Fuel Cell System Testbed

Minimize integration effort. Maximize testing capabilities.
Fuelcell Testbed

AVL designed the integrated Fuel Cell System Testbed (FCS TS™) to provide highly efficient and accurate testing while minimizing integration efforts. Reusing our reliable and proven modules and transferring our R&D expertise and maturity into a compact solution was crucial. This solution is also suited to maximize future proven testing capabilities. Most of the relevant FCS TS™ modules have been integrated into one frame; the Combined Conditioning Supply and Measurement (CCSM) Unit.

This includes: 

  • ConsysCool™, Coolant conditioning modules 
  • HyTronTM , Hydrogen supply module 
  • F-FEM™ and FEM4™, I/O modules

Many of our customers are facing the challenge of complying with increasingly stringent emissions legislation by means of new complex technical solutions. In addition, there is unprecedented momentum in hydrogen and fuel cell technology worldwide. The development of complex solutions requires a state-of-the-art test environment for continuous optimization of fuel cell systems. An optimized test bench solution that enables interaction between virtual and real hardware is essential to shorten development time and reduce investment risk.



Our integrated solution can range from light duty (nominal FCS power from 30 kW up to 160 kW) to heavy duty (nominal FCS power up to 400 kW) applications. It fulfils all required control and measurement accuracies.

The integrated solution supports a full range of testing needs including:

  • Fuel consumption (e.g., EU2017/1151)
  • Emission (e.g., SAE J2578)
  • Performance (e.g., GB/T24554-2019)
  • Fuel cell control unit calibration
  • Benchmarking
Property Unit

Sensor Principle

AVL Electrical Particle Counter (EPC)
Measurement Range Up to ~ 3 x 107 [#/cm3]
Measurement Rate Up to 10 Hz
Dilution Rate 10:1 fix (LD) or 6:1 fix (HD)
Operating Temperature -10 … +45 °C
Operating Altitude Up to 3000 m


Zip file

AVL Fuel Cell System Testbeds are designed to accelerate the development of next generation technologies.

Broad Range of Applications

Designed to cover tests ranging from research to series development and validation

Easy Installation

Many interfaces were moved within the CCSM unit to minimize the remaining integration effort and allow self installation by the test bed engineers

Safe Investment

Future-proven solution thanks to high degree of upgradability, for a seamless adaption to evolving R&D demands

Robust Automation

Operates on AVL PUMA 2™ Fuel Cell, a robust and proven high-end real-time automation system

Model-Based Calibration

Interface directly with the fuel cell control unit. Assisted by comprehensive simulation models, the fuel cell system can behave just like in the vehicle. Calibrate the full range of performance, consumption, and durability in a safe and repeatable environment.

Tailored Modularity and Integration

AVL offers application optimized testing solutions based on modular test equipment. Be ready for future changes with flexible and upgradable devices. Equipment and components can be shared, relocated, and used across entire test fields.

Degradation Toolchain

Fully integrated tools to track and predict fuel cell stack degradation based on specified operating conditions and measurements. Lifetime and durability of prototype designs can be directly predicted and optimized in real-time.

Test Field Consistency

As part of AVL’s tool chain, test procedures and results are consistent across the entire test field. The full capabilities of the test beds can be utilized by both newcomers and fuel cell experts.

Jeremy Leung

Whether you’re new to fuel cell development and looking for your first test bed, or you’re building a custom test field with dozens of test units, we can use our decades of fuel cell expertise to provide the solution that will work for you now and in the future.

– Jeremy Leung, Lead Engineer Fuel Cell Testing Solutions, AVL

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