Modularization of Fuel Cell Systems for CV-Applications

Future automotive powertrains will be different. Digitalization, the limited availability of fossil fuels and especially the tightening of CO₂ legislation and other emissions are one of the key development drivers. For commercial vehicles, a CO₂ reduction of 30% by 2030 compared to 2019/2020 was defined by European legislation. A potential solution to reach these ambitious targets are fuel cell electric powertrain configurations. System efficiencies of up to 60% as well as the high gravimetric energy density of hydrogen are beneficial for long-haul applications. Furthermore, fuel cell systems can be integrated in existing electrified vehicle platforms. The availability for fuel cell system units on the market is currently limited to around 100 kW of maximum power, which is insufficient for a 40 t heavy-duty truck. Consequently, a modularization of fuel cell systems and the integration of multiple units is necessary. In this context, a model-based development approach for evaluation of system modularization concepts in terms of performance, durability, efficiency, package and costs was developed by IAV. With this proceeding, different fuel cell systems topologies for a 40 t long-haul truck are investigated.