Abstract: A new evaluation method was established with taking account of the residual space of vehicle
structure, hydrogen fuel cell and hydrogen tank under rolling-crash. The method was in accordamce with
the safety regulations and standards of different countries to meet the requirements of the ECE R66 by the
Economic Commission of Europe. A finite element model (FEM) was made by using LS-DYNA for a hydrogen
fuel cell bus made in China. The model was used to simulate some schemes for the different arrangements of
hydrogen tanks and for the condition with adding foamed aluminum bumper beam. The results show that using
foamed aluminum bumper-beam decreases 30% of the hydrogen tank peak acceleration. Therefore, the vehicle
hydrogen safety is improved.

Key words: vehicle engineering, passive safety, roll-crash, fuel cell bus, hydrogen tank, foamed aluminum bumper beam