Paper: Optimized fuel cell electric powertrains for trucks

As heavy-duty transport accelerates toward zero-emission solutions, selecting the optimal powertrain configuration is a decisive factor in vehicle performance, cost, and sustainability outcomes. For fuel cell electric trucks, the architecture and integration of fuel cell and battery systems are especially critical - these components account for up to 70–80% of the powertrain cost and approximately 30–40% of the total vehicle cost. System architecture is therefore essential to ensure efficiency, longevity, and economic viability.

In a new paper, focused on optimized powertrains for decarbonized trucks, Ballard Power Systems’s expertise in the development and application of fuel cell technology is combined with Forsee Power’s capabilities in smart battery systems. The partnership leverages the strengths of both companies to deliver integrated hybrid energy systems - providing OEMs and fleet operators with a structured, duty-cycle-informed methodology for powertrain configuration.

In the jointly developed paper, Ballard and Forsee Power have collaborated to model real-world duty cycles that guide vehicle OEMs, integrators and end-users in selecting the most efficient powertrain mix for each use case. It addresses key decision points such as:

• Whether to prioritize battery-electric, fuel cell, or hybrid architectures
• Trade-offs between weight, energy cost, vehicle range, and payload capacity
• The impact of energy management and control strategies on system performance and degradation
• How duty cycle variables (e.g., range, terrain, operational flexibility) affect the optimal fuel cell/battery balance