252 pre‑ignition, backfire) that could damage engine components. Additionally, the long‑term impact on NOₓ emissions and engine durability must be assessed. On‑board electrolysis also requires deionized water supply logistics, which must be considered for mining environments. 3. MATERIALS AND METHODS Embedded System Prototype: The embedded hydrogen injection system was developed for integration into a mine-haul road truck. The prototype includes: • Alkaline electrolyzer (ALK): hydrogen production at 4.5 L/min, 55 °C, 25 A. • Bubbler: purification and cooling to reduce moisture and impurities. • Desiccant filter: residual moisture removal. • Flame arrestor: flashback protection. • Sensors: pressure, temperature, hydrogen flow; engine operating parameters (RPM, load, exhaust gas temperature). • Control unit: real-time control of hydrogen generation/injection and safety logic. • Data acquisition (SD/RTC): logging of operational data and safety events for traceability. Control and Safety Architecture: Safety was a core design requirement. The control architecture includes interlocks and fail‑safe logic: • Automatic shutdown under abnormal conditions (sensor failure, out‑of‑range pressure/temperature, safety alarms); • Continuous EGT monitoring with hydrogen reduction/cutoff above a defined limit; • Sensor‑failure cutoffs that revert the engine to diesel‑only operation; • Fail‑safe behavior prioritizing safe diesel operation in uncertain states. Figure 1 – Conceptual diagram of the embedded hydrogen generation and injection system.
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