The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) has developed an innovative fuel cell module—the Fuel Cell Power Pack (FCPP)—that extends the range of electric cargo bikes and doubles the service life at a price comparable to that of battery-operated systems.

The FCPP combines a fuel cell designed for continuous output of 300-500 W with a small lithium-ion battery. The system charges the battery, which can be activated during acceleration or other peak load periods. The hydrogen fuel cell can be filled up in a matter of seconds and is engineered to operate reliably at low temperatures. Several shifts can be performed by a cargo bicycle equipped with the FCPP without the need for battery replacement or charging.

A cold-start module engineered for winter use relies on metal hybrids to preheat the fuel cell without extracting energy from the unit and reducing its range.

A spin-off project to demonstrate the quiet, emissions-free operation of the FCPP is being planned by DLR researchers.

The Fuel Cell Power Pack combines a fuel cell with a small lithium-ion battery. Source: DLRThe Fuel Cell Power Pack combines a fuel cell with a small lithium-ion battery. Source: DLR

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