Fuel Cell Technologyat MAHLE
IAA Transportation 2022

Project House Fuel Cell

Fuel Cell System Approach
VehiclePeripherals

Air Management
SystemApproachCharge
Air Cooler System simulation& architecture

El. Fan FuelCell test rig
Air Filter

Humidifier

CoolingModule BALLARD AllianceElectronics

ThermalManagement

Coolant Pump
12V | 24V | 48V | 800V

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Fuel Cell Converter

MAHLE provides the full portfolio of BoP components
embedded in a strong system approachDevelopment Competences3|

Project House Fuel Cell

Interlinked disciplines ofdevelopment

Our development teams cover the full bandwidth of requireddisciplines from early concept to the final optimization

System Engineering and Simulation

Concept, Design and Thermal
Simulation of Electronics

Full Air path CFD Analysis andoptimization

Flow field & performance
optimization on module level▪ State of the art HW design tools withcircuit verification and design rulechecks▪ State of the art simulation tools forelectrical, magnetic, thermal anmechanical simulation▪ Rapid prototyping environment for
design verification (MABX, P-HiL, SHiL)▪ Advanced aero- and thermodynamic
simulation (pressure drops, flow fieldanalysis)▪ Water Separation: detailed simulation
facilitate geometry optimization toachieve best water separation
efficiency▪

▪ Full functional system simulation(digital twin)▪ Full system architecture, design andoptimization

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Advanced aero- andthermodynamic simulation
Airflow evaluation and/or validation
including heat rejection calculationfor each heat exchanger
Advanced aeroacoustics simulation(for modules)
Geometry optimization of ducts andsupporting geometry

MAHLE testbench
for Fuel Cell Stacks
and BOP components.
−−−−

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up to 250kW
highest safety standards
media conditioning
seamless hydrogen supply

MAHLE Fuel Cell Components

6|Fuel Cell Air Management

Air Path System

The integrated cathode module provides the full air conditioning
The sub module contains the following products▪ Charge Air Cooler▪ Humidifier▪ Water Separation▪ Air Flap Valves
The first available unit is designed for a module of about 120kW.
Further variants will follow.
Prototypes available from Q4/2022

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Fuel Cell Air Management

Charge Air Cooler

Compact heat exchanger to reduce compressed air temperature▪ Scalable design ensures perfect ﬁt from LV to HD application.
▪ Mature product based on technology already proven on light vehicle
fuel cell applications▪ Cost efﬁcient design thanks to synergies with high volume charge aircooler applications▪ Patented passivation process to meet stringent fuel cell conductivity
requirements▪ Parts available, full validation for HD applications in 2021

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Fuel Cell Air Management

Flat Membrane Humidiﬁer
Humidiﬁer with ﬂat membranes for high performance andextended durability▪ Using the humidity of the exhaust gas to protect the fuel cell stackfrom dry-out▪ Stack of ﬂat semi-permeable membranes▪ Plastic housing with integrated functions (e.g. charge air cooler)▪ Small package and low cost due to ﬂat membrane concept▪ Improved robustness compared to hollow ﬁbers▪ High temperature range (90…120 °C)▪ Higher humidiﬁcation efﬁciency

9|Fuel Cell Air Management

Air Filter
Harmful gas absorption (NOX SO2 NH3 H2S HC)▪ High fractional ﬁltration efﬁciencies for dust, soot and salt
▪ ‘Off-the-shelf’ solutions for stack size from 25 kW to 375 kW▪ Filter housing in high volume production▪ Protection and lifetime extension of the fuel cell stack▪ High particle separation efﬁciency of > 99.9%▪ Up to 45 g - SO2, 40 g - NH3 and 16 g - NOX adsorption capacity▪ Robust product concept by using proven ﬁltration materials▪ Service lifetime of 40.000km and above.

10 |Electronics

Fuel Cell Converter
The fuel cell converter ensures a constant voltage leveltowards the vehicle HV net up to 180 kW▪ 180 kW non galvanic isolated DC/DC-Converter▪ Boost operation (Buck optional)▪ Input current control with input and output voltage limitation▪ Input voltage range: 50 - 515 V▪ Output voltage range: 520 - 850 V▪ Max. input current 600 A (scalable in 200A steps)▪ SiC MOSFET semiconductors for a high system efficiency >97 %▪ Integration of additional components possible, e.g. contactors, …
▪ High power density of 6.5 kW/l
▪ ASIL-capable µC to ensure functional Safety accoring ISO 26262▪ Low input ripple due to multiphase design▪ Power electronics functionality proven on testbench▪ First prototypes for customer testing in Q1/2022

11 |Thermal Management

Coolant Pump High Voltage
A coolant pump for medium and heavy duty vehicle applications▪ Voltage range up to 850V, Electric Power 1,0 - 2,5 kW▪ Volume flow 300 l/min @ 2.5 bar delta pressure▪ Lifetime 40.000 h / 1.2mil km mileage▪ Low ion emission materials▪ Sensorless control algorithm▪ ASIL B level on rpm (medium flow)▪ CAN J1939 (optional LIN)
▪ Diagnostic functions / fault detection capability▪ Functional samples from Q3/22▪ SOP 2026

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Thermal Management

Coolant Pump Low Voltage
A coolant pump for medium and heavy duty vehicle applications▪ Modular design (12V / 24V / 48V) with wet runner concept▪ Flow of 7 lpm to 250 lpm (by-pass possible)▪ Up to 650 / 850 / 1200W el. and 6250 rpm▪ Fluid: Ethylene Glycol▪ Pump Efficiency > 50% across wide working point range▪ Temperature Fluid: -40 to +115°C Ambient: -40 to +100°C▪ Noise <80 dB (A)▪ Lifetime >45k hours▪ Pump Weight <2,5kg▪ Communication Protocol: LIN, PWM and CAN▪ SOP: Q4/2023

13 |Hydrogen Path

Coolant-to-Coolant Heat Exchanger
Description▪ High performance coolant to coolant heat exchanger for Fuel Cellcircuit▪ Enables separation of Fuel Cell (high cleanliness requirement) fromthe rest of the cooling circuit▪ Extended portfolio to fit to Fuel Cell cooling requirements: big platefor Stack indirect cooling, medium plate for brake resistor andretarder coolingBenefits▪ Reduced need for passivation of components of the cooling circuit▪ Improved fuel cell protection▪ Enable cooling synergies on HT-Loop

14 |Class-leading high pressure hydrogen
vessels for hydrogen powered vehicle
applications

Related Vehicle Components

Cooling Module
Complete cooling modules will provide thermal stabilityto FC Systems up to heavy duty sizes▪ High maturity level through use of ICE-proven design andcomponents▪ Easy to integrate into existing vehicle architecture▪ 3 Layer Cooling Module to cool fuel cell stack, E-Powertrain andbrake retarder▪ Based on existing series components▪ Fuel Cell radiator passivated to achieve coolant conductivity
requirements▪ Specific application for FCEV

15 |Related Vehicle Components

Electrical Fans
Description▪ 5…10…15kW E-fan Family▪ 800V Fan drive with integrated inverter▪ Can be arranged in single fan or dual fan configuration -> up to30kWBenefits▪ High performance▪ Compact packaging with integrated inverter
Milestones (10kW motor)▪ First customer samples: Q1-2022▪ First SOP: Q1-2024

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