Author Topic: Focus on hydrogen at '07 SW  (Read 4387 times)

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Offline RidgeRunner

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Focus on hydrogen at '07 SW
« on: September 29, 2007, 11:18:52 AM »
Rick,

     Often it is not only what, but how something is accomplished.  Congratulations to you and your team on both components of your efforts at '07 SW.

     Having been unable to attend in person, I would be interested in reading anything you can post on this project.

                                     Ed Purinton

     

Offline Rick Byrnes

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Re: Focus on hydrogen at '07 SW
« Reply #1 on: September 29, 2007, 07:30:50 PM »
OK Ed here goes.
But, to understand how I feel about a lot of things, I retired from Ford in 2000 after more than 32 years of engineering work, all in Powertrain, mostly engine component design.  I was born with a Ford crest in my forehead and after this recent program feel even more strongly about Ford Motor Co., SO my views may be swayed just a little.

The Fusion 999 (car number borrowed from Sam Wheeler) is an electric car with a single motor (same design as OSU), driving the rear wheels.  The car carries no batteries and gets power from a fuel cell "engine" powered by Hydrogen.  We also chose to use compressed gas rather than a typical air compressor that fuel cell test cars use because of the cell stacks suseptability to contamination of salt air.  We used a 40% O2 with the remainder helium.  The oxydizer is contained in two tanks that are in the rear of the car, and Hydrogen is contained in one tank just behind the firewall.  If I remember correctly only 2 Kg of Hydrogen is used in each pass.

It is a production based car in that it uses Ford Fusion sheet metal in all the correct relationships, but is truly a full boogie race car.   Since the car would be running for time only, a "radiator in a bathtub" was used that at first calculation required 400 pounds of ice per run.  Actually I think we ended up using less.

The design began in February 06, and build actually began in Feb 07 just before I joined the program.  Many things were changed from the original design as the build progressed. It seemed to take forever.  The car seems very complex, but is pretty much layers of simple systems.  All except the Fuel Cell tray.  It is still PFM to me...

Essentially, the fuel cell stacks make DC current which goes thru an inverter/controller to the AC motor.   The power exceeded 400 KW later in the week and with each pass the power got better.  It seems that the power production happens in an aqueous environment, meaning that each fuel cell membrane needs to be saturated with water.  The effencientcy of each membrane is a function of how well hydrated it is and the scientist responsible for this was getting really smart really quickly.  (racing improves the breed).  The stacks were hydrated better each time right after a run and power just kept going up to a point we had to limit for fear of failing other electrical components.  We did not know the limits and still don't untile further testing is done.
These stacks were old technology that has been around for several years and was used in the Focus test fleet.  The OSU stacks are different and more powerfull.

More tomorrow if anyone is interested.

Rick
 

Rick

Offline Rick Byrnes

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Re: Focus on hydrogen at '07 SW
« Reply #2 on: September 29, 2007, 07:43:36 PM »
Photos that I should have sent with first post.

Photo credits to Pork Pie
Rick

Offline Peter Jack

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Re: Focus on hydrogen at '07 SW
« Reply #3 on: September 29, 2007, 07:45:29 PM »
Hey Rick!

I've always been a Chevy and GM guy, but this sort of technology transcends those boundrys that we've all set up and should be very interesting to all. Keep up with the write up. I'm looking forward to the full meal deal.

Thanks,
Pete
« Last Edit: September 29, 2007, 09:07:07 PM by Peter Jack »

Offline Stainless1

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Re: Focus on hydrogen at '07 SW
« Reply #4 on: September 29, 2007, 08:52:49 PM »
Wow, I sure am glad you guys didn't blow up the salt flats with your Hydrogen Bomb...  :roll:

When Ben Jordan ran hydrogen in 1981, we didn't have an escort service or quarentine, there was a traveling trophy for fastest hydrogen powered vehicle up till about 5 years ago when it was made very difficult to run hydrogen at speedweek.  I think Clemson has it now.

Again, great job and thanks for not killing us all and destroying the salt flats forever with your obviously highly dangerous vehicle  :roll:  :roll:  :roll:  :roll:  :roll:
Stainless
Red Hat 228.039, 2001, 65ci, Bockscar Lakester #1000 with a little N2O

Offline RidgeRunner

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Re: Focus on hydrogen at '07 SW
« Reply #5 on: September 29, 2007, 10:14:22 PM »
     Thank you, all very interesting.

     Nice to hear that racing, particularly LSR, still has a place in truly improving the breed.

     Good to see an American corporation investing in innovation with a class scientific approach rather than a throw the buck$ circu$ act.

     More information always welcome whenever you get the chance.

                            Ed

Offline PorkPie

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Re: Focus on hydrogen at '07 SW
« Reply #6 on: September 30, 2007, 01:42:53 AM »
Rick,

during the time I checked my picture for for the Speedweek article I collect a set of picture for you, which I cleaned up and prepared (correcting the light/trim) to improve the quality - it will be send from Wendover on another CD-ROM to you - so please wait if you like to make prints for friends and family.

And by the way, thanks that you took care that I got a wonderful welcome in the Ford pits.
Pork Pie

Photoartist & Historian & 200 MPH Club Member (I/GL 202.8 mph in the orig. Bockscar #1000)

Offline Rex Schimmer

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Re: Focus on hydrogen at '07 SW
« Reply #7 on: September 30, 2007, 10:51:37 AM »
Comment from the peanut gallery. That car was STUFFED full of machinery and electronics!! There was just barely room for the driver. If you happen to see the high pressure tank truck parked out (a long way out!)by itself that was the O2 truck that carried the Ox and the He for the fuel cell. Neat to see Ford doing something like this but I won't be in line to try to get one.

Is the Ohio State streamliner going to be at the salt next week?

Rex
Rex

Not much matters and the rest doesn't matter at all.

Offline Rick Byrnes

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Re: Focus on hydrogen at '07 SW
« Reply #8 on: September 30, 2007, 03:15:14 PM »
Yes Rex, OSU should be on the way now.  Last report I got was they had everything buttoned back up with LOTS of upgrades since SpeedWeek.  They should be quite well prepared.
Ford is still involved with them and several of the 999 team will be on hand for support at WF.  (sorry I wont be there).
I sure hope they do well

Relative to safety with H2 fuel and/or with an oxydizer (although 40% O2 will not make everything organic burn)
You guys are right.  The car was stuffed right up to the roof, and interestingly enough it was designed around MY fat little body :=d.  I came on board in March, and the Roush race shop in Livonia was just laying out the rectangular tube frame rails.  They basically mocked up the motor, and all tanks and built the rest around me.  Because the fuel cell tray is under the car, I sit about 10" higher than production and lay back at 30 degrees in a full containment Butler seat.  All the controls were set for my weird little body and not too many other people will fit.  If I can get photos of the fuel cell tray, I'll publish, because it is an absolute work of art.  Plumbing that just makes my heart grow weak.

I began this program with lots of reservations about H2 fuel and a high pressure oxydizer on board, but as the Ford guys helped me understand the safety record, and the discipline they have built into their organization I grew more comfortable.  Not totally relaxed mind you, but not much different than if I had 15 gallons of nitro sitting behind me.  Besides that, the H2 tank is incredibaly strong.  A pressure vessle 2" thick then wound with carbon fiber strand another 2" thick.  It is vitrually bullet proof, and has been tested to failure, and is DOT approved. (although that doesn't mean much to a 200 MPH+ crash).   Also the amount of H2 carried on board if let free due to a failure of the tank would burn for only 38 seconds.  I realize it could be disastrous for the driver, but the event would be over by the time any safety workers could get near the car.
Ford had a number of hydrogen sensors on board, set at a very sensitive level that would shut down all systems before a concentration to support combustion would be possible.  In fact one of our aborted runs was a contamination of underbody air to a point that it triggered and shut us down.  Since flames of H2 are not visable, and UV/IR sensors are notoriously unreliable, we chose a smoke sensor wired to automatically trigger a 1301 halon system in the back of the car.  Bob Stroud, who now owns Phoneix Fire systems supplied the first parts and we are now working out details.  I don't know if he will market this, but I will have it on the liner wannabe before next Speedweek.

Segregation of Ford and the fuel supplies from the rest of the pits is understandable because most racers and SCTA are not used to high pressure gasses.  I worry more when I see how Nitrous Oxide and/or propane bottles are handled by many people.
Not much difference when you think about it.
I  know there is a pressure diffenrence but the point is that reasonable care can do wonders in the safety department.
OH, the H2 tank has also an internal shut off valve that senses a change in the pressure differential and will automaticall shut off at the tank outlet, so other than a complete rupture, there would be very little H2 to burn.

OK time for the shop now.
More when someone asks?????

Rick
Rick