v1.5.1
Fusion Fuel

Fusion Fuel

A controller for a green-hydrogen reactor

20kWh
high-voltage supply integrated
CAN bus
communication with the power stage
PoC → mass production
architecture path

Fusion Fuel is developing green-hydrogen production technology. They needed a hydrogen reactor controller, from proof of concept to a hardware architecture ready for mass production.

We built and validated the controller, then integrated a 20kWh high-voltage power supply over CAN bus, taking the design from a lab-bench PoC toward something manufacturable at scale.

Project stages

  1. 01

    Proof of concept

    We developed a proof-of-concept hydrogen reactor controller: the electronics and firmware responsible for driving and monitoring the reactor safely.

    Early control logic proven on a breadboard before the first enclosure.
  2. 02

    Architecture for mass production

    Once the control logic was validated, we developed the hardware architecture with mass production in mind, rather than a one-off lab prototype.

    3D render of the enclosure, designed for manufacturability.
  3. 03

    High-voltage power integration

    We integrated a 20kWh high-voltage power supply over CAN bus, bringing the power stage and the controller into a single validated system.

    Bench validation: oscilloscope, pressure sensors and live data logging.

In detail

The Hevo Chain controller running its live Fusion Fuel interface.
The Hevo Chain controller running its live Fusion Fuel interface.
Breadboard prototype of the control electronics.
Breadboard prototype of the control electronics.
The 3D-printed enclosure on the test bench, pre-wiring.
The 3D-printed enclosure on the test bench, pre-wiring.
Bench setup with thermocouples and pressure transducers.
Bench setup with thermocouples and pressure transducers.
Internal wiring: Raspberry Pi, I/O boards and terminal blocks.
Internal wiring: Raspberry Pi, I/O boards and terminal blocks.
Close-up of the controller interface and connectors.
Close-up of the controller interface and connectors.
3D render of the Hevo Chain switching box enclosure.
3D render of the Hevo Chain switching box enclosure.