Research on Durability and Reliability Technology of a Fuel Cell Logistics Vehicle

Durability assessment of fuel-cell logistics vehicles over their full lifecycle demands efficient accelerated testing methods. Based on load spectra from real-world highways and reinforced proving-ground pavements, this study employs pseudo-damage equivalence, load-frequency correlation, and NSGA-II optimization to develop a 14,000 km/60-day accelerated test protocol and to design power spectral density inputs for fuel-cell stack vibration bench tests. Experimental results show pseudo-damage ratios of 0.8–1.25 in key frequency bands, closely matching real-world conditions, and tri-axial vibration RMS levels of the stack below those of power-battery standards. This methodology can be extended to various operating conditions and vehicle types, and—when combined with online monitoring and digital twins—can continuously enhance reliability.