A Novel Fault-Tolerant Model Predictive Control Energy Management for Fuel Cell Hybrid Electric Vehicles

This paper presents a novel fault-tolerant model predictive control (FTMPC) framework for fuel cell hybrid electric vehicles (FCHEVs) used for postal delivery applications. The main contribution of the proposed FTMPC is the adaptive adjustment of the model predictive control cost function weights based on fault severity. The proposed reformulation incorporates fault characterization across the diverse degradation mechanisms while maintaining reliable vehicle operation. The FTMPC approach dynamically adapts cost function weights and system constraints based on the fault severity index. The resulting control strategy provides fault-aware power allocation between the fuel cell and battery while accounting for the specified operating and safety constraints. To isolate the contribution of the proposed health-dependent adaptation mechanism, a controlled ablation study was performed against a structurally identical fixed-MPC controller under the same vehicle model, driving cycle, initial conditions, prediction and control horizons, solver configuration, and fault scenarios. The adaptive FTMPC achieved a 10.6956% reduction in direct hydrogen consumption relative to the fixed-MPC baseline. Because differences in terminal battery state of charge (SoC) can influence comparisons based solely on hydrogen consumption, a charge-corrected hydrogen-equivalent metric was also evaluated; using this more conservative metric, the adaptive FTMPC retained a 2.7276% improvement. The final quadratic programming implementation achieved a 100% successful optimization rate in the validation run with no fallback-controller activation, while the maximum soft-constraint slack remained on the order of 10−9. Additional sensitivity analyses were conducted to evaluate the influence of relevant vehicle and operating conditions on energy consumption and battery utilization. These results provide direct quantitative evidence of the contribution of the proposed fault-adaptive mechanism and demonstrate its numerical feasibility for FCHEV energy management, while the limitations of the present simulation-based validation are explicitly acknowledged.