Case Study: Ricardo’s strategic and technical groups evaluated packaging options for a Class 8 Truck Fuel Cell

Case Study: Ricardo’s strategic and technical groups evaluated packaging options for a Class 8 Truck Fuel Cell

Challenge

The client was interested in understanding packaging options and performance requirements for their fuel cell powertrain in a class 8 truck that could be used in port drayage operations. The study employed data collection procedures, duty cycle calculations and modeling, model verifications based on real-world operating data, outreach activities with existing fleets to quantify requirements, and assessments of various system integration options to support product feasibility.

Approach

  • Researched drayage truck duty cycles, characterized routes, and defined vehicle requirements
  • Performed vehicle ride along on drayage truck route to collect vehicle operating data and compared data to NREL Fleet DNA data
  • Developed CAD models to demonstrate various package options; end of project workshop conducted with representative vehicle present
  • Performed energy and duty cycle analyses to calculate vehicle range and power requirements

Recommendation 

  • Fuel cell specifications were defined based on the baseline vehicle energy requirement analysis and included definition of demand road load (tractive effort)
  • The ancillary power requirements were defined for the HVAC, power steering, air brakes, alternator and other electrical equipment
  • Power requirements were defined for three duty cycles: local, regional, and long haul.
  • Recommendations were provided regarding the efficacy (mechanical and financial) of energy recovery systems

Results

Provided client multiple packaging options and recommended integration strategies that minimizes changes to the vehicle’s operational characteristics.

The client used project results to justify approval to proceed to the next stage of their product development process.