Durable and cost-efficient

Fuel Cell Development for Truck and Bus

Clean power for all applications

Global emission regulations are driving innovation in fuel cell technology as a possibility to fulfill the needs and obligations of truck and bus markets. As well as emission regulations, OEMs and truck and bus operators face many challenges in cleaning up their fleets. This includes issues such as driving range and fuel infrastructure. Additionally, durability, payload, total cost of ownership (TCO), packaging and thermal management all influence the adoption of these new technologies in the commercial sector.

Fuel cell technologies are already showing promise across the industry for some use cases, for example long-haul heavy-duty trucks and intercity buses. Polymer Exchange Membrane Fuel Cell (PEMFC) technology, in particular, is an attractive option for truck and bus applications that require dynamic fuel cell operation. Solid Oxide Fuel Cell (SOFC) technologies are ideal as range extenders or auxiliary power units.

Strategy Meets Technology

PEMFC technology has many traits that make it a potential alternative to diesel as a main propulsion. For example, it offers high efficiency, durability, low powertrain weight, zero emission, low NVH and ultimately has a comparable TCO with green hydrogen.

On the other hand, SOFC technology is ideal as base load or even as a range extender for buses and light- or medium-duty vehicles. The advantage of SOFC lies in its potential to bridge a world where hydrogen is not widely available as a fuel, as well as its high operating efficiency.

With decades of powertrain development and electrification experience – as well as broad fuel cell know-how – at AVL we can deliver customized technologies and services. These include:

  • Full development engineering services from lab prototype to pre-production samples of fuel cell systems and stacks
  • A model-based approach for quicker iteration cycles
  • Modular fuel cell systems and operating strategies with optimal durability and cost
  • Degradation modelling with state-of-the-art AVL proprietary code
  • Mechanical design and integration into defined packaging spaces
  • Cost engineering of every component to explore cost drivers and cost reduction possibilities
  • Knowledge of latest systems through our fuel cell system benchmarking activities (Nexo and Mirai available)
  • Electric and Electronic (E/E) integration
  • FMEA, Safety Concept, functional safety, requirements management, risk and hazard analysis, technology consulting, and much more

Furthermore, our own fuel-cell testing infrastructure is here to help you with your design and validation activities. We can provide you with modular system test performance which meets the high power demands from the commercial vehicle industry.

Our extensive experience with the technology, its application and the environment in which it operates, make it a realistic option for reduced/zero emission technology demands. In addition, with our know-how and global network of experts, we are the ideal partner to support you with your implementation needs.