Designing at the Limits – Specialized Vehicles with Fuel Cell Drive

Authors

B. Lechner, C. Doppler, D. Schlüter, A. Romero Mancebo, R. Schruth, M. Waltenberger, Virtual Vehicle Research GmbH, Graz; W. Luftensteiner, G. Außermayr, Rosenbauer International AG, Leonding; R. Balbach, AC agility consulting GmbH, Altmünster

Year

2025

Print Info

Production/Publication ÖVK

Summary

Zero-emission-vehicle legislation requires alternative propulsion systems in all vehicle classes throughout the next decade. In this work, the specific use case of a fuel cell powered specialized vehicle is evaluated. Both high power (900 kW) and high energy (600 kWh) requirements have to be met, while maintaining absolute operational readiness even under thermally challenging boundary conditions. Propulsion is provided by a 300 kW fuel cell system and a 100 kWh Li-Ion battery with NMC chemistry for peak power. A packaging analysis was carried out, setting the capacity of the hydrogen tank to 28 kg. To improve thermal management, a radiator optimized for fuel cell applications was developed. To mitigate the risk of cathode poisoning by harmful gases, extensive testing was conducted on the performance of the filters under long-term exposure. Finally, a cost analysis was performed. 
• Thermal management always needs a careful proper design to meet an acceptable trade-off. Cooling of the vehicle with commercially available components can be ensured. 
• The prevention of poisoning of the cathode by harmful gases has not yet been satisfactorily completely solved. 
• For low drive power and low mileage, the Diesel drive is currently the most cost-effective option. For higher mileages, the use of a battery-electric drive - eventually with range extender - is advantageous. 
• For 2035, a hybrid fuel cell drive with a medium-sized battery appears most promising.

ISBN

978-3-9504969-4-9

DOI

https://doi.org/10.62626/wbjg-6soo Copy link

Order Members Login