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If fuel cell vehicles are to compete in the same marketplace as conventional vehicles, then they must provide the consumer with the same, or improved, levels of convenience, comfort, refinement and performance at the same, or lower, price. In 2003/4, several vehicle manufacturers are planning to launch their first commercial fuel cell vehicles onto the market. In this remarkably short timeframe, many systems must be integrated into a vehicle including the fuel cell system plus thermal and water management, cabin heating, ventilation and air-conditioning, control and on-board diagnostics, power electronics, electric motor and gearbox, suspension, steering, braking, refinement and crash protection. This paper presents a range of modelling techniques which allow the user to design and develop key systems, including the power management system, compressed air supply, thermal management and control algorithms.

A fuel-cell-powered vehicle requires a plentiful supply of hydrogen to achieve good performance. This can be produced from methanol via an on-board reformer and gas clean-up unit. Since the reformer can take several minutes to reach its operating temperature, it is initially necessary to provide an alternative power source, such as a battery or ultra-capacitor, in order to drive the vehicle. This paper describes the use of a fuel cell vehicle simulation to predict behavior over a drive cycle from a cold start and to evaluate different warm-up control strategies in terms of performance and fuel efficiency.

Numerous vehicle manufacturers are currently demonstrating vehicles that illustrate the potential of fuel cell technology to be packaged within a vehicle and to provide an enjoyable driving experience. There are however significant challenges to be overcome before fuel cell vehicles are commercially viable, particularly with respect to cost reduction and high volume component manufacture. To reach the goal of a mass-market fuel cell vehicle, engineers will need to capitalize on the latest developments in technology. This paper describes advances in materials and manufacturing techniques that may contribute to the future success of fuel cell vehicles.