HyCar - Switzerlands's first Fuel Cell Vehicle, 2002

Zero emissions, fuel cell, hydrogen. Terms which are currently hotly discussed in relation to sustainable mobility.

While a development project, ESORO dealt in-depth with specific implementation of various ideas. The result was the HyCar, a fully operable concept vehicle with fuel cell drive train and battery in a hybrid configuration. With its top speed of 120 km/h and range of approx. 360 km, the HyCar is more than a match for traffic – and is almost silent. The HyCar is fueled with gaseous hydrogen and the only “waste gas” produced is water vapor.

HyCar is a fully functional concept car – Driven by a fuel cell system and a battery in hybrid configuration. The entire project was realized by ESORO from first concepts to the operating vehicle, evaluation of the components, simulation, virtual mock-up, system integration, design of the control system, stationary and mobile testing etc. Hycar is used for know-how generation and demonstrates the possibilities of this promising technology.

Technical Specifications:

Speed: 120 km/h
Range: approx. 360 km
curb weight: 1160 kg
Fuel cell system: 5 kW at > 40% efficiency
Tank: 80 kWh hydrogen
Battery: 23 kWh NaNiCl
Engine: 35 kW asynchronous with 90 Nm
Transmission ratio: 10:1

Special

The fuel cell system is accommodated beneath the glass load floor in the HyCar’s tail. This allows a view of this novel drive technology.

The front number plate conceals a conventional 230 V socket outlet. This means that the HyCar doubles up as a mobile energy source for DIY enthusiasts or for leisure activities.

The fuel cell system

The fuel cell system was the actual focus of the project. ESORO developed the entire system around a bought-in fuel cell stack. This included the entire conception, evaluation of the various components and dimensioning them, system integration in the vehicle, development of the monitoring and control system for fully automatic operation and, finally, implementation and testing of the system.

Drive train

The above illustration shows the arrangement of the various subsystems in the HyCar. The fuel cell system is accommodated in the rear beneath a viewing panel. The two hydrogen accumulators are accommodated in the rear section of the passenger cell, fully encapsulated from the rest of the vehicle. The battery for the hybrid drive train of the HyCar is accommodated beneath the seats. The electric motor drives the front wheels and lies centrally between them. The radiator for the fuel cell system is arranged conventionally in the front section of the vehicle.

Hydrogen accumulators

The HyCar is operated with gaseous hydrogen. This hydrogen is stored in two high-pressure tanks at a pressure of 200 bar. Each tank features a gastight interior tank made of aluminum which is wound with carbon fibres and weighs 32 kg. This means that 76 liters of hydrogen can be stored per tank. The vehicle is refuelled using the HyStation for instance, and the refueling operation is thus as safe and convenient as on a conventional vehicle.