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Fuel-cell hybrid truck shows energy losses and thermal management limits

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Research area:engineering-energytransport-infrastructure

What the study found

The study found that the fuel-cell hybrid electric heavy-duty truck lost a large share of its initial energy before it reached the wheels, and that its thermal management was only partly effective. It also found limited energy recovery during deceleration and some performance drop in the motor under certain operating conditions.

Why the authors say this matters

The authors conclude that the energy flow analysis framework can quantify energy consumption distribution, component efficiency, and thermal management behavior in fuel-cell hybrid electric heavy-duty trucks. They say the work provides a reference for improving performance and engineering application of these trucks.

What the researchers tested

The researchers experimentally investigated a fuel-cell hybrid electric heavy-duty truck under user-defined driving cycles. They examined energy consumption distribution, efficiency of key powertrain components, and thermal management system performance, using a newly built energy flow analysis framework.

What worked and what didn't

The fuel cell stack achieved 47.98% conversion efficiency, but the abstract reports 49.6% thermal losses through the coolant system with power fluctuations. After losses in power electronics, transmission, and auxiliary systems, only 38.99% of the initial energy reached the wheels. The power battery helped balance loads, but it recovered only 26.1% of energy during deceleration, and motor efficiency fell below 85% during medium-speed and low-torque operation in intermediate gears. Thermal control was basic but not fully sufficient: battery cell temperature rose to 35°C, motor temperature increased from 27°C to 50°C and then stabilized at 45-50°C, cabin temperature varied by 2-4°C, and compressor instability was observed.

What to keep in mind

The abstract describes limitations in handling heat load at the battery end and says the cooling design needs improvement, either by increasing cooling capacity or optimizing algorithms. It also notes HVAC needs for outlet redesign or improved control strategies. Other limitations are not described in the available summary.

Key points

  • The fuel-cell stack achieved 47.98% conversion efficiency.
  • Only 38.99% of the initial energy reached the wheels after system losses.
  • The power battery recovered 26.1% of energy during deceleration.
  • Motor efficiency dropped below 85% in medium-speed, low-torque operation in intermediate gears.
  • Battery cell temperature rose to 35°C, while motor temperature increased from 27°C to 50°C and then stabilized at 45-50°C.

Disclosure

Research title:
Fuel-cell hybrid truck shows energy losses and thermal management limits
Authors:
Renhua Feng, Zhanye Hua, Zhichao Zhao, Faguang Li, Xing Shu, Licheng Luo, Huikai Zhai
Institutions:
Chongqing University of Technology, Chongqing University of Technology, Chongqing University of Technology, Chongqing University of Technology, Chongqing University of Technology, Chongqing University of Technology, Merchants Chongqing Communications Research and Design Institute
Publication date:
2026-02-11
DOI:
10.1016/j.csite.2026.107819
OpenAlex record:
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AI provenance: This post was generated by gpt-5.4-mini (OpenAI). The original authors did not write or review this post.

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