The fuel cell based vehicles powertrain is an extensive system that comprises a fuel cell (FC) as the primary energy source, a set of power converters both unidirectional and bidirectional and batteries or supercapacitors as secondary energy sources. Its design is a complex task that affects the mass, volume, cost, efficiency and fuel economy of the vehicle. This paper describes a graphic and straightforward sizing of the secondary energy sources needed to fulfil the vehicle load requirements, as well as the set of equations related to the mass, cost and volume of each one of the power distribution subsystems. Moreover, this paper analysis ten different power distribution architectures to conclude which is the most suitable secondary energy source, the minimum sizing, cost, volume and weight, depending on the amount of power delivered by the fuel cell. Also, a 1.6 kW fuel cell based architecture is implemented and testing. The experimental results confirm the proposed methodology.

This paper develops step-by-step a complete electric model of a light hybrid electric vehicle propulsion system. This model includes the vehicle mass, the radius and mass of the wheels, the aerodynamic profile of the vehicle, the electric motor and the motor drive, among other elements. Each element of the model is represented by a set of equations, which lead to getting an equivalent electric circuit. Based on this model, the outer and inner loop compensators of the motor drive control circuit are designed to provide stability and a fast dynamic response to the system. To achieve this, the steady-state equations and the small-signal model of the equivalent electric circuit are also obtained. Furthermore, as these elements are the main load of the power distribution system of the fully electric and light hybrid electric vehicle, the input impedance model of the set composed of the input filter, the motor drive, the motor, and the vehicle is presented. This input impedance is especially useful to get the system stability of the entire power distribution system.

The design of the optimal power distribution system (PDS or powertrain) for fuel cell-based vehicles is a complex task due to PDS comprising one or more power converters, several types of secondary energy sources, a fuel cell, several control loops, and protections, among others. The optimized powertrain design tries to minimize the mass, volume, and cost, and also to improve system efficiency, fuel economy (both hydrogen and electricity), and vehicle autonomy. This paper analyzes the influence of four different factors that deeply affect the optimal powertrain design, in particular: the minimum power delivered by the fuel cell, the storage of the recovered energy from the regenerative braking periods, the battery technology, and the maximum battery state-of-charge variation. The analysis of these factors is carried out over a set of 9 different fuel cell-based architectures applied to a light vehicle, and a 10th architecture corresponding to a pure electric vehicle. This analysis provides the knowledge of how these design factors affect the mass, volume, and cost of the optimal power distribution architectures, and how they can be considered in the design.