Master's Thesis

Simulation of a fuel cell city bus in a driving cycle

Final Thesis 11.63 MB

Author of thesis: Hasan Barkin Nalbantoglu

Acad. year: 2025/2026

Supervisor: Ing. Michael Böhm, Ph.D.

Reviewer: Ing. Kateřina Fridrichová, Ph.D.

Abstract:

This thesis presents a GT-SUITE simulation study of a hydrogen fuel cell city bus in a driving cycle. The main objective is to create a complete simulation model which includes the fuel cell system, hydrogen storage, DC/DC converter, high-voltage battery, inverter-motor unit, braking system, cooling circuit, driver block and vehicle body model. The model is developed by combining a vehicle/truck powertrain template with a fuel cell system template. The Solaris Urbino 12 hydrogen bus is selected as the reference vehicle.

The simulation focuses on transient operation in an urban driving cycle. Since the Braunschweig city bus cycle was not available in the selected GT-SUITE cycle library, the CHTC-B cycle is used as the main urban bus driving cycle. VECTO Heavy Urban is considered as a secondary comparison case. The baseline model is first used to check vehicle speed tracking, fuel cell power, battery state of charge and hydrogen consumption. After that, selected fuel cell stack parameters are optimized.

The optimization study includes number of cells, membrane thickness, active surface area, gas diffusion layer thickness, anode and cathode stoichiometry, and channel height. The battery and electric motor are not fully re-designed because detailed public manufacturer maps are not available. Instead, their suitability is checked by battery SOC behaviour, regenerative braking behaviour and vehicle speed tracking. The optimized model reduces the simulated hydrogen consumption from about 13.3 kg/100 km to about 6.70 kg/100 km under the CHTC-B cycle. The battery SOC remains close to its initial value, so the improvement is not caused by extra battery discharge. A rated-power check is also carried out. In this check, the fuel cell electrical power reaches about 70 kW and the current density increases to about 0.32–0.33 A/cm². This shows that the optimized model can reach the nominal fuel cell power while still operating at relatively low current density. Therefore, the final stack configuration represents a simulation-based optimized case rather than a directly validated commercial stack design.

Keywords:

Fuel cell city bus, PEMFC, GT-SUITE, CHTC-B cycle, VECTO, hydrogen consumption, fuel cell stack optimization

Date of defence

17.06.2026

Result of the defence

Defended (thesis was successfully defended)

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Grading

E

Process of defence

The student presented the committee with the progress of the work, the results and conclusions of the thesis, and answered the reviewer's questions. The committee returned to the reviewer's first question and asked for the reasoning behind the choice of those particular boundary values, which the student explained to the committee. Doc. Lízal asked the student to describe the optimisation process in detail. The student explained that the optimisation had been carried out in the GT-SUITE software. Doc. Lízal asked what equations the software uses and whether the student understood what happens inside the software rather than merely changing the input and obtaining the output. Doc. Jan refined the question further, asking about the physical background of the optimisation. The student had only changed inputs and obtained outputs, without addressing what happens internally or the underlying physics. Doc. Charvát returned to the optimisation and added that the student should be familiar with the physical principles of the optimisation. Doc. Jan then asked about the optimal voltage on the cell, which the student clarified. When asked how the voltage changes with a change in the number of cells, the student was unable to answer. Prof. Novotný asked about the software and how many parameters there are to be changed within it. The student responded that he had changed approximately 100. Prof. Novotný asked whether the student had varied those parameters only within the range of the template, or whether he had carried out some review of the values to confirm that they were physically meaningful. The student preferred not to go beyond the given ranges.

Language of thesis

English

Faculty

Department

Study programme

Mechanical Engineering (N-ENG-A)

Composition of Committee

doc. Ing. Pavel Charvát, Ph.D. (předseda)
prof. Ing. Pavel Novotný, Ph.D. (místopředseda)
doc. Ing. František Lízal, Ph.D. (člen)
doc. Ing. Vít Jan, Ph.D. (člen)
doc. Ing. Jiří Šremr, Ph.D. (člen)
doc. Ing. Pavel Rudolf, Ph.D. (člen)

Supervisor’s report
Ing. Michael Böhm, Ph.D.

Mr. Hasan Barkin Nalbantoglu’s master’s thesis focuses on the simulation of a hydrogen fuel cell-powered city bus in a driving cycle. The main objective was to create a simulation model of a fuel cell-powered city bus using the GT-SUITE software.

The text is clear, and the student has successfully described the basic theoretical background of hydrogen, PEM fuel cells, hydrogen storage, fuel cell buses, and electric drive components. The theoretical section provides a broad introduction to the topic. On the other hand, some sections are rather general and descriptive, and a more detailed focus on the modeling methodology itself, energy management strategy, and validation of fuel cell bus models would improve the technical quality of the work.

The practical part of the thesis is based on the development of a model of a city fuel cell bus in GT-SUITE. Key vehicle parameters, such as vehicle weight, hydrogen tank volume, fuel cell power, aerodynamic parameters, and state of charge (SOC) limits, were adjusted according to available public data.

The student conducted a simple optimization study of selected fuel cell parameters, including the number of cells, membrane thickness, active area, diffusion layer thickness, anode and cathode stoichiometry, and channel height. The optimized model reduced the simulated hydrogen consumption in the CHTC-B cycle. The final result is close to the values reported for actual fuel cell buses, but this comparison must be interpreted with caution, as the model has not been experimentally verified.

The main limitation of the work is that the model relies heavily on existing GT-SUITE templates and uses a number of simplified assumptions. The battery and electric motor were not completely redesigned. Their suitability was verified mainly by monitoring vehicle speed and SOC behavior. The energy management strategy is also simplified and uses a constant DC/DC output power demand instead of a realistic control system algorithm. Auxiliary loads, particularly HVAC, were not included as a finely optimized subsystem, which is a relevant limitation for city bus operations.

Another important limitation is the absence of actual experimental validation. The model is compared mainly with general reference values and expected trends.

The optimization method is transparent but relatively simple. The final optimized stack configuration should therefore be interpreted as an optimized case based on simulation under the given model assumptions, not as a directly verified commercial fuel cell design. The author correctly acknowledges this limitation in the thesis.

The formal quality of the thesis is acceptable. The structure is logical, and the figures and tables support the explanation of the model. However, the thesis is relatively short for a master’s thesis, and the discussion of the results could be more in-depth. The text contains repeated grammatical and stylistic errors. While these do not hinder comprehension, they reduce the overall formal quality of the thesis.

Overall, the thesis meets the main objectives of the assignment at a basic to good level. The thesis is not methodologically or scientifically exceptional, and the model has several significant limitations, particularly in the areas of verification, power management, and component sizing. Nevertheless, the thesis contains a complete simulation procedure, and the results are technically comprehensible.

I recommend the thesis for defense and propose an overall grade of C / Good.
Evaluation criteria Grade
Splnění požadavků a cílů zadání C
Postup a rozsah řešení, adekvátnost použitých metod D
Vlastní přínos a originalita D
Schopnost interpretovat dosažené výsledky a vyvozovat z nich závěry C
Využitelnost výsledků v praxi nebo teorii D
Logické uspořádání práce a formální náležitosti C
Grafická, stylistická úprava a pravopis C
Práce s literaturou včetně citací C
Samostatnost studenta při zpracování tématu B

Grade proposed by supervisor: C

Mr. Nalbantoglu’s thesis focuses on the simulation of a fuel cell city bus within a driving cycle and addresses a highly relevant and timely topic. The work begins with a clear explanation of fuel cell principles and different hydrogen production approaches, followed by a description of the model and the results obtained using the GT-SUITE software.

However, the literature review in the first part of the thesis would benefit from greater depth and a broader academic perspective. The entire text is quite brief and could have been significantly expanded. Furthermore, the readability of the thesis would be notably improved with images and graphical explanations; the text does not even include an image of the vehicle being studied. There is also a noticeable tendency to repeat certain pieces of information multiple times throughout the text.

The strongest asset of this thesis lies in its practical application. The student has successfully constructed a functional simulation model and executed a valuable evaluation of various parameter modifications. Through a systematic approach, the author achieved a remarkable optimization goal and provides a clear, insightful analysis of how each modified parameter influences the overall efficiency and hydrogen consumption of the bus. The primary shortcoming of the text remains the limited overall scope of the work. The student used mostly data from GT-Suite database without any further research.

Structurally, the thesis is logically organized, and from a formal standpoint, it meets standard academic requirements. The use of sources is appropriate, the references are correctly cited, and the bibliography includes a sufficient number of recent and reputable scientific publications.

Nevertheless, several typographical and formatting issues are present in the text. For example, isolated articles or prepositions are frequently left at the ends of lines, and numerical values are incorrectly separated from their corresponding units across line breaks. Additionally, the document layout contains unresolved formatting gaps, including abrupt blank spaces on several pages and sequences of disjointed, exceptionally short paragraphs. The list of symbols and abbreviations is completely missing.

In conclusion, the author has delivered a sound thesis that effectively combines theoretical knowledge of fuel-cell vehicles with practical modelling and simulations. Despite the limited scope, I recommend the thesis for defense.
Evaluation criteria Grade
Splnění požadavků a cílů zadání B
Postup a rozsah řešení, adekvátnost použitých metod C
Vlastní přínos a originalita C
Schopnost interpretovat dosaž. výsledky a vyvozovat z nich závěry C
Využitelnost výsledků v praxi nebo teorii B
Logické uspořádání práce a formální náležitosti B
Grafická, stylistická úprava a pravopis D
Práce s literaturou včetně citací B
Topics for thesis defence:
  1. Even though you do not include degradation in your simulation, would your optimization affect the degradation of the fuel cell and how?
  2. On page 36, you write: „When the battery SOC reaches the upper limit (SOCmax = 0.85), the extra braking energy is taken by the mechanical brakes.“ Could you explain this SOC limit and why it is used in this kind of powertrain?

Grade proposed by reviewer: C

Responsibility: Mgr. et Mgr. Hana Odstrčilová