By ATN
Summary: The UK-based Project ARCHER consortium – including Intelligent Energy, Drive System Design, and General Engine Management Systems – has revealed a new 200kW fuel cell system engineered for heavy-duty vehicles. Backed by the UK government’s DBT and the APC’s DRIVE35 Demonstrate programme, the IE-DRIVE fuel cell system delivers certification-ready, zero-emission power for buses and trucks. Key innovations include DSD’s first-of-its-kind multi-input, multi-output converter surpassing the 200kW barrier, GEMS’ ISO 26262-compliant ECU for robust control, and Intelligent Energy’s proven fuel cell stack integration.
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Key engineering takeaway: The IE-DRIVE HD system integrates a 200kW fuel cell stack with a pioneering multi-input, multi-output converter and an ISO 26262-compliant ECU, enabling scalable, high-power solutions for heavy-duty vehicles.
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Why it matters: Heavy trucks and buses face range and refuelling challenges that batteries alone struggle to meet. This next-gen fuel cell system provides a viable, certification-ready zero-emission pathway that supports the UK’s net zero goals.
The UK-based engineering consortium behind Project ARCHER has unveiled a cutting-edge 200kW fuel cell system designed specifically for heavy-duty vehicles. This next-generation technology marks a significant leap forward in the drive toward zero-emission transport, aligning with the UK’s net zero ambitions.
Backed by funding from the Department for Business and Trade (DBT) through the Advanced Propulsion Centre’s DRIVE35 Demonstrate programme, the consortium – comprising Intelligent Energy (IE), Drive System Design (DSD), and General Engine Management Systems (GEMS) – has developed the latest IE-DRIVE fuel cell system to tackle the most pressing electrification challenges in the truck and bus sectors, including range limitations and refuelling efficiency.
Leading the innovation, Intelligent Energy has integrated its proven core fuel cell stack with a suite of advanced balance-of-plant components, engineered to meet rigorous lifetime and certification standards.
Engineered by DSD, the fuel cell’s multi-input, multi-output converter is a transformative component. As the first converter of its kind, it’s capable of delivering more than 200kW of power, surpassing previous limits of 150kW. This breakthrough enables seamless coupling of multiple fuel cell systems to meet the high-power demands of heavy-duty applications.
To support safe and reliable operation, GEMS has delivered a dedicated ISO 26262-compliant electronic control unit (ECU), providing robust system control in line with automotive safety requirements.
Dr Ashley Kells, Programme Director at Intelligent Energy, commented:
“With simplified vehicle integration, longer life and being certification ready, the IE-DRIVE HD fuel cell is now even better positioned to provide a zero-emission solution for heavy duty applications”
James McGeachie, Head of Electrified Powertrain at DSD, said:
“Our first-of-its-kind converter will give the heavy-duty vehicle industry a welcome power boost to drive it forward on its electrification journey.
“Working closely with GEMS and Intelligent Energy has been key to this success. Each partner has brought sector-leading experience, expertise and innovation to the programme, delivering a world-class fuel cell system solution.”
Peter Bannister, Director at GEMS, added:
“We’re proud to introduce the XCU8 ECU, building on the proven success of our EM80-M controller. Designed for the automotive sector, the XCU8 offers a robust platform for deploying custom control strategies – including Simulink® models – with enhanced functional safety and cybersecurity.”
Intelligent Energy, DSD, and GEMS will be joining forces at the Cenex Expo in Millbrook on 3-4 September, where they’ll showcase their cutting-edge fuel cell system development on the DRIVE35 Demonstrate stand. Attendees will discover how this innovative technology is set to accelerate the sector’s journey toward full electrification.
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