Regardless that eHGVs have reached the market first, producers are nonetheless exploring FCEVs choices. Is there sufficient house 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 functions that can’t be solved with a one-size-fits-all resolution. 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 gas cell electrical automobile (FCEV) vehicles or hydrogen inner combustion engine (ICE) choices. Whereas truck producers are nonetheless exploring hydrogen powertrains, eHGVs are in a position to supply zero-emission options instantly.
Mark Collins, E-Mobility and Physique Builder Product Supervisor at Volvo Group, underlined the problem of discovering an acceptable resolution for vehicles in comparison with different automobiles. “The place electrical passenger vehicles and most vans draw vitality from the batteries to predominantly energy the drivetrain, a number of lorries require the vitality to energy the auxiliary tools. Due to this fact, the vitality throughput may very well be important in relation to the mileage. A mixer or a crane automobile, for instance, may very well be on web site drawing energy over an extended time period earlier than transferring.”
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 functions. Beneath the Enginius sub-brand, which is devoted to different fuels, the corporate presents 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 gas 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 could be achieved with a variety of 250km. A 6×2 chassis presents 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 important advantages, a few of that are shared throughout the gas varieties. In municipal and concrete environments, maneuverability is a crucial attribute to keep up. Consequently, producers are challenged with packaging bulkier powertrain elements into brief wheelbases.
“We attempt to work inside the shortest wheelbase we will,” mentioned David Graham, Head of Engineering at FAUN Zoeller, “And infrequently 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 general automobile size to a minimal. This configuration additionally gives flexibility for various our bodies to be added relying on the applying.
Subsequent to house restrictions are weight limits with producers juggling vary capabilities, payload capability and laws. “For lorries, the volumetric density of batteries is an important attribute, as a consequence of constraints on automobile measurement,” mentioned Collins. “So, while batteries are being developed constantly, different elements are additionally being developed to unencumber house for the extra packs, resembling e-axles.”
Energy take-offs
Crucially, for the success of alternatively fueled vehicles that function auxiliary tools, resembling concrete mixers, cranes, skiploaders and refuse assortment, automobiles have to be fitted with the suitable energy take-off models. For vehicles that require excessive ranges of energy, like concrete mixers, Volvo makes use of an electro-mechanical PTO to attach with hydraulic methods. “This can be a motor that was chosen as a consequence of the truth that it will probably function impartial of the automobile’s driveline in order that it will probably energy the hydraulic system for the mixer drum each when the automobile is stationary and on the transfer,” mentioned Collins. “In addition to this, the PTO may also 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 functions resembling refuse collectors, tippers, cranes and so forth.”
In terms of effectivity, Collins sees enhancements could be achieved with electrical PTOs. “We will specify automobiles with a direct electrical PTO which might at present present as much as round 40kW of energy, excellent for lower-power functions like refrigeration models, 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 mentioned. “Future enhancements in automobile expertise will permit for a extra highly effective direct electrical PTO for use sooner or later, which may get rid of the necessity for hydraulics, therefore cut back the variety of transferring components and enhance effectivity and vary.”
Since FAUN Zoeller’s FCEVs are tailor-made to regional and municipal functions, the corporate suits electrical PTOs for the best effectivity. Graham additionally anticipates the electrical PTO would be the favored resolution transferring ahead.
Thermal administration
With an electro-mechanical PTO fitted, further cooling is required however elsewhere the cooling system in an electrical truck is pretty typical. “It consists of a closed circuit with three loops – the batteries, powertrain and cab heating – the place every loop has a special temperature management with impartial coolant pumps,” mentioned Collins. “To reduce cab heating losses, there may be further insulation and laminated glass on the facet home windows and the automobiles have a ready-to-run function to carry 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 tools, and first and secondary cooling methods for every gas cell. “Roughly talking, the output of a gas cell is 50% energy, 50% warmth,” Graham mentioned, “Every gas cell has its personal radiator system and the auxiliary tools like motors and inverters have their very own cooling system as nicely.”
The gas cells use the non-conductive coolant glysantin. A FCEV’s cooling methods are probably 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 different fuels, software program surrounding the automobile is equally as essential as software program controlling its features. To find out buyer energy utilization, FAUN Zoeller installs {hardware} on a buyer’s present automobile to assemble information about their typical routes. Utilizing an algorithm which considers components resembling velocity, gas utilization, payload and driver conduct, the corporate can calculate a buyer’s energy necessities.
“We’ve bought hundreds of knowledge studies so we all know that municipal automobiles will usually do 60 to 70 miles a day and carry 1,200 bins,” mentioned Graham. “These information loggers are a software that we will put onto buyer automobiles earlier than they purchase a automobile to make it possible for 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 observe and determine any points, minimizing downtime.
At Volvo, simulation expertise is employed to work out one of the best automobile specification for a buyer’s wants. “Shifting to EVs the place vary and effectivity is much more in-focus has offered a platform to overview and optimize options via pump choice to motor velocity managed through the CAN,” mentioned Collins. “This info is at all times fed via the engineering staff and can be utilized to enter information into our in-house ‘Electrical Vary Simulator’ which might precisely programme routes, together with varied components resembling 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 finally 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 turn out to be a extra essential issue.
The primary variations between eHGVs and FCEVs at this stage is value and refueling instances. Whereas a hydrogen automobile can fill its tanks in underneath 10 minutes, electrical automobiles depend on super-fast charging or in a single day stints to organize for the following 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 functions for gas cell automobiles and functions for electrical automobiles,” mentioned Graham. “I believe relating to refuse assortment automobiles, it’s in all probability going to be 70% electrical and 30% gas 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, applicable 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 vehicles which college students will probably be in a position work on, the school bought an Enginius Bluepower FCEV. The ability, which is considered the primary of its form in Europe, will ship Institute of the Motor Trade (IMI) Degree 1 hydrogen automobile consciousness, IMI Degree 2 hydrogen automobile routine upkeep actions and IMI Degree 3 hydrogen FCEV system restore and substitute programs. Larger degree programs are additionally deliberate together with the IMI Degree 4 award within the prognosis, testing and restore of electrical/hybrid automobiles and elements with hydrogen consciousness.
Simon Hyde, CEO at FAUN Zoeller UK mentioned, “The talk round different automobile fuels has largely centered on electrical energy and hydrogen-sceptics have cited funding, fueling, efficiency and expertise as obstacles to adoption.
“We imagine that none of those are insurmountable. With the launch of this coaching facility and the dedication that SCCB has demonstrated, the present and future workforce will profit from probably the most applicable 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 which will contain sustaining hydrogen automobiles. FAUN Zoeller plans to coach new UK-based technicians via the school because it expands its community of cell engineers.
Various decarbonization choices
Whereas a lot of the main focus rests on zero-emission options which are anticipated to switch diesel vehicles, some truck producers are exploring interim options to decarbonize fleets within the short-term. In laborious to decarbonize sectors like building, fleet operators are more likely to want different gas options in situations the place infrastructure and dealing patterns are troublesome to adapt for zero-emission powertrains.
“Zero-emission battery electrical automobiles are only one expertise which might present advantages from an environmental perspective,” mentioned Collins. “There are a number of different applied sciences and fuel-types which may also be utilized in totally different segments. For instance, drop-in fuels that come from a renewable feedstock can exchange EN590 diesel at present 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 at present alongside battery electrical automobiles.”
These options require comparatively minimal price funding from operators and producers. Adapting present tools or discovering fuels that can be utilized with no modifications to present tools is probably the most price efficient technique to influence CO2 emissions earlier than the value of EVs and FCEVs comes down.
