We sat down with Ford Otosan to chat about Pilot 5, its characteristics, challenges, and ongoing development. You can now read all about it below!

 

Can you provide a general overview of your pilot and explain the specific requirements associated with it?  

The pilot features an e-axle drive type with a three-gear transmission. It is designed to accommodate up to two PEMFC modules, each providing 125 kW, and up to two packs of 123 kWh Li-ion batteries. The vehicle is a 4×2 configuration, with a gross combined weight of up to 44,000 kg and a wheelbase of 3,750 mm. It offers a peak power output of up to 600 kW, with a continuous power capacity of 360 kW.

What are the unique aspects of your pilot, and what makes it innovative for the long-haul truck sector?

Fuel Cell electric vehicles present significant challenges in terms of thermal requirements and efficiency. Our pilot aims for a range of 700 km on a single fuelling, supported by a control strategy designed to optimise vehicle efficiency. To address the demanding thermal requirements, we have implemented a size-optimised hybrid cooling system alongside advanced thermal management controls.

Why did you choose that route to test your truck?

In our pilot, we use two routes: the VECTO Long Haul Cycle and a Germany-France-Spain route. The VECTO Long Haul Cycle, developed by the European Commission, is a standardised tool used to determine CO2 emissions and fuel consumption in heavy-duty vehicles. For this reason, the VECTO Long Haul Cycle was selected as a key part of our pilot.

What is the current status of the pilot?  

  • Powertrain Model Generation: Developing the vehicle model using GT-Suite.
  • Fuel Cell and Battery Selection: Identifying the most efficient system by comparing fuel cell power capacities and battery quantities.
  • Thermal Layout Generation: Creating the thermal layout for the e-drive, fuel cell, battery, and other components.
  • Defining Heat Rates: Extracting heat rate values from the generated model.
  • Thermal Performance Evaluation: Assessing the thermal performance of components to ensure they meet the specified requirements.
  • Thermal Layout Optimisation: Enhancing efficiency by optimising the thermal layout.

What challenges did you face, and how did you overcome them? What are the next steps until the end of the year?

One challenge is generating or gathering the TEN-T Route profile, as finding a suitable road profile can be difficult. Additionally, implementing advanced thermal management systems presents its own set of challenges.

The next steps include completing the Tent Route profile and finalising the integration of advanced thermal management systems.