In order to meet the challenge of electrification of heavy commercial vehicles with up to 41 t gross vehicle weight restriction, one possible promising approach is the development of a modular electric powertrain kit. In the following analysis, an integrated electric drive axle is designed for a 41 t tractor-trailer-unit in long-haul transport as part of a modular drive system with an integrated fuel cell. The lay out design begins with selected static driving profiles from which the requirements, such as the maximum drive torque and power, are derived for the drive axle. Subsequently, a concept with two permanent magnet synchronous motors and different gear stages is being analysed. In a parameter study, a simulation of the drivetrain in different driving cycles shows how a possible length variation of the motors and the change from a single- to a two-speed gearbox contribute to optimal energy efficiency and thus to lower energy consumption in the selected cycles. Furthermore, the existing conflict of objectives between motor and transmission package is addressed.

Fuel cell trucks are a promising solution to reduce the disproportionately high greenhouse gas emissions of heavy-duty long-haul transportation. However, unlike conventional diesel vehicles, they lack combustion engine waste heat for cabin heating. As a result, electric heaters are often employed, which increase auxiliary energy consumption and reduce driving range. To address this challenge, advanced control strategies are needed to improve heating efficiency while maintaining passenger comfort. This study proposes and validates a methodology for implementing Model Predictive Control (MPC) in the cabin heating system of a fuel cell truck. Vehicle experiments were conducted to characterize dynamic heating behavior, passenger comfort indices, and to provide validation data for the mathematical models. Based on these models, an MPC strategy was developed in a Model-in-the-Loop simulation environment. The proposed approach achieves energy savings of up to 8.1% compared with conventional control using purely electric heating, and up to 21.7% when cabin heating is coupled with the medium-temperature cooling circuit. At the same time, passenger comfort is maintained within the desired range (PMV within ±0.5 under typical winter conditions). The results demonstrate the potential of MPC to enhance the energy efficiency of fuel cell trucks. The methodology presented provides a validated foundation for the further development of predictive thermal management strategies in heavy-duty zero-emission vehicles.

A methodology for the development of nonlinear model predictive control for thermal management of a 40-ton fuel-cell heavy-duty truck is presented, using the medium-temperature cooling circuit as a case study. The approach integrates control-oriented modeling, parameter estimation, and experimental validation based on drivetrain test bench measurements under controlled high-temperature ambient conditions. A lumped-parameter model of the medium-temperature circuit, including coolant, oil, electric motors, and power-electronics auxiliaries, is derived and implemented in a Simulink environment, with heat-transfer parameters calibrated from test bench data and radiator air-side resistance and fan characteristics derived from CFD simulations and manufacturer specifications, respectively. Model parameters are identified using a systematic estimation procedure and the resulting model is validated against long-duration roller test measurements, achieving coefficients of determination above R² = 0.9 and normalized RMSE values below 10% for all key temperatures. The validated model is then used as the prediction model in a model predictive controller that manipulates radiator fan and coolant-pump speeds, while treating component heat losses, vehicle speed and ambient temperature as measured disturbances. The controller is evaluated in a model-in-the-loop environment for representative long-haul and urban driving cycles and different ambient temperatures, and its performance is benchmarked against conventional rule-based and PI-based control strategies. Depending on the driving cycle and ambient conditions, the proposed NMPC reduces cooling system energy consumption by up to 39.6% compared to a PI controller (VECTO Urban Delivery cycle, 35 °C ambient), with an average reduction of 16.6% across all investigated driving cycles and ambient conditions, without a significant increase in average or maximum coolant temperature. The proposed methodology provides a transferable workflow for developing predictive thermal management control in fuel-cell heavy-duty vehicles and other complex automotive cooling systems.