Design and Development of a Hydrogen Fuel Cell Range-Extender for Last-Mile Electric Ve...

Objective: To engineer and demonstrate a hydrogen fuel cell-based auxiliary power unit that extends the driving range of last-mile electric vehicles operating in Indian urban environments.

Last-mile delivery vehicles in India, such as electric auto-rickshaws and mini-vans, face critical limitations in operational range due to battery capacity and long charging times, impacting logistics operators, drivers, and the e-commerce sector.

This project proposes a compact hydrogen fuel cell range-extender system to supplement the main battery of electric vehicles, thus enabling longer operation per charge and rapid refueling, while reducing downtime and emissions. The approach involves selecting a suitable PEM fuel cell stack, designing the integration with an EV's electrical and thermal systems, and ensuring safety and cost-effectiveness for urban deployment.

Key deliverables include a bench-tested prototype of a 1-3 kW PEM fuel cell module, hydrogen storage with pressure regulation, power management electronics (DC-DC converter, BMS interface), thermal management subsystem, and a validated demonstration on a real or simulated EV drivetrain. The project also provides technical documentation, cost analysis, and a deployment roadmap under Indian conditions.

Scalable for mass adoption, this solution addresses urban air quality, extends asset utility for fleet operators, and aligns with 'National Hydrogen Mission' goals, offering a real pathway for industry adoption in the growing urban last-mile logistics sector.