Thermal System Design for a Fuel Cell Electric Truck

In today’s world, due to fast depletion of fossil fuel and the increasing CO2 emission, the need to switch to alternate energy sources are higher. Stringent norms on exhaust emissions in IC Engine vehicles implies, very complex after treatment systems. Already many OEMs have refined their development strategies towards phasing out of IC Engines and bringing in Fuel Cell vehicles, Battery Electric Vehicles and Hydrogen IC Engine vehicles. Focus is on Hydrogen for Long Haul vehicles. In this paper cooling system design is demonstrated for Fuel Cell, Battery and Power Electronics system in a Heavy Duty Fuel Cell Electric Truck. Radiator and Fans are selected based on the overall heat rejection and Coolant inlet temperature requirements of components. Cooling system circuit and pump is decided to meet the coolant flow rate targets. High temperature cooling system and Low temperature cooling system are explained in detail. Thermal simulation is done using simulation software KULI. Test results signifies good correlation.