Optimizing the Powertrain of a Fuel Cell Electric Bus: A Sizing and Hybridization Analysis

In this study, the impact of the electric motor size and the hybridization ratio of a Fuel Cell Electric Bus on its vehicle performance (i.e., gradeability and acceleration) and fuel consumption was investigated using the ADVISOR software. The investigation first involved a parametric analysis with different electric motor and fuel cell sizes for the dynamic performance metrics, specifically the 0–60 km/h vehicle acceleration and the maximum gradeability (%) at a constant speed of 20 km/h. The results revealed that the acceleration is most sensitive to fuel cell power. Regarding gradeability, a more complex relationship was observed: when the electric motor power was below 215 kW, gradeability remained consistently low regardless of the fuel cell size. However, for motors exceeding 215 kW, fuel cell power then became a significant influencing factor on the vehicle’s climbing capability. Subsequently, the analysis focused on the effect of the hybridization ratio, which represents the power balance between the fuel cell and the energy storage system, varied between 0 and 0.8. Results showed that increasing the hybridization ratio decreases gradeability and acceleration performance and increases total energy consumption. This trade-off is quantitatively illustrated by the results over the Central Business District (CBD) driving cycle. For instance, the pure battery-electric configuration (a hybridization ratio of 0), featuring a 296 kW battery system, recorded a gradeability of 12.4% and an acceleration time of 16.3 s, while consuming 28,916 kJ. At an intermediate hybridization ratio of 0.4 (composed of a 118.4 kW fuel cell and a 177.6 kW battery), performance remained high with a gradeability of 12.2% and an acceleration of 17.3 s, but the energy consumption increased to 43,128 kJ. Finally, in the fuel-cell-dominant configuration with a hybridization ratio of approximately 0.8 (a 236.8 kW fuel cell and a 59.2 kW battery), gradeability dropped to 8.4%, acceleration time deteriorated to 38.9 s, and total energy consumption increased further to 52,678 kJ over the CBD driving cycle.