Cost Effective

Electric Bus

Working with Chassis Partner Agrale (Argentina) the CELEB consortium has produced a fully integrated electric chassis that enables coachbuilders to produce electric buses without requiring EV knowhow.

The heating, cooling and ventilation (HVAC) of an electric bus can use as much energy as the traction loads. CELEB, through novel integration of the HVAC, has delivered a reduction in required battery capacity of 30% through waste heat recovery via a heat pump system.  In addition, the bus utilises a novel, highly distributed electrical architecture for air quality monitoring to provide a lightweight solution for optimisation of air change to the outside environment, further improving HVAC efficiency.

A cost-effective motor architecture has been developed and integrated with a straight cut gearbox, manufactured at far lower cost than current bus drive systems. A modular battery pack architecture facilitates configurability and optimisation for bus routes, and the BMS handles this flexibility without compromising functional safety.

Multipack BMS Architecture

The multipack BMS architecture supports up to 8 sub-packs, calibratable for any parallel/series configuration. The system works on a Master/Slave arrangement, with sub-pack controllers looking after individual packs and a Master controller collating data and interfacing with external systems.

The system can provide for redundancy, including the ability to disconnect individual sub-packs and still maintain overall battery system operation.

The multipack system builds on the ISO26262 ASIL C single pack Gen 5 BMS system developed by Potenza and will be taken through the full ISO26262 during 2020.

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Environmental  Monitoring via Ethernet Over Powerline

The CO2 monitoring system for CELEB uses Potenza’s Ethernet over Powerline system, allowing sensor modules to receive power and communicate over the same wire, greatly reducing material and labour costs of manufacture.

Each sensor module has a simple 24V power connection, onto which it overlays Ethernet packets at radio frequencies. Any other device connected to the same power source can see these packets, and thus a network is formed.

The engineering display uses the same technology, demodulating the powerline data, extracting the Ethernet packets, and displaying useful data on the screen, all via the single power wire.

Electric Drivetrain

The CELEB drivetrain incorporates twin APM200 motors integrated into a 2 speed gearbox. The motors are driven by Semikron SKAI inverters. The powertrain components are water / glycol cooled, with the thermal energy being captured and used to heat the saloon during cold periods.

The APM200 has been designed specifically to meet the requirements of a high performance traction motor.

Its unique spoke architecture enables the rotor to be liquid cooled increasing the motors continuous power output capability. The motor has a maximum speed of 10,000 rpm and has an optional integral 5.5 :1 epicyclic gearbox which means that the output shaft of the gearbox can be connected directly to the wheel hub. The motor has a peak power of 220kW, and a peak torque of 450Nm.

The multipack BMS architecture supports up to 8 sub-packs, calibratable for any parallel/series configuration. The system works on a Master/Slave arrangement, with sub-pack controllers looking after individual packs and a Master controller collating data and interfacing with external systems.

The system can provide for redundancy, including the ability to disconnect individual sub-packs and still maintain overall battery system operation.

The multipack system builds on the ISO26262 ASIL C single pack Gen 5 BMS system developed by Potenza and will be taken through the full ISO26262 during 2020.

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electrical
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Statistics

The main barrier for electrical bus adoption is the capital cost, the major contributor to the capital cost is the batteries. CELEB has overcome this with a ground up redesign, including:

  • 315kWh Battery pack mounting around rear axle – Maintains weight distribution and no loss of saloon space
  • Bespoke 2 speed eAxle – 2 motors and 2 gear ratios
  • Fully Integrated Thermal – Management to reduce battery consumption
  • Powerline Carrier Multiplex body wiring system

This has achieved:

  • A real-world range of 150-200 miles daily
  • No need for in-service recharging
  • A cost-effective solution
  • Innovative technologies to reduce the battery requirement for the vehicle
  • A significant reduction in unladen weight

Our Partners

Potenza is an engineering consultancy company, specialising in powertrain electrification and HV battery systems. On the CELEB project Potenza developed the Ethernet over Powerline environmental system and the multipack BMS architecture.

Millbrook is a leading provider of vehicle test and validation services and systems. It has a range of test facilities for full vehicles, tyres and components located in the UK, the USA and Northern Finland.

Depe Gear has some of the most advanced gear manufacturing equipment in Europe.  Our Design Unit has also designed and collaborated on the development of gear box solutions for the EV market. 

SEMIKRON is one of the world’s leading manufacturers of power modules. SEMIKRON’s innovative power electronic products enable our customers to develop smaller, more energy efficient power electronic systems.

+44 (0) 1953 857650

Unit 15, Hethel Engineering Centre, Chapman Way, Hethel, Norwich, Norfolk NR14 8FB, United Kingdom