A Bevy of Battery and Fuel-Cell Electric Truck Reveals

The barrage of electric commercial vehicles continues as several OEMs revealed their latest offerings at the ACT Expo.

Navistar’s new fully-electric International eMV Series trucks are already rolling off of production lines. (Navistar)

As one should expect from an industry event called Advanced Clean Transportation (ACT) Expo, several truck OEMs revealed their latest battery-electric and fuel-cell-electric offerings in Long Beach, California, both in prototype and production form.

The eMV’s 210-kWh capacity, high-voltage battery pack provides a 135-mile (217-km) range when fully charged. (Navistar)

Navistar used the occasion to launch its new fully-electric International eMV Series trucks, which are available to order. Designed for improved visibility and maneuverability, the eMV is suitable for any straight rail application and available in four different wheelbase options: 217-, 236-, 254- and 272-in. (5512-, 5994-, 6452- and 6909-mm). The Diamond Logic electrical system is standard equipment.

A digital instrument cluster provides details of the eMV’s operational status, including propulsion and regenerative load, state-of-charge indicator and regen braking indicator. (Navistar)

“Our team has worked tirelessly to build an all-electric medium-duty vehicle solution that offers our customers all the environmental benefits of a zero-emissions vehicle, while delivering the capabilities of a traditional medium-duty truck to help you take care of business,” said Debbie Shust, VP Medium-Duty Truck, Navistar. “Rolling off our production lines now, we are proud to offer the International eMV complete with inclusive consultation services provided by our specialized NEXT eMobility Solutions team to ensure seamless integration of electric vehicles into customer fleets.”

The eMV’s battery electric motor provides peak power of more than 335 hp (250 kW), with continuous power of 215 hp (160 kW). A 210-kWh capacity, high-voltage battery pack provides a 135-mile (217-km) range when fully charged. Batteries are packaged between the frame rails for additional protection and under warranty for five years or 100,000 miles (161,000 km). The eMV also is equipped with three levels of regenerative braking. A “state-of-the-art” digital instrument cluster provides the driver with details of the eMV’s operational status, including information on propulsion and regenerative load, state-of-charge indicator and regenerative braking indicator.

Both AC and DC charging capabilities are offered as standard equipment to allow customers to choose the best option for their fleets. The recommended Level 2 AC charging station is suitable for overnight charging and provides roughly 19.2 kW of power. The DC Fast Charge station option, which provides up to 125 kWh, has the capability to provide multiple power options. At its highest kWh input, it can provide a full charge to the eMV in under two hours.

Hino’s Class 8 XL8 prototype employs two Toyota fuel cells under the hood, a top unit and a bottom unit. (Hino Trucks)
Starting in 2023, a dedicated line at Toyota Motor Manufacturing Kentucky will begin assembling integrated dual fuel cell modules for use in heavy-duty commercial trucks. (Toyota)
With up to 185-kW CCS1 charging capability, the extended-range version of BYD’s 8TT and 6F can drive up to 200 miles on a charge. (BYD)
A Class 6 fuel-cell electric truck powered by Hexagon Purus and Ballard launched at ACT Expo. (Hexagon Purus)

Navistar executives stress that the company is committed to assisting customers in developing an “e-mobility business model” that delivers on business objectives. To this end, the NEXT eMobility Solutions team acts as a resource for customers in addition to the dealer network, providing education and assistance beginning at buyer consultation and continuing through vehicle end of life. NEXT provides support throughout the entire fleet-electrification process including vehicle charging complexities like requirements for proper charging, suitable infrastructure partners, charging installations and collaborations with local power companies to ensure adequate power is available for vehicle charging.

“The entire Navistar team is proud of our progress in eMobility and our thoughtful approach on accelerating the adoption of zero-emissions vehicles,” said Gary Horvat, VP of eMobility. “We are centered around providing a complete ecosystem solution that will allow our customers to seamlessly integrate our EVs into their fleets and are confident the eMV will provide an extremely positive total ownership experience.”

Heavy-duty hydrogen prototype

Hino Trucks announced less than a year ago that it was building a Class 8 hydrogen fuel cell electric truck in collaboration with Toyota. The result of this joint development was revealed at the ACT Expo, Hino’s first Class 8 XL8 prototype.

“It’s amazing what our team has been able to accomplish in a relative short period of time. I know our customers are going to be extremely impressed with this fuel cell electric truck,” said Glenn Ellis, senior vice president Customer Experience, Hino Trucks. “We are looking forward to validating the performance, reliability and efficiency of our hydrogen fuel cell electric system in the XL Series chassis.”

In a pre-event video introduction of the XL8 FCEV in Ann Arbor, Michigan, Toyota engineer Jonathan Sander provided some details of the truck’s fuel-cell (FC) kit. Under the hood where a diesel engine would typically reside are two Toyota fuel cells designed specifically for commercial vehicles, a top unit and a bottom unit. The prototype has a 12-volt battery system with shutoff similar to a diesel truck, plus a high-voltage battery that works with the fuel cells to provide comparable power to a traditional Class 8 truck. The hydrogen tanks are inside a cabinet behind the cab. At the rear center of the vehicle is a two-motor system and transmission, and a prop shaft leading to the rear differential. Torque output also is comparable to a Class 8 over-the-road, 80,000-lb application, Ellis said.

Toyota announced in August that starting in 2023, a dedicated line at Toyota Motor Manufacturing Kentucky in Georgetown, Kentucky, will begin assembling the integrated dual fuel cell modules for use in heavy-duty commercial trucks. The modules weigh approximately 1,400 lb (635 kg) and can deliver up to 160 kW of continuous power.

“We’re bringing our proven electric technology to a whole new class of production vehicles,” said Tetsuo Ogawa, president and CEO, Toyota Motor North America. “Heavy-duty truck manufacturers will be able to buy a fully integrated and validated fuel cell electric drive system, allowing them to offer their customers an emissions-free option in the Class 8 heavy-duty segment.” The second-generation Toyota fuel-cell system delivers more than 300 miles (483 km) of range at a full load weight of 80,000 lb.

“From our Project Z announcement last October, we have received significant interest from customers, and now we have something tangible to show them in our prototype FCEV,” said Bob Petz, senior vice president of Vehicle and Parts Sales, Hino Trucks.

Next-gen electric trucks

BYD unveiled two battery-electric heavy-duty trucks, the Gen3 8TT and 6F, that feature cabs styled by Wolfgang Josef Egger, the renowned former Audi chief designer. The cabs offer improved aerodynamics and energy efficiency. The trucks come standard with advanced driver-assistance systems (ADAS) and are equipped with an Electronic Parking Brake system, keyless entry and push-to-start functions. With up to 185-kW CCS1 charging capability, the extended-range version of the 8TT and 6F can drive up to 200 miles (322 km) on a charge.

The versatile Gen 3 8TT is suitable for drayage, regional haul and distribution work. The 6F can perform regional haul and distribution work, and also can be equipped with a body for refuse collection.

“We listen to our customers and their drivers to ensure we provide the features and performance they need to get a job done,” said Stella Li, President of BYD North America. “With our next-generation 6F and 8TT, we’re setting a new standard for driver comfort and safety in an electric vehicle.”

BYD claims to be the leader in battery-electric truck deployments with more than 8,000 trucks in service around the world and over 200 in service across the United States.

Class 6 FCEV collaboration

Hexagon Purus and Ballard Power Systems announced a new collaboration to produce Class 6 and 7 fuel cell electric trucks powered by Hexagon Purus’ turnkey electric drivetrain and hydrogen storage system and Ballard’s 8th generation fuel-cell module, the FCmove. The truck is expected to offer a range of more than 400 miles (644 km) and refueling times comparable to conventional trucks.

With Hexagon Purus’ lightweight type 4 H2 storage systems, high energy density ProPack battery storage and fully integrated electrified accessory systems, the companies expect the truck to enter California’s Hybrid and Zero-Emission Truck and Bus Voucher Incentive Program (HVIP) eligible vehicle list in 2022. First fleet deployments will be in and around the Los Angeles Basin area.

The companies expect this collaboration to enable accelerated adoption of hydrogen and fuel cells in heavy-duty transport applications. “Fuel cell and hydrogen technologies will enable the decarbonization of the heavy-duty transportation sector with long range and quick vehicle refueling, without compromising on payload. Our partnership with Hexagon Purus will deliver a high-performance, zero-emission Class 6-7 truck with the integration of state-of-the-art fuel cell engine, hydrogen storage and electric drivetrain,” said Nicolas Pocard, VP marketing and strategic partnerships at Ballard.

First prototypes of the hydrogen truck will be delivered in the second quarter of 2022.