Powertrain Design and Energy Management Strategy Optimization for a Fuel Cell Electric Intercity Coach in an Extremely Cold Mountain Area

Facing the challenge that the single-motor electric drive powertrain cannot meet the continuous uphill requirements in the cold mountainous area of the 2022 Beijing Winter Olympics, the manuscript adopted a dual-motor coupling technology. Then, according to the operating characteristics and performance indicators of the fuel cell (FC)–traction battery hybrid power system, the structure design and parameter matching of the vehicle power system architecture were carried out to improve the vehicle’s dynamic performance. Furthermore, considering the extremely cold conditions in the Winter Olympics competition area and the poor low-temperature tolerance of core components of fuel cell electric vehicles (FCEV) under extremely cold conditions, such as the reduced capacity and service life of traction batteries caused by the rapid deterioration of charging and discharging characteristics, the manuscript proposed a fuzzy logic control-based energy management strategy (EMS) optimization method for the proton exchange membrane fuel cell (PEMFC), to reduce the power fluctuation, hydrogen consumption and battery charging/discharging times, and at the same time, to ensure the hybrid power system meets the varying demand under different conditions. In addition, the performance of the proposed approach was investigated and validated in an intercity coach in real-world driving conditions. The experimental results show that the proposed powertrain with an optimal control strategy successfully alleviated the fluctuation of vehicle power demand, reduced the battery charging/discharging times of traction battery, and improved the energy efficiency by 20.7%. The research results of this manuscript are of great significance for the future promotion and application of fuel cell electric coaches in all climate environments, especially in an extremely cold mountain area.