A manufacturer of mass transit buses worked with Creaform and BAE Systems to integrate a new parallel hybrid propulsion system on their 40 ft. and 60 ft. buses. Creaform was responsible for the mechanical and electrical engineering integration of this system. It addition, the engineering team provided project management as well as prototyping and production line support at the customer’s plant.
The drive system consisted of a diesel engine coupled with a generator that drove the electric traction motor. An energy storage system with lithium-ion batteries was used to provide energy to the electric motor and recapture energy when the vehicles slowed down. Crash simulation and modal analysis were also performed to ensure all components meet the customer standards.
Several challenges were encountered in this engineering project, such as space availability, weight distribution and optimization, security concerns for passengers over high voltage cable routing, component environmental protection, manufacturing feasibility, cost reduction issues requirements. Despite these challenges, the team delivered the project on spec and on time.
- Mechanical engineering, including structure, piping, sheet metal, etc.
- Electrical engineering, including integration, routings, harnesses design, etc.
- 3D and 2D CAD drawings including general assembly drawing (Autodesk Inventor)
- Weight, materials and process management
- Weight optimization
- Finite element modeling for crash (MIL-STD-810), dynamic behaviors, fatigue and static stress requirements
- Static and transient linear and non-linear analysis; frequency response (sine), random vibration simulations
- Project management
- On-site technical support for prototyping and production line setup
TOOLS AND METHODS USED
- NEi Nastran
- Autodesk Inventor