Hydrogen has never been more important for the commercial vehicle industry. Under the extremely high requirements of environmental protection and efficiency, more and more hydrogen commercial vehicles have come out. Solutions and supporting technologies are emerging in an endless stream, and representative technologies such as hydrogen fuel cells and hydrogen internal combustion engines are no longer the products of "earth-shattering". While their commercialization is still under question, there's no denying that the era of hydrogen is dawning before us.
Today, the Iveco Group from Italy is in the midst of a strong transformation, with a "multi-fuel" strategy at its core: the traditional commercial vehicle industry is dominated by diesel fuel. With the development of the times, natural gas, pure electric and other drive forms have also become an important part of the commercial vehicle industry. It is for this reason that IVECO continues to advance its traditional drive technology and invests heavily in pure electric and hydrogen energy.
In September 2024, the "world's largest exhibition in the commercial vehicle industry": Hannover Motor Show in Germany (hereinafter referred to as IAA Motor Show) was officially held. At this grand event in the commercial vehicle industry, Iveco brought us two hydrogen internal combustion engine heavy trucks in a row. They are available as pure internal combustion engine drives and as extended-range hybrids. Relying on FPT's strong technology, IVECO has perfected its hydrogen fuel heavy-duty truck solutions, and has a "troika" of hydrogen internal combustion, hydrogen internal combustion range extender hybrid, and hydrogen fuel cell. In today's article, Tiga takes two show cars as examples to take you through IVECO's hydrogen fuel product lineup.
One of the two show cars is a "Headless Horseman" without a cab, and the other is a complete version with a cab, which is the one pictured above. Named by IVECO: S-Way H2-ICE Concept, it is a concept heavy-duty truck equipped with a hydrogen internal combustion engine (H2-ICE). Although this model is a derivative of the Iveco S-Way platform, it has undergone significant changes in appearance. First of all, let's take a look at the exterior design of the Iveco hydrogen internal combustion engine heavy truck with the help of this show car.
In 2019, Iveco and Nikola Trucks, a new truck start-up, hit it off to jointly develop pure electric trucks and hydrogen fuel trucks. Based on Iveco's S-Way model platform and some of FPT Industrial's technologies, Nikola has launched the TRE series of pure electric heavy-duty trucks and hydrogen-fueled heavy-duty trucks. In 2023, Iveco Group acquired the European branch of the joint venture. From now on, Nikola will focus on the North American market, while Iveco will focus on the European market, and the legacy of the cooperation between the two will also evolve into the Iveco S-eWay electric heavy-duty truck and the S-eWay H2 hydrogen fuel cell heavy-duty truck.
Relying on FPT's strong R&D strength, Iveco has also brought hydrogen internal combustion heavy trucks to us. The S-Way H2-ICE Concept hydrogen internal combustion engine heavy-duty truck is modelly platformed in the same way as the S-eWay H2 hydrogen fuel cell heavy-duty truck, and although it is based on the S-Way series models, its front face has been significantly modified. Its main features are roundness and smoothness, and its front face protrudes outwards as a whole, with a sleek bumper, which greatly reduces the air resistance of the vehicle. At the same time, it also gives the vehicle a more powerful appearance.
The picture above shows the Iveco S-eWay H2 hydrogen fuel cell heavy-duty truck, and you can see the similarities between the two
If the front face shape of the Iveco S-Way gives people a sense of intimacy, then the front face shape of the Iveco S-Way H2-ICE Concept hydrogen internal combustion engine heavy truck is completely based on the sense of technology and muscle. Although its overall shape is relatively rounded, the internal lines are also quite powerful, showing a visual perception of "rigidity and softness". For low drag, the surface of the bumper is smoother, and the underside of the headlights is designed with cutouts to allow air to flow smoothly.
Compared with the Iveco S-Way model, the headlight shape of this car has also been improved, and the lines are sharper, like an eagle's eye. Inside the headlights are two LED light sources for excellent illumination. The daytime running lights function as turn signals, and are vertically integrated into the outside of the headlights, forming a natural "hook edge" that accentuates the body contour lines.
Compared with diesel, hydrogen has a higher heat during combustion, and the problem of heat dissipation during work is more serious, so it is difficult to obtain higher thermal efficiency, and heat dissipation is also a big problem. The front face of the Iveco S-Way H2-ICE Concept hydrogen internal combustion engine heavy-duty truck is designed with a large area of air intake, which is covered by a honeycomb grille, combined with a large radiator at the rear, to bring better heat dissipation to the engine.
Turning to the side, you can feel it even more: the Iveco S-Way H2-ICE Concept hydrogen combustion engine heavy-duty truck. Its hydrogen storage system adopts a piggyback design and is equipped with a large area of shroud, forming an extra-long "stacking area" behind the original cab. With the long-wheelbase chassis, the vehicle shape is more symmetrical, and the "top-heavy" feeling of the traditional Oka is greatly reduced.
As a heavy-duty truck with a hydrogen internal combustion engine, the cab of the Iveco S-Way H2-ICE Concept is identical to that of the diesel version of the S-Way. It also features an AS-type cab with a high roof with sleeper, which is built for long-distance trunk transport and can accommodate two drivers. Outwardly, the size of the cab seems to have been increased. In reality, however, a similarly enlarged area at the rear is used to house the vehicle's hydrogen storage system.
The black section is the car's shroud, which is extremely long and enhances the vehicle's sense of majesty. The electrical cable gantry is integrated into the rear wall of the hydrogen storage system and has a working light to help enhance safety.
Now that we're out of the way, let's talk about the powertrain. At this year's IAA Auto Show, the exhibits of the two hydrogen internal combustion engine heavy-duty trucks of Iveco are not the same. The complete version of the model equipped with the cab in the picture above is a "pure hydrogen internal combustion" route, without the blessing of the hybrid system, using a mechanical transmission method, providing a more stable and solid power output, and the whole system is more reliable, simple in structure, suitable for demanding and harsh working conditions.
In November 2023, Iveco officially unveiled the facelifted S-Way flagship heavy-duty truck model, and brought the all-new Fiat xCursor 13 series inline-six engine at this press conference. The engine is a multi-fuel platform engine that is compatible with natural gas, hydrogen and a variety of renewable sources in addition to the standard version of diesel. It is FPT Industrial's first multi-fuel engine, designed and manufactured so that most of the components can be used in common, thus reducing the production cost of different fuel models and making it compatible with a wide range of vehicle types.
Compared to the previous Cursor 13 diesel engine, the new xCursor 13 engine has an upgraded cylinder block and cylinder head that is significantly lighter by 10 percent. At the same time, Iveco has improved and optimized other engine structures, using lightweight low-friction materials, optimizing engine valves and other structures, with a new thermal management system, fuel injection system, matching higher compression ratio and eVGT electronically controlled variable geometry turbocharger to enhance power output performance and reduce fuel consumption.
Back in the 2023 edition of the Agritechnica agricultural exhibition, FPT Industrial presented the xCursor 13 hydrogen internal combustion engine for off-road applications. Today, it is also integrated into the Fiat family: Iveco heavy-duty trucks. It makes 500 hp and 2,500 Nm of torque, and is mated to a ZF TraXon 12-speed AMT gearbox, mated to the rear axle of the Meritor. In addition to the engine, all its mechanical components are the same as those of diesel models, reducing development and manufacturing costs. For users, it is also easier to maintain and has a lower purchase price.
Compared to hydrogen fuel cell trucks, hydrogen internal combustion engine trucks are more suitable for demanding heavy-duty conditions. Hydrogen internal combustion engine is similar to diesel trucks, with high reliability, stable power output, lower external influence, continuous working performance, and maximum output power, which can form a "complementary" product matrix together with hydrogen fuel cell heavy trucks and pure electric heavy trucks.
Regarding the cruising range parameters of this car, Iveco did not give an intuitive figure. However, the vehicle is equipped with three hydrogen storage tanks in a piggyback structure and hydrogen storage tanks on the side of the chassis, providing a total of 1,800 liters (72 kg) of hydrogen storage. For reference, the MAN hTGX hydrogen internal combustion heavy-duty truck carries 56 kg of hydrogen and has a range of 600 km. If the same hydrogen consumption is used to calculate the hydrogen consumption, the range of the Iveco S-Way H2-ICE Concept hydrogen internal combustion heavy-duty truck should be at the level of 800 km.
At the scene, Iveco also brought another hydrogen internal combustion engine heavy truck. It doesn't have a cab installed, and the engine is exposed, which makes for a better display. Named S-eWay H2-Hybrid Concept by IVECO, this hydrogen internal combustion heavy-lift truck adopts the overall architecture of extended-range hybrid, with a hydrogen internal combustion engine as a range extender, and is equipped with an energy storage system and electric drive axle provided by FPT Industrial Technology, which is a cutting-edge concept car.
The car is equipped with a Fiat Cursor 9 H2 hydrogen internal combustion engine under the cab, with an inline six-cylinder structure and a displacement of 9 liters, with an output of 310 hp and 400 Nm of torque, which is a medium-sized hydrogen internal combustion engine. As a range extender for the vehicle, it works at a constant speed range with high efficiency to drive the generator to charge the power battery, thereby extending the mileage of the vehicle. This allows the vehicle to operate in different modes of pure electric and hybrid, which can achieve zero-emission transportation and get rid of the shackles of range as much as possible.
The Fiat Cursor 9 H2 hydrogen engine is based on the tried-and-tested diesel version and features an improved fuel injection system with inlet injection instead of the more popular direct injection route. Its maintainability is comparable to that of diesel engines, its structure is simple and reliable, it can not only achieve a clean and environmentally friendly environment, but also a cost-effective choice with a balanced cost, and is better and easier to use than hydrogen fuel cells.
In addition to being used as a range extender, the Fiat Cursor 9 H2 hydrogen combustion engine can also be matched with the gearbox to directly output power in the form of mechanical transmission, which can be used in medium-duty trucks and buses, and is suitable for medium- and long-distance heavy-duty transportation conditions.
Like the Iveco S-Way H2-ICE Concept hydrogen engine heavy-duty truck next door, this hydrogen internal combustion extended-range hybrid heavy-duty truck also adopts a piggyback hydrogen storage tank design, with three carbon fiber hydrogen storage tanks installed behind the cab, stacked in a rack-like manner, and attached to the shell to shield and protect the effect.
A hydrogen storage tank is also installed on the side of the chassis, which is combined with a piggyback hydrogen storage tank to achieve a hydrogen storage capacity of 1,800 liters (72 kg). Combined with the high efficiency of the extended-range hybrid system, the cruising range of the car will reach the level of 1,000 kilometers, so as to meet the needs of long-distance trunk transportation.
In addition to the hydrogen combustion engine and hydrogen storage system, the Iveco S-eWay H2-Hybrid Concept is equipped with FPT Industrial's electric energy storage system, with two battery packs mounted on the inside of the frame, resulting in higher chassis space utilization and enhanced chassis rigidity. The battery capacity is 80 kWh per battery and 160 kWh per two batteries. They have the function of "peak shaving and valley filling", which can meet the high power demand under climbing, starting and other working conditions. At the same time, the range extender can continuously charge the battery in a more stable and high-efficiency range, resulting in higher overall energy efficiency.
In terms of drive, the Iveco S-eWay H2-Hybrid Concept hydrogen combustion extended-range hybrid heavy-duty truck also uses Fiat technology and is equipped with an electric axle provided by the company, which outputs 400 kW of power, or 544 hp. Higher integration and higher transmission efficiency of electric axles are the future development direction of hybrid and electric trucks.
依维柯S-eWay H2-氢燃料电池重卡
At the same time, thanks to the high level of integration brought about by the e-axle technology, a lot of chassis space is liberated, which opens up the possibility of more flexible chassis layouts. It is based on this technology that the Iveco S-eWay H2-Hybrid Concept hydrogen internal combustion extended-range hybrid heavy-duty truck adopts a mid-battery structure. The Iveco S-eWay electric heavy-duty truck and the Iveco S-eWay H2-hydrogen fuel cell heavy-duty truck, which are also equipped with electric axles, also have a battery in the middle of the frame to achieve higher power, thereby extending the cruising range and greatly improving the vehicle's usability.
Compared with traditional diesel heavy trucks, the curb weight of hydrogen internal combustion and hydrogen fuel cell heavy trucks will be much higher, mainly due to their additional equipment such as hydrogen storage systems. In order to share the weight, the two hydrogen internal combustion heavy-duty trucks unveiled at the IAA Motor Show this time are both in a 6x2 drive form with a long wheelbase of more than 3.9 meters. The second axle is a drive axle and the third axle is a follow-up steering axle, which compresses the turning radius of the vehicle to less than 12.5 meters to meet the relevant requirements of regulations. In addition, the rear axle of the vehicle is also air-suspension. The damping performance is better and the structure is compact, making more room for the chassis.
Both hydrogen internal combustion heavy-duty trucks are based on the latest Iveco S-Way model platform, and the sleek technology of electronic mirrors has also appeared on the vehicle, replacing the traditional, bulky optical mirrors.
The electronic rearview mirror adopts a single-camera solution, which can provide a brighter field of view in bad weather and pitch darkness for the rear view, which is safer than the traditional optical rearview mirror. In addition, the electronic rearview mirror also has lower wind resistance, less wind noise, and has a positive gain on energy consumption and interior quietness.
In terms of interior, the car also uses the latest generation of intelligent interior, the steering wheel has been changed to a four-spoke design, and the new Iveco flat logo has been replaced. Combined with a new generation of instrument panel, multimedia screen, plus the electronic rearview mirror screen above the A-pillar, the multimedia interior of four large screens is formed, which is full of science and technology.
The car's push-button start button is designed on the steering wheel, located below the multi-function button on the left, and can be quickly reached by the left thumb, giving it the look of a supercar. There is a keyhole under the handbrake that allows you to store your keys in it, which also has a different flavor. The multi-function buttons on the steering wheel are backlit, while the push-button start button is also backlit to make it easier for the driver to maneuver in dark conditions.
A large touchscreen infotainment screen is added to the centre console, which allows the driver to adjust the vehicle's functions, multimedia entertainment system and other functions. On the lower screen, a variety of physical buttons and storage slots are still retained, and air conditioning and important body functions can be quickly and intuitively controlled through buttons, which is convenient for the formation of muscle memory and enhances the convenience and safety of control.
Although it is not a head-to-tail equal-width design, the size of the sleeper is also quite impressive
Relying on the strong technical strength brought by FPT Industrial Technology, Iveco brought two hydrogen internal combustion heavy truck products in a row at this IAA Auto Show, covering both pure hydrogen internal combustion drive and extended range hybrid routes, with considerable strength and no less than other first-line Oka brands. Together with the previously released Iveco S-eWay H2 hydrogen fuel cell model, Iveco has formed a triple technical route of hydrogen fuel cell + hydrogen internal combustion + hydrogen internal combustion hybrid, and continues to invest in the field of hydrogen fuel commercial vehicles. Combined with leading diesel, natural gas and electric solutions, IVECO is ready for the future of transportation. Thank you for reading this article! If you want to see more interesting and informative commercial vehicle content, don't forget to follow us!
文图：heseaotter