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Tuesday, August 19, 2025

FEATURE: BEV vs FCEV – Room for 2?


Although eHGVs have reached the market first, producers are nonetheless exploring FCEVs choices. Is there sufficient area for each applied sciences?

The problem of decarbonizing street freight and municipal automobiles is one entwined with financial penalties, entry to dependable infrastructure and the necessities of an enormous array of purposes that can’t be solved with a one-size-fits-all answer. As impending deadlines for automobile decarbonization loom, all seven main European truck producers have launched electrical variations of present fashions. With present infrastructure and clear authorities assist in some international locations, eHGVs have reached the market faster than hydrogen gasoline cell electrical automobile (FCEV) vehicles or hydrogen inside combustion engine (ICE) choices. Whereas truck producers are nonetheless exploring hydrogen powertrains, eHGVs are capable of supply zero-emission options instantly.

Mark Collins, E-Mobility and Physique Builder Product Supervisor at Volvo Group, underlined the problem of discovering an acceptable answer for vehicles in comparison with different automobiles. “The place electrical passenger automobiles and most vans draw vitality from the batteries to predominantly energy the drivetrain, lots of lorries require the vitality to energy the auxiliary gear. Due to this fact, the vitality throughput could possibly be vital in relation to the mileage. A mixer or a crane automobile, for instance, could possibly be on website drawing energy over a protracted time period earlier than shifting.”

Regardless of hydrogen expertise being in its infancy in comparison with EVs, FAUN Zoeller has pushed forward with its FCEVs for municipal and regional distribution purposes. Beneath the Enginius sub-brand, which is devoted to various fuels, the corporate affords Bluepower and Citypower fashions with FCEV powertrains.

Each fashions use Mercedes-Benz chassis, Bluepower borrows the Econic whereas Citypower has an ​​Atego chassis. Bluepower has three 30kW gasoline cells, an 85kWh battery and storage for as much as 16.4kg of hydrogen gasoline at 700bar. Utilizing a 4×2 chassis, a payload of as much as 12-tonne may be achieved with a spread of 250km. A 6×2 chassis affords the identical vary and payload as much as 18-tonne.

Powertrain packaging
No matter whether or not FCEV or BEV expertise would be the prevailing selection sooner or later, each current challenges and vital advantages, a few of that are shared throughout the gasoline varieties. In municipal and concrete environments, maneuverability is a vital attribute to keep up. Because of this, producers are challenged with packaging bulkier powertrain elements into brief wheelbases.

“We attempt to work inside the shortest wheelbase we will,” stated David Graham, Head of Engineering at FAUN Zoeller, “And sometimes use 3.9m wheelbases.” As a substitute of positioning hydrogen tanks between the cab and physique, FAUN Zoeller mounts them between the chassis rails to maintain total automobile size to a minimal. This configuration additionally gives flexibility for various our bodies to be added relying on the applying.

Subsequent to area restrictions are weight limits with producers juggling vary capabilities, payload capability and rules. “For lorries, the volumetric density of batteries is an important attribute, on account of constraints on automobile dimension,” stated Collins. “So, while batteries are being developed constantly, different elements are additionally being developed to liberate area for the extra packs, corresponding to e-axles.”

Energy take-offs
Crucially, for the success of alternatively fueled vehicles that function auxiliary gear, corresponding to concrete mixers, cranes, skiploaders and refuse assortment, automobiles should be fitted with the suitable energy take-off items. For vehicles that require excessive ranges of energy, like concrete mixers, Volvo makes use of an electro-mechanical PTO to attach with hydraulic methods. “It is a motor that was chosen on account of the truth that it may function unbiased of the automobile’s driveline in order that it may energy the hydraulic system for the mixer drum each when the automobile is stationary and on the transfer,” stated Collins. “In addition to this, the PTO can be activated when the automobile is charging on AC or DC energy. That is extra versatile and energy-efficient than a gearbox PTO and can be utilized to energy many different purposes corresponding to refuse collectors, tippers, cranes and so forth.”

With regards to effectivity, Collins sees enhancements may be achieved with electrical PTOs. “We are able to specify automobiles with a direct electrical PTO which may at present present as much as round 40kW of energy, superb for lower-power purposes like refrigeration items, which require peak energy of round 15kW, however might not fairly be sufficient energy for an 8m3 cement drum through the loading/unloading part, which may require as much as round 50kW,” he stated. “Future enhancements in automobile expertise will permit for a extra highly effective direct electrical PTO for use sooner or later, which may eradicate the necessity for hydraulics, therefore cut back the variety of shifting components and enhance effectivity and vary.”

Since FAUN Zoeller’s FCEVs are tailor-made to regional and municipal purposes, the corporate suits electrical PTOs for the best effectivity. Graham additionally anticipates the electrical PTO would be the favored answer shifting ahead.

Thermal administration
With an electro-mechanical PTO fitted, extra cooling is required however elsewhere the cooling system in an electrical truck is pretty standard. “It consists of a closed circuit with three loops – the batteries, powertrain and cab heating – the place every loop has a distinct temperature management with unbiased coolant pumps,” stated Collins. “To reduce cab heating losses, there’s extra insulation and laminated glass on the facet home windows and the automobiles have a ready-to-run function to convey the cab setting and batteries as much as working temperature when nonetheless plugged in to the charger.”

The cooling system for FCEVs is barely extra complicated with a cooling unit for prime voltage gear, and first and secondary cooling methods for every gasoline cell. “Roughly talking, the output of a gasoline cell is 50% energy, 50% warmth,” Graham stated, “Every gasoline cell has its personal radiator system and the auxiliary gear like motors and inverters have their very own cooling system as nicely.”

The gasoline cells use the non-conductive coolant glysantin. A FCEV’s cooling methods are essentially the most complicated a part of the powertrain, so common upkeep inspections concentrate on making certain the methods are working as they need to with the right coolant ranges.

Know-how to facilitate change
On this transitionary interval to various fuels, software program surrounding the automobile is equally as vital as software program controlling its capabilities. To find out buyer energy utilization, FAUN Zoeller installs {hardware} on a buyer’s present automobile to collect information about their typical routes. Utilizing an algorithm which considers elements corresponding to velocity, gasoline utilization, payload and driver conduct, the corporate can calculate a buyer’s energy necessities.

“We’ve obtained hundreds of information studies so we all know that municipal automobiles will sometimes do 60 to 70 miles a day and elevate 1,200 bins,” stated Graham. “These information loggers are a device that we will put onto buyer automobiles earlier than they purchase a automobile to guarantee that the automobile will give them what they want out of it.” As soon as automobiles are deployed, these information loggers act as diagnostic instruments to watch and establish any points, minimizing downtime.

At Volvo, simulation expertise is employed to work out the most effective automobile specification for a buyer’s wants. “Transferring to EVs the place vary and effectivity is much more in-focus has supplied a platform to evaluation and optimize options by pump choice to motor velocity managed by way of the CAN,” stated Collins. “This info is all the time fed by the engineering workforce and can be utilized to enter information into our in-house ‘Electrical Vary Simulator’ which may precisely programme routes, together with numerous elements corresponding to PTO utilization, ambient exterior temperature, street topography, automobile payload, regeneration, all the best way right down to the extent of element of which tire rolling resistance class is specified to supply an output to find out whether or not the routes are potential or not, and in the end what number of batteries are required.”

Sensible suitability for any utility extends past merely finishing the duty itself. For producers, a lot of the logistical preparations for charging or refueling are out of their management. Therefore, route planning and exploring the viability of those automobiles grow to be a extra vital issue.

The primary variations between eHGVs and FCEVs at this stage is worth and refueling occasions. Whereas a hydrogen automobile can fill its tanks in beneath 10 minutes, electrical automobiles depend on super-fast charging or in a single day stints to organize for the subsequent workday. Whereas eHGV deployment is accelerating extra shortly, there’s more likely to be a necessity for each applied sciences in addition to different alternate options sooner or later.

“There are purposes for gasoline cell automobiles and purposes for electrical automobiles,” stated Graham. “I feel on the subject of refuse assortment automobiles, it’s most likely going to be 70% electrical and 30% gasoline cell in 10 years’ time.”

Hydrogen coaching facility
The deployment of any alternatively fueled automobile depends on extra than simply the availability of the automobile itself. Entry to fueling, acceptable subsidies or funding choices and a community of technicians to keep up the automobile as soon as it’s in operation are key elements. South and Metropolis Faculty Birmingham (SCCB), in collaboration with FAUN Zoeller UK has opened a brand new hydrogen coaching facility to upskill present technicians and new mechanics in hydrogen expertise.

Following a £1.5 million funding, SCCB unveiled a brand new 450m² ATEX-compliant workshop devoted to engaged on hydrogen automobiles. Alongside passenger automobiles which college students shall be in a position work on, the faculty bought an Enginius Bluepower FCEV. The power, which is regarded as the primary of its form in Europe, will ship Institute of the Motor Business (IMI) Stage 1 hydrogen automobile consciousness, IMI Stage 2 hydrogen automobile routine upkeep actions and IMI Stage 3 hydrogen FCEV system restore and alternative programs. Increased degree programs are additionally deliberate together with the IMI Stage 4 award within the analysis, testing and restore of electrical/hybrid automobiles and elements with hydrogen consciousness.

Simon Hyde, CEO at FAUN Zoeller UK stated, “The controversy round various automobile fuels has largely targeted on electrical energy and hydrogen-sceptics have cited funding, fueling, efficiency and expertise as limitations to adoption.

“We consider that none of those are insurmountable. With the launch of this coaching facility and the dedication that SCCB has demonstrated, the prevailing and future workforce will profit from essentially the most acceptable coaching to allow them to successfully service, preserve and perform diagnostics on hydrogen-powered municipal automobiles.”

SCCB plans to open up its hydrogen coaching facility to college students throughout its automotive programs to organize them for jobs sooner or later that will contain sustaining hydrogen automobiles. FAUN Zoeller plans to coach new UK-based technicians by the faculty because it expands its community of cellular engineers.

Various decarbonization choices
Whereas a lot of the main target rests on zero-emission options which might be anticipated to interchange diesel vehicles, some truck producers are exploring interim options to decarbonize fleets within the short-term. In onerous to decarbonize sectors like building, fleet operators are more likely to want various gasoline options in eventualities the place infrastructure and dealing patterns are tough to adapt for zero-emission powertrains.

“Zero-emission battery electrical automobiles are only one expertise which may present advantages from an environmental perspective,” stated Collins. “There are a selection of different applied sciences and fuel-types which can be utilized in totally different segments. For instance, drop-in fuels that come from a renewable feedstock can change EN590 diesel immediately which have a useful well-to-wheel CO2e saving.

“Alongside this, gas-powered automobiles that may run on biomethane can present each CO2e financial savings on the tailpipe (tank to wheel) and well-to-wheel, once more, when utilizing a feedstock from a renewable supply. These are options that may be adopted to decarbonize transport immediately alongside battery electrical automobiles.”

These options require comparatively minimal price funding from operators and producers. Adapting present gear or discovering fuels that can be utilized with no modifications to present gear is essentially the most price efficient solution to affect CO2 emissions earlier than the worth of EVs and FCEVs comes down.

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