90-day wonder: five companies team up to develop working hybrid shuttle bus prototype in three months - Alternatives - Ford, American Axle & Manufacturing, Supreme Industries, TransTeq and Magtec

Diesel Progress North American Edition, Oct, 2002 by Mike Brezonick

When you're talking about developing almost any new product, three months isn't much time. And when a development requires the involvement of five different companies, including an automaker, 90 days is barely the space of a single heartbeat.

Yet in just that amount of time, five companies -- Ford, American Axle & Manufacturing, Supreme Industries, TransTeq and Magtec -- came together to build the prototype of a new hybrid bus targeted for airport shuttle and mass transit use. The FASTM bus, (the designation signifying the first letter of the participant's names) was unveiled during the recent FutureTruck 2002 competition at California Speedway in Fontana, Calif.

"This was a project that brought together advanced technologies from five different companies and we put it together to show what's possible," said Paul Szilagyi, CEO of TransTeq, which managed the program and provided hybrid technology. "It is a prototype and was done in 90 days, which might be the greatest story in and of itself, to have these organizations get together for a common goal and get this done."

"Ford is very pleased to be part of the FASTM team," said Paul Moore, director of sales and operations at Ford Power Products. "As an environmentally conscious company, we fully support the development of cleaner running vehicles and the FASTM bus is something we are extremely proud of."

"The goal was to start from a clean sheet of paper to quickly design and build a completely new hybrid vehicle capable of running in a zero emissions mode," Szilagyi added. "We've done it and we're very proud of that."

The FASTM bus is based on a Ford E450 Econoline chassis that is used in a number of medium truck applications. But once you get past the outward appearance, all similarities to the typical Econoline end.

Instead of the standard V-10 gasoline engine and drivetrain, the FASTM bus is powered by a Ford ESG 642 sparkignited engine operating on propane. The engine is a 4.2 L, V-6 operating at 1800 rpm, where it produces approximately 70 hp. It incorporates a range of features that allow it to operate on dry fuel, such as hardened valve inserts.

A series type hybrid, there is no direct mechanical connection between the engine and the rear drive wheels. Instead, the engine drives a Magtec 40 kW generator operating at 370 Vd.c. The generator is used to maintain 28 sealed, 12 V deep cycle lead acid batteries. The batteries power a Magtec TD8 permanent magnet traction motor, as well as all other bus accessories. The motor, which has an integral parking brake assembly has a maximum output of 134 hp and a peak torque of 405 lb.ft.

The traction motor is positioned behind the AAM rear axle, which is inverted to allow the steel driveshaft connection from the motor to the wheels to come in from the rear. The axle has a GAWR of 9450 lb., with a ring gear diameter of 10.5 in. and a ratio of 4.56:1.

"This is taking series hybrid technology that we have demonstrated in Denver, where we have the world's largest fleet of heavy-duty hybrids," said Szilagyi. "It's not just a concept.

They're carrying 60,000 people a day.

"Series hybrid electric technology allows you to get the most out of the fuel and you can have different choices. This one is propane because of the availability of that.

"You can get in an argument as to whether parallel or series technology is better. We believe series hybrids give you the maximum flexibility to avoid technological obsolescence and embraces what will happen in the future when instead of an engine, you have a fuel cell."

In normal operation, the engine on the FASTM bus is operating about two-thirds of the time, Szilagyi said, keeping the batteries at peak charge. Battery levels are also maintained through regenerative braking.

With a fuel capacity of 180 lb. of propane -- the twin tanks are positioned forward of the axle between the frame rails for extra safety -- the bus can operate for 10 hours before refueling. Maximum speed is 60 mph. The FASTM bus is also capable of operating with the engine off in a zero emissions mode. "That is especially valuable in sensitive areas, such as airports where you go to pick up people and you might be under a canopy," said Szilagyi. "Then you don't have exhaust considerations and concerns."

The bus can operate for 30 miles in zero emissions mode before engine restart is required. Zero emissions mode can be selected manually or can be programmed to operate on the basis of global positioning, which can be integrated into TransTeq's control electronics. "You can have it so that when you pull under the canopy at the airport, boom, engine off," said Szilagyi. "You pull out, boom, engine on. The system manages the power level and state of charge of the batteries and it will put the engine on when it needs it."

With the interior and body designed by Supreme Industries, the FASTM bus is 24 ft., 6 in. long, 7 ft. 9 in. wide and 9 ft. 7 in. high. It can carry up to 15 passengers with luggage.

Besides airport shuttle service, the FASTM bus concept could be used for a variety of applications, including mass transit or pickup and delivery. "This is a prototype, but we plan to go into production," said Szilagyi. "And obviously we believe there can be a number of applications where this would work. We just have to spread the word."