Fuel Cell System Integration for Heavy-Duty Applications

A concept for converting conventional diesel-powered long-haul trucks to a combined battery and hydrogen fuel cell powertrain is presented. The development of the concept is outlined whereas the focus is on the operational strategy, the thermal design, the spatial constraints, FEM strength simulations and safety aspects. Based on a costumer drive cycle the battery capacity as well as the fuel cell power output is determined with the help of a 1D-Matlab/Simulink model. Beside this the thermal system and especially the low temperature and high temperature circuit requirements are defined by system simulation. The results of these simulations were implemented in the design concept of the fuel cell heavy duty tractor (“HyBatt truck”) and are validated by the testing results of the first prototype.