Holistic Optimization of Heavy Duty Trucks with Fuel Cell Hybrid Powertrains

Authors

T. Stoll, H.-J. Berner, FKFS, Stuttgart; A. Kulzer, Institute of Automotive Engineering, University of Stuttgart

Year

2025

Print Info

Production/Publication ÖVK

Summary

The EU-wide defossilization of the transport sector, in particular for heavy-duty commercial vehicles, requires a reduction of local CO₂ emissions, in the fleet average, of 90 % by 2040 (2030: 45 %, 2035: 65 %). This poses major challenges for manufacturers in terms of optimizing powertrain technology, particularly in the long-haul transport segment up to 40 tons. Battery-electric powertrains require battery systems with high capacities and fuel cell systems require high cooling capacities in the nominal power range. An optimal combination of these two powertrain systems makes it possible to reduce the disadvantages mentioned by using the respective powertrain systems efficiently. In order to evaluate the potential of fuel cell hybrid powertrain systems in heavy-duty commercial vehicles, a parameter study with subsequent optimization is carried out. In this context, optimal concepts for different combinations of fuel cell system and battery capacities are simulated to determine consumption values and exclude critical operating conditions. At the same time, the cradle-to-grave greenhouse gas emissions of the respective variants are determined and the expected total costs per tonne-kilometer are evaluated. This enables the presentation and optimization of the two target values with the units CO₂-eq. / tkm and € / tkm as a function of battery capacity and installed fuel cell nominal power. Finally, the results are discussed in the context of a technology assessment of the powertrain topology for selected applications. The study aims to provide a perspective for the year 2030.

ISBN

978-3-9504969-4-9

DOI

https://doi.org/10.62626/ip4y-uids Copy link

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