From the early ethanol-powered prototypes of the Model T to the Ford Escape Hybrid, Ford Motor Company has long been an innovator in the use of alternate energy sources for its vehicles. Combined with Ford's long experience with Compressed Natural Gas (CNG) and Propane vehicles, it should be no surprise to see a fleet of hydrogen-powered shuttle buses being placed in service in the United States.
Ford started its research into hydrogen internal combustion engines (H2ICEs) in 1997 and developed its first test vehicle in 2001. That prototype was succeeded by a more powerful next-generation supercharged product nicknamed Kermit for its green color and unconventional appearance. With Kermit, Ford showed that H2ICE s could not only be fuel efficient and have near-zero tailpipe CO2, but could also be fun to drive, moreover, it proved that they could meet any emissions standard, present or anticipated.
Despite the success of the Kermit vehicle, it was the hydrogen hybrid Model U and the H2RV developed for the 2003 North American International Auto Show and the Ford Centennial Celebration that really drew attention to Ford's growing H2ICE activities. Deemed the world's first H2ICE hybrids, the credibility and success of these products propelled Ford to cultivate a strategy for further development and deployment of H2ICE technology. As a result, the 2006 H2ICE pilot fleet program was born.
From Vision to Reality
While research efforts certainly broadened Ford's knowledge of H2ICE technology, Ford was eager to gain insight into whether customers would perceive hydrogen as a viable automotive fuel and how the vehicles would stand up to everyday customer usage. The potential advantages of putting this technology into real world use were compelling. Widespread adoption of hydrogen powered engines could some day result in improved air quality, reduced generation of green-house gases, and reduced dependence on imported petroleum. Furthermore, H2ICE s could also serve as a bridge between the gasoline engines of today and the fuel cell vehicles of tomorrow by raising awareness of hydrogen as a fuel and spurring the development of hydrogen fueling infrastructure, advanced hydrogen storage technology and the revised codes and standards necessary for a transition to a hydrogen-based economy.
Building a Team and Charting a Course
In September 2003 taking the existing hydrogen-powered engine group at the Ford Research and Innovation Center and combining them with core members of the Alternate Fuel Vehicle staff from the Product Development Center, a team soon formed and engineering plans quickly fell into place. Engineering prototypes would be built using the E450 chassis cab frame and a limited fleet for external customers would follow.
By using a shuttle-bus type of vehicle as the prototype application, this maximized the number of individuals who would come in contact with the vehicles. In addition, because alternative fuel vehicles with the capacity to carry large numbers of passengers seemed like prime candidates for government funding under the different local, state and federal incentive programs, this made a shuttle bus platform even more desirable to the team. Although most of the expenses associated with the research and development of these vehicles would be internal to Ford, it was expected that customers using these vehicles would be true partners in the effort and be willing to pay the incremental cost to produce their individual vehicles.
The public announcement for the H2ICE program was made at the 2005 North American International Auto show in Detroit, Michigan, where two prototype buses were used during Press Week to shuttle more than 600 reporters, photographers and journalists around the downtown area and to and from the airport. The passengers reacted positively to the power, ride and handling of these vehicles, but perhaps the biggest surprise for many of the riders was the transparency of the fuel compared to a gasoline powered shuttle bus. Another highlight for the team occurred when Bill Ford was interviewed by NBC Nightly News while riding in one of the shuttle buses.
Before any customer units were built, ten test vehicles were assembled and tested to Ford's exacting standards. The first ten chassis were ordered and shipped to Corbeil Enterprises, a bus manufacturing facility outside of Montreal, Quebec in April 2005 to begin this process. After the bus bodies were installed on the chassis, they were returned to Michigan where the tank assembly and engine installation took place. Once this step was completed, the vehicles were essentially operational and ready to begin testing.
Ensuring Safety, Quality and Durability
Knowing that the H2ICE shuttle bus would likely be the first contact a customer would have with a hydrogen vehicle, the engineering team wanted to make sure this first impression was a positive one. To support this goal, a test plan was defined to parallel that of any new vehicle program. The vehicles were subject to extensive testing including development and durability work using both dynamometer and test track regimens. The vehicles were also tested for electromagnetic capability, noises and vibrations; weather, temperature and altitude extremes; and for crash safety.
To further support the robustness of these vehicles, each vehicle is equipped with a fuel management system that constantly monitors for hydrogen presence in the fuel storage area, the passenger area and under the hood. Should a leak occur, automatic sensing will alert the driver well before any level of hydrogen becomes present that could be of concern.
Engineering the Hydrogen Engine
Although preliminary engine design modifications to support the use of hydrogen had been undertaken several years earlier, the technology would be taken one step further in the fleet program. The engine underwent vehicle and dynamometer durability testing, as well as NVH (noise, vibration and harshness), hot and cold weather, and altitude testing. Extreme temperature tests were performed near Palm Springs California where the team experienced temperatures up to 117 degrees, and in Thompson, Manitoba where they conducted cold starts in temperatures as low as 30 degrees below zero.
Extensive testing was also done in Ford's laboratories in Dearborn and with key partners such as Quantum for fuel injectors and Dynetek for fuel systems to make sure all aspects of the engine's performance would be satisfactory. This lab testing was supplemented by extensive driving and vehicle evaluations in different environments to ensure the customer has a satisfactory drive regardless of their location or climatic condition.
In early 2005, the first shuttle bus fleet location was formally announced – an eight vehicle agreement with the State of Florida. An additional 22 vehicle placements have been identified and the final fleet size of 30 units promises to be more than sufficient to meet the technical goals of the program. In December of 2006 the first 3 units were delivered to the Canadian Government for use on Parliament Hill in Ottawa Canada. The fleet locations span North America and have the potential to expose hundreds of thousands of consumers to the pleasure of riding in a clean, safe, and green Ford hydrogen vehicle.
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