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Electrification is one of the main solutions for the decarbonization of the transport system. It is employed widely by the automotive industry in light- and medium-duty vehicles and recently started to be considered in heavy-duty applications. However, powertrain electrification of heavy-duty vehicles, especially for Class 8 trucks, is very challenging. In this study, the battery-electric powertrain energy and technical performance of a DAF 44 tones truck are compared for two different electric drives. The case study truck is modeled in AVL CRUISE M software and the battery electric powertrain is evaluated for long haul driving cycle. The minimum number of battery packs is determined by defining the lowest energy consumption of the powertrain designed for the proposed drive cycle. Also, a transient analysis is accomplished to investigate the impact of various electric drives on energy consumption and performance of the proposed electric powertrain.

To decarbonize heavy-duty vehicles solely through electrification with batteries is challenging as large batteries are required for a meaningful range, severely impacting payload. Employment of hybrid electric powertrains where fuel cells are integrated with batteries can deliver increased range and payload. However, the energy balance between the fuel cell and the battery needs to be analyzed to optimize the sizing of the powertrain components. This study has performed a multi-objective optimization using genetic algorithm to obtain the optimum range and hydrogen consumption for a DAF 44 tons heavy-duty truck. The proposed truck powertrain has been numerically modelled in AVL CRUISE M software. The electric drive from Involution Technologies Ltd and Bramble Energy Ltd’s printed circuit board fuel cell (PCBFC) are used in the model.

Electrification of the transportation sector requires an energy-efficient electric powertrain supported by renewable sources of energy to limit the use of fossil fuels. However, the integration of battery electric powertrains in heavy-duty trucks seems more challenging than other types due to the high battery demand and negative impacts on the truck’s cargo capacity. In this paper, the battery sizing of a 41-tons Mercedes Actros truck is performed based on battery safety zone operating conditions. A parametric study is conducted to assess the impacts of sizing on a truck’s total cargo capacity as well as the body dynamic parameters. The numerical model of the Mercedes Actros electric powertrain is developed in AVL CRUISETM M software. The hybrid pulsed power characterization tests are performed on 3Ah lithium-ion NMC cells in the lab for fitting the second-order equivalent circuit model’s parameters used in the analysis.

Li-ion batteries (LIBs) optimum performance and lifetime depend on temperature, with the commonly suggested operating temperature being in the range of 25 to 40 °C. It's also crucial to keep the temperature difference between battery cells below 5°C. Operation at different temperature ranges can adversely affect or degrade the performance and lifetime of LIBs. A battery thermal management system (BTMS) is essential for keeping the battery temperature within the optimum range. This paper aims to develop and analyze the BTMS for an electric heavy-duty truck. To achieve this aim, battery cells and modules are modelled in ANSYS Fluent software. Validation with experimental results and mesh sensitivity studies are also performed to increase confidence in simulation data. The model is then analyzed for a specific cooling systems to investigate its effect on battery thermal performance during the operation.