Throughout the project duration, CoacHyfied advanced the design and virtual validation of key subsystems for hydrogen fuel cell coaches, despite its premature termination in April 2024 prior to the demonstration phase.
WP1 “FC coach operation and management system” successfully delivered a hybrid energy management architecture for fuel cell coaches, with interfaces defined between FC, battery, and H2 systems (D1.1). Health and diagnostic indicators (D1.2) were evaluated and an optimised rule-based energy manager was implemented (D1.3) supporting predictive control strategies and energy-efficient operation across the full state-of-charge range.
WP2 “H2 fuel system” completed a comparative analysis of 350 and 700 bar storage architectures for long- and medium-range coaches. Detailed system designs were developed for both use cases (D2.1–D2.3) including vessel selection, frame integration and balance-of-plant components. Safety considerations, packaging feasibility and supply chain issues were also addressed.
WP3 “Thermal management” defined a thermal system concept optimised for energy efficiency in cold climates, leveraging FC waste heat for cabin heating. The TMS design was validated virtually using digital models of both coach configurations, demonstrating >20% reduction in hydrogen consumption compared to conventional approaches (D3.4).
WP4 “Vehicle certification” analysed the evolving regulatory framework, focusing on the shift from EC79 to UN Regulation No. 134 (R134) and its implications for system and vehicle-level certification. Certification strategies, risk assessment protocols and safety validation procedures were documented (D4.1–D4.6) including a comprehensive Safety Plan.
WP5 “Business models and market development strategy” collected operator needs and market data through stakeholder interviews and questionnaires. A techno-economic analysis of FC coaches versus diesel alternatives was carried out (D5.1–D5.2) including input from operators in Latvia, France, the Netherlands, and the UK.
WP6 “Long distance FC coach demonstration” completed component selection and packaging studies for a newly built coach by OTOKAR. Layouts for FC stacks, batteries, e-motor and auxiliary systems were developed. However, integration and commissioning of the full drivetrain could not be completed due to the project suspension.
WP7 “Regional FC coach demonstration” defined the technical framework for retrofitting regional coaches, comparing high-floor and low-floor vehicle platforms. Operator engagement and feasibility analyses informed the final selection of the retrofit candidate. Integration activities were prepared but not executed.
WP8 “Project management, dissemination & exploitation” ensured overall coordination, risk monitoring, and knowledge sharing. The project held regular GA and advisory board meetings, maintained SharePoint-based collaboration tools, and disseminated progress through its website and LinkedIn presence. Dissemination was limited in scope due to the early termination.
