Advancements in fuel cell stack technology—such as improved power density, catalyst utilization, and durability—have significantly enhanced system efficiency and reduced hydrogen consumption in heavy-duty fuel cell electric vehicles (FCEVs). In parallel, innovations in auxiliary subsystems, including air supply management, thermal regulation, and energy storage integration, have minimized parasitic losses, optimized fuel usage, and improved battery state-of-charge dynamics. These technological improvements collectively influence vehicle operation under varying load conditions, affecting both transient response and overall energy efficiency.
To systematically assess these impacts, this study evaluates key performance metrics such as compressor-related energy losses, fuel utilization, and battery performance. The current vehicle simulation model relies on an outdated fuel cell system based on technology from 20 years ago, which no longer accurately reflects the efficiency potential of modern systems. To address this gap, a new physics-based fuel cell model has been developed and integrated into an open-platform vehicle simulation software. This integration ensures a more realistic representation of fuel cell performance in heavy-duty trucks, providing valuable insights for optimizing system architectures. The findings will support the development of next-generation fuel cell vehicles by informing strategies for improved efficiency, reduced energy losses, and accelerated adoption of sustainable heavy-duty transportation solutions