Controller Regulates Hydrogen Generation in Hybrid System for Diesel Engine Trucks

We were approached by a company who was in the process of developing a hydrogen hybrid system for improving fuel efficiency on diesel engine trucks.  The company required a solution to prevent their electrolysis cell from drawing excessive current as the cell’s resistance decreased during operation. They also required a solution that would allow them access to programming and ability to make adjustments to optimize performance on a variety of trucks and diesel equipment applications.


The OEM's innovative product, not only increases fuel efficiency but provides increased power and burns cleaner. The system is easily installed on any diesel truck, and given normal usage, has a payback period of less than a year. The hydrogen hybrid system is designed around an innovative electrolysis device which keeps strict control of internal temperatures, corrosion, and electrical flux fields, but the device suffered from wide ranges of current draw which needed to be managed across a wide range of conditions and applications.  

Project Challenges

1. Control high current (15 Amps to 50 Amps) over wide swings of electrolysis cell’s resistance.
2. Programmable control module to optimize performance across variety of diesel applications.
3. One solution for all 12 and 24 VDC applications.


After discussing requirements in detail, we proposed the CL-305 control module as ideal for this application.  The outputs of the CL-305 module has a current control feature that allows the Pulse Width Modulation (PWM) duty cycle to auto adjust utilizing a PI control algorithm to maintain the target current.  The customer was also provided with access to our do-it-yourself application programming tool Composer™ to write their own customized control logic.  They were able to access Composer's adjustable parameter feature (EEPROM) which provided them with further access to our Conductor™ tool allowing them to optimize the configuration for each diesel truck without the need to change the base program.

The customer can now program their own system and have confidence it will continue to operate as expected over the varying resistance conditions of the Flux Capacitor. Users of the hydrogen hybrid system are experiencing fuel savings up to 20% and are easily  and quickly getting a good return on their investment (ROI).

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