Building on nine generations of fuel cell development, Ballard Power Systems' new compact design FChamba®-The XD fuel engine delivers class-leading volumetric power density, with an open architecture design that makes the fuel cell the smallest and lightest in its power range.
The compact FCMove®-The XD module is scalable from 120-360kW providing an ideal solution for Class 6 to 8 trucks, delivering a simple integration platform for automotive OEMs and assemblers. The module is designed to deliver unparalleled performance – with a driving range of up to 800km combined with the highest volume power density in the global truck industry.
FCMove® range of heavy-duty fuel cell modules designed, developed, and sold by Ballard, and are the longest-running fuel cell modules in operation. These new products have completed more than 200 million real-world kilometers and demonstrate market-leading performance with a stack life of 25,000+ hours and 98% module reliability. It is this proven performance technology and experience, built on over 30 years of off-road experience, that informs and powers Ballard's latest generation engine.
Innovating with fuel cell technology
The low-end 120kW fuel cell module includes a regulated DC/DC output, enabling up to three modules to deliver 360kW, operating as a single engine with a single interface. The integrated power controller includes a DC/DC converter, an air compressor inverter, and a power distribution unit.
The open engine design delivers the greatest power published in the industry,
and the high-efficiency engine enables a total cost of ownership, effective heat rejection, and ensures a long driving distance of 800km – depending on the final hydrogen capacity on board.
Ballard's latest FCgen®-HPS stack design enables high operating temperature up to 95°C and extended durability with low cost carbon bi-polar plates.
The open design of the fuel cell architecture has resulted in a 33% reduction in components and a 25% reduction in size compared to previous modules. FCMove®-The XD is designed to fit diesel engine space requirements and up to two (240kW) units can be installed vertically in the engine bay of a heavy truck, maintaining easy access for service and maintenance.
Benefiting from longer range and faster refueling than battery-electric alternatives, fuel cell trucks are also a true zero-emissions solution compared to internal combustion hydrogen engines, which produce no NOx or tailpipe emissions. As production increases, the reduced complexity and efficient energy conversion that fuel cells bring has great potential to provide a low-cost solution to meet heavy duty mobility needs.
FChamba®-XD on the road
As one of the first manufacturers to use Ballard's most powerful fuel cell engine, German e-mobility specialist Quantron has integrated two 120kW generating modules into its 44-ton QHM AERO electric truck.
The QHM AERO offers a class-leading range of up to 700km, a hydrogen storage capacity of over 50kg, and a battery capacity of 120kWh. The truck's hydrogen consumption is optimized by a specially developed management system, which realizes great efficiency in the interaction between the e-axle, fuel cell and electric battery.
As part of Ford Trucks' integrated transformation to decarbonise its global fleet, Ballard will also supply FCmove.®-XD in Ford Otosan's hydrogen-powered F-MAX FCEV heavy-duty prototype.
The fuel cell engine will be integrated into a 44-ton long tractor, which will be built and assembled in Turkey for the European market; with the Ten-T corridor demonstrations scheduled for 2025 as part of the European Union's Horizon Europe Zero Emission Freight EcoSystem (ZEFES) project.
It shows the versatility of Ballard's product platform, FCmove®-XD also powers Applied Hydrogen's zero-emission 30-ton excavator. Based on the Volvo EC300E crawler, the vehicle was developed for the Scandinavian construction company, Veidekke, and will eliminate around 60 tons of CO.2 annual carbon emissions.
Ballard showcased its most powerful fuel cell technology at the IAA TRANSPORTATION 2024 international trade show at Booth C01, Hall 24, in Hannover, Germany from September 16-22.
Topping the company's participation in the event, Ballard's technology team introduced FCmove®-The 240kW XD system, featuring flexibility, flexibility and flexible integration that presents a heavy-duty fuel cell engine suitable for Class 8 trucks 19 tonnes and above. Watch the video below for Ballard's IAA highlights: