Project ARCHER

A 200-kilowatt fuel cell system, powerful enough for a heavy goods lorry, is being built to meet the same certification and lifespan standards as a diesel engine. Heavy-duty vehicles—trucks, buses, construction equipment—are among the hardest to decarbonise. Battery-electric versions struggle with weight, range, and charging time for long-haul routes. Hydrogen fuel cells offer a cleaner alternative, but existing systems have not been rugged or durable enough for the vibration, dust, and constant use of commercial fleets. Project ARCHER addresses this gap by designing a fuel cell that can survive real-world heavy-duty operation and pass the same regulatory safety tests as a conventional engine. If successful, the project will deliver a 200kW+ regulated voltage fuel cell system ready for integration into trucks and buses. The system couples Intelligent Energy’s established core stack with new balance-of-plant components built for longevity. A dedicated ISO 26262-compliant electronic control unit from GEMS will manage safety, while Lyra Electronics’ multi-input DC-DC converter will handle startup power, simplifying installation. The result could accelerate the shift to zero-emission heavy transport without compromising payload or duty cycles.