do maybe more if you order custom. What is the charging voltage for the 2013 Zero S? If the motorcycle is in operation (moving) and the fuel cell is connected will it charge or is there a way to fool the BMS into charging even if it is being used? I know from the manual and reading on the forum that the motorcycle has safety features and interlocks I need to know and understand these so that maybe there is a way to “keep†them but also charge the battery with the fuel cell while the motorcycle is in operation. According to the 2013 owner's manual page 6.11 the BMS communicates with the charger to stop charging is this true? I always thought the BMS just disconnects its main contacts??
I believe the beauty of the system (fuel cell and battery) is that it is almost plug and play if you can call it that. The fuel cell to battery interface is where it gets interesting.
Once again any suggestions/comments are more than welcome.
