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DaimlerChrysler NECAR 5 and Commander 2

DaimlerChrysler recently introduced two new prototype fuel-cell vehicles - the NECAR 5 (fifth-generation New Electric CAR), which is based on the Mercedes-Benz A-Class car, and the Jeep Commander 2 SUV. Both concept vehicles generate hydrogen fuel onboard by reforming methanol. Company engineers characterize the status of the company's current fuel-cell drive technology as "fit for practical use". In the past six years, the clean drive system has been shrunk sufficiently, so that it requires no more space than a conventional drive system.

The NECAR 5's design, which features a Ballard Mark 900 fuel-cell unit and a methanol reformer that runs at 280°C (535°F), is focused on improving packaging, according to Christian Mohrdieck, Senior Manager for Fuel-cell Systems at Liberty and Technical Affairs. In the NECAR 5, the entire fuel-cell system with methanol reformer has been accommodated within the underbody of a Mercedes-Benz A-Class model. That makes the available space comparable to a standard A-Class vehicle. At the same time, the fuel cell's weight has been substantially reduced. In addition, the efficiency of the fuel-cell system has been increased by 50% over the company's previous fuel-cell test vehicle.

The Jeep Commander 2 likewise operates on a fuel cell fueled by hydrogen generated from methanol in a reformer. Peak power output is supplemented by a battery. The SUV demonstrates that the use of fuel cells is by no means limited to compact vehicles.

The Jeep's hybrid-electric powertrain combines the fuel-cell stack with dual front and rear ас-induction electric motors that provide full-time, four-wheel drive. A 90-kW nickel/metal-hydride battery pack is included to provide a power assist boost for acceleration and towing heavy payloads, faster fuel-cell warm-up, and regenerative brakes capture energy normally lost upon stopping. Mohrdieck noted the battery contributes 300 V of current for these purposes for only 18 s at a time. Commander 2, which can go from 0 to 97 km/h (0 to 60 mph) in 12s, produces near-zero tailpipe emissions and gets 24 mpg (gasoline equivalent) in combined-cycle driving tests.

To compensate for the additional weight and cost of the fuel cell and battery system, Jeep designers incorporated DaimlerChrysler's light-weight injection-molded thermoplastic polymer body technology. Because of its low-mass body, the Commander 2 scales 2590 kg (5715 lb)- slightly more than typical full-size SUVs. This includes more than 1100 kg (2500 lb) for the hybrid-electric fuel-cell powertrain, which is 500 kg (1100 lb) more than a standard IС engine.

For the California Fuel Cell Partnership demonstration program, DaimlerChrysler introduced the California NECAR, or NECAR 4A. Unlike 1999's liquid-hydrogen-fueled NECAR 4 vehicle on which it is based, the California NECAR operates on pressurized hydrogen. With its optimized 55-kW electric drive system, it reaches a top speed of 145 km/h (90 mph). Development engineers have been able to considerably reduce the weight and volume of both the drive system and the compact fuel-cell unit, whose core comprises a Ballard Mark 900 stack; for instance, the stack weighs only about two-thirds that of NECAR 4's Mark 700 unit and takes up only half as much space. As a result, the entire occupant cell and luggage compartment can now be used to full capacity. The use of lightweight components, both in the interior and on the bodywork, reduces weight even further. Three hydrogen tanks with a maximum pressure of 35 MPa (5100 psi) are integrated into the vehicle; with a filling capacity of about 1.8 kg (4 lb) of hydrogen, the new NECAR has an operating range of up to about 190 km (120 mi).

During intensive testing at the XCELLSiS laboratories in Nabern, Germany, the new reactor unit performed well under stationary and dynamic operating conditions. "We were very pleased with the speed m which we came to results in this research project," said Ferdinand Panik, head of DaimlerChrysler's fuel-cell project. "This is a good example of the versatility of the new fuel-cell technology. Because of the expected high costs, we will continue to work on a methanol reactor as our first priority, as this is the most advanced technology today. But we will also keep an eye on the progress the CPO reactor will make."

DaimlerChrysler and partner Mitsubishi announced in November that they may develop automotive fuel-cell technology jointly. Cooperative development of fuel-cell cars would be a key step in an expected deepening of cooperation after the German auto company took a 34% stake in Mitsubishi.