Gebze - Ismir (500 km)
Grenoble - Munich (800 km)

Designed for long-haul operations with a GVW of 40 ton, BMC Tuğra diesel tractor truck, will be engineered to achieve an 800 km range on a single refueling capacity and modular hybrid powertrain combining two 100 kW fuel cells, having hydrogen storage tanks up to 700 bar and 100 kWh modular battery pack ensuring high operational flexibility and short refueling times creating configurable powertrain for different distance of transport.

Main objectives

Challenge: PEM Fuel Cell technology will be integrated into this diesel-origin heavy-duty vehicle. As a result of this transformation, new solutions will be developed for both the transmission and auxiliary systems. The modularity of the innovative components is another key feature of this pilot.

Innovation: Fuel-cell stacks will be connected to the high pressure hydrogen tanks and the lithium-titanium-oxide battery group. The transmission components will be integrated into a single platform, combining the transmission, e-motor, inverters, e-actuators, and the engine control unit. This system will replace the transmission of an ICE vehicle. Thus, it will ensuring seamless torque delivery and powerful acceleration.

Range: The pilot a regional (500km) and a cross-border element. Whereas the  regional mission includes a daily route of around 500km, including a mobile hydrogen filling station,  The cross-border mission from Grenoble covers a distance of around 800km total distance with a single refueling process.

Vehicle:

Vehicle: BMC Tugra diesel tractor truck of 4×2 will be converted into a fuel cell propulsion heavy duty vehicle platform.

Components: Two fuel-cell systems each with an output of 120kW, four high-pressure ‘type IV composite tanks’, LTO technology-based battery, as well as an e-motor.

Energy: The truck will be powered by a 240 kW fuel cell system, which is supplied by composite hydrogen tanks. Additionally, batteries will be used to supply energy to the auxiliaries.

Charging & Refueling: Components such as battery packs, fuel cells, and hydrogen storage systems can be adjusted based on range and power requirements, which also allows to scale the system and facilitates the process of upgrading or replacing parts.

Key Performance Indicators:

800 km on a single refill range at GVW 44t at chassis dyno in real-world

Min. 500 km daily operation under full load at various ambient temperatures

Route:

There are two test routes planned, one regional and a cross-border route:
Route 1: Gebze-Izmir (500km):
The regional route is planned from Gebze to İzmir in Türkiye with a length of about 500km. This will be a daily test path for 6 months. The fuel-cell integrated vehicle will be tested with loads of DHL and is accompanied by a mobile refilling station.

Route 2 (Grenoble-Munich):
The cross-border mission covers a route of 800km, while the truck can refuel at Engie refuelling stations throughout its way. The path is chosen, as it represents one of the main arteries for heavy-duty road freight transport in Western Europe.

Start: Gebze (TR) & Grenoble (FR)

Intermediate stops for route 2: ENGIE refuelling stations

Finish: Izmir (TR) & Munich (DE)

Turkish Route: Gebze – Izmir

Cross-border route: Grenoble-Munich

Technical Aspects About This Pilot

Thanks to hydrogen’s high energy storage capacity as a fuel, it will be possible to achieve higher range targets compared to conventional energy sources with equivalent volume fuel storage systems. Components such as battery packs, fuel cells, and hydrogen storage systems can be adjusted based on range and power requirements creating scalability, standardized parts not only reducing manufacturing costs but also making replacements or upgrades more seamless gives interchangeability.
Depending on the distance, payload, or refueling infrastructure, the configuration can be adjusted to meet operational needs.

As the central electric motor of the f-HDV tractor truck, the ZF CeTrax is used as a single platform integrating transmission, e-motor, invertors, e-actuators and ECU replacing the transmission of an ICE vehicle delivering seamless torque delivery and powerful acceleration optimizing driving experience with smooth operation.