Geneva – Lyon – Barcelona (800 Km)

Long Haul Fuel Cell Refrigerator Truck with optimized e-Powertrain & Hybrid Freight Cooling 

Vehicle group: 9 VECTO

Specific Objective

Flexible lightweight frame design with optimized powertrain components and optimal use of on-board energy with data-driven algorithms, as well as energy-optimized innovative cargo compartment cooling systems based on propane gas and hydrogen expansion together with highly efficient modular e-drive train concepts (FC + eaxle) for long haul applications.

  • Vehicle & Components: Optimum sizing and packaging of a cooled 44-ton trailer with a modular e-axle, up to 3 modules of a 100 kW PEM fuel cell (peak efficiency 56%) and a 96 kWh Li-ion battery (640 V), and an on-board energy storage system with up to 80 kg of H2 storage at 700 bar → 800 km range. Novel FC and modular battery design integrated with lightweight cooling and housing concept. 
  • On-board energy: combination of innovative propane gas refrigeration module and H2 expansion utilization for cooling integrated with predictive real-time implementable energy management algorithm. 
  • Range: Up to 800 km with Single-Fueling; 
  • Logistics: AI predictive maintenance algorithm4FC system to reduce total costs of operation and enhance durability. 
  • Demonstrator Vehicle: FORD 44t fuel-cell refrigerator truck.
Proposed Technical Solutions: 
  • Modular & Scalable High Efficiency FC4LongHaul; 
  • Modular e-axle (high power EM + WBG Inverter); 
  • Robust and Accurate Thermal Management Design via Virtual product Development Methodology; 
  • Optimized Hybrid Cooling System; 
  • Smart Predictive Energy Management Algorithm; 
  • Innovative freight cooling concept integrated in an overall energy optimization for range extension possibilities. 
  • Integration of component DT in the simulation model to realize overall energy optimization for long ranges.
Scenario Pilot 5.1-Vecto Long Haul Cycle
The first scenario will be defined as long haul. To optimize the e-drivetrain components and evaluate its technology potential the VECTO Long Haul Delivery cycle, which is an EC
test cycle to represent HDV mission profile will be used to represent typical long-haul, highway-dominated driving. The selected test cycle is distance-based and include road grade as shown in the right figure. 
Scenario Pilot 5.2-Cross-border 
  • Mission: Long-Haul transport with a 44t GVW. 
  • Route: Germany – France – Spain. 
  • Scenario: The envisioned scenario will be a one-way trip of 800 km with a single refill of H2 tank of 44t fuel cell long haul truck carrying temperature sensitive goods from Berlin (Germany) to Trabajo (Spain) with 3 breaks on TEN-T corridor and metropole areas (Geneva, Lyon, Barcelona) + headquarter with short interruptions for breaking necessities. 
A high efficiency modular FC system with a peak efficiency of 56% will be developed. Pilot 5 partners will demonstrate the scalability of the system. The control algorithm will be developed by working on the management of thermal loads of Components by Ford. In addition, since there are two different power sources in the vehicles, a hybrid control mechanism will be developed to provide energy management. Therefore, control algorithms will aim to minimize energy consumption. The main model will analyze energy and H2 consumption for cycles with the Vecto tool or cycles with velocity-slope graphs. According to the H2 consumption result, the tank capacity to be used in the vehicle will be determined, and the geometry of the fuel line, pressure drop, flow rate analysis will be performed, and the decisions will be assisted in finalizing the model architecture. Simulations will take place with the simulation tool to be determined by Ford. 
KPIs with Targeted Values: 
  • KPI-1: Peak FC efficiency >56%; 
  • KPI-2: H2 consumption <9 kg/100km; 
  • KPI-3: Range min. 800 km with single refill @GVW.