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ManGo Product Design has been working with Emoss, a manufacturer of powertrains for electric vehicles, since 2007. Many innovative projects have been realised over the years in our productive collaboration. When Nedstack, one of the largest European manufacturers of PEM fuel cells requested to develop a truck for the Hy4ever project that could run on hydrogen, we joined forces to make it happen.
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Nedstack was responsible for supplying the hydrogen fuel cells, Emoss for the electric drive train and ManGo for developing the complete hydrogen system. This range extender can be seen as a “mini-factory” that stores liquid hydrogen and combines it with oxygen from the air in the fuel cell. The chemical reaction that then takes place provides electricity to the battery to drive the electric motor. Water generated in the process is neatly disposed of.
Besides an appealing design for the hydrogen system, ManGo was responsible for the complete technical development and construction. A major challenge because hydrogen is the smallest molecule in the periodic table and permeable materials are not allowed to be used anywhere. To prevent leakages which can result in explosions. This means that all pipes, valves and fittings have to be developed with very specific materials and production methods.
The legal requirements for these types of systems regarding safety are immense. No dangerous situations should arise when braking hard, accelerating or crashing. Strict standards and testing at Notified Bodies such as the RDW ensure this. The most challenging requirement in this regard is that the entire structure and all components inside it must withstand accelerations and decelerations (braking or impact) up to 6.6 g-force. By comparison when you are in a roller coaster you only experience a maximum of 1.5 to 2 g-force. During the process, FEM analyses were executed to test the interaction of forces in all directions on the construction and to optimize the design. And it was also important to ensure that maintenance on all components would remain possible in this robust construction.
From the initial research phase to realisation, the entire project took about a year and a half. The first prototype of the hydrogen system was jointly built by Nedstack and ManGo. Emoss subsequently carried out the integration of the assembly on the truck.
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