Hybrid Electric Golf Car

Sponsor: Challenge X/GREATT, Dr. Daniel Haworth

Course: ME415 Spring 2005

Instructor: Prof. Gary Neal

Team Members: Neil Godbout, Greg Lacock, Dave May, Ray Rutkowski, Vern Trageser

Objective:

Three electric golf cars have been recently donated to the Penn State Graduate Research and Education in Advanced Transportation Technology (GREATT) Project and the Challenge X Advanced Vehicle Technology Competition Team.  One of these is to be converted into a hybrid-electric vehicle that can be used for outreach and public relations activities.

The main objective of this project is to convert the powering of an electric golf car into one that uses batteries and a fuel cell, rather than just batteries.  The car will also be decorated in a manner that will attract attention in an effort to gain interest in fuel cell technology.  This way, the car can be used to demonstrate how a fuel cell works.

Requirements:

• Golf Car must showcase power of hydrogen fuel cell

• Fuel cell unit must be removable

• Fuel cell unit must be visible to onlookers, yet completely protected

Deliverables:

• Fuel cell housing

  • 0.25” coated Polycarbonate Housing with 6061 angle Al structure

• Sled removal system (SRS)

  • 0.75” 6061 Al square tubing sled with fixed caster wheels

• NiMH batteries with liquid cooling system
  • Heat Exchanger
  • 1.5 GPM FLOJET Diaphragm Pump

  • Coolant Reservoir

• Hydrogen and Fuel Cell System
  • 1.2kW Ballard NEXA Power Module
  • Size 10 Hydrogen Tank with 99.999% Purity

  • DC/DC Voltage Regulator

Finished Product:

• The SRS satisfies our sponsor’s request to mount the fuel cell on the vehicle in a manner which displays the technology

  • Also: removable and roomy enough to be upgraded with a larger tank

• All construction and fabrication is structurally sound and designed for long-term use

• The new batteries are mounted in the same trays as the original batteries, and are lighter in weight by 216 lbs.
  • Batteries have been cycled and tested

  • Cooling system designed and installed to satisfy the cooling needs of the batteries

• All of the electrical work was designed under supervision of an instructor and tested with the fuel cell

• The car has been given a fresh, attention-grabbing paint job

• All aspects of design and manufacture were performed by the students in the group

Recommendations:

• Solenoid shut off valve for hydrogen tank, to safeguard against forgetfulness

• Heat sink for pump

• Thermistor control switch for pump (would keep the pump on standby until necessary)

• DOT/SAE rated carbon fiber hydrogen tank (safety)

• Bring golf car up to spec for trips to a hydrogen fueling station in the future

HEV Solutions is:

Neil Godbout

Greg Lacock

Dave May

Ray Rutkowski

Vern Trageser

Links/Resources:

http://www.ballard.com/ - Ballard Website, contains information about the NEXA Power Module used in the project

http://www.clubcar.com/ - Club Car Website, has many pictures and specifications for their products

http://www2.mne.psu.edu/futuretruck/ - PSU Challenge X Website

http://www.challengex.org/ - Challenge X Website, explains the program and its mission in greater detail