8-Meter and 12-Meter Battery Electric Bus Project in Turkey
Project Overview
- Project Start Time: 2022
- Project Vehicle Types: 8-meter and 12-meter battery electric bus
- Country: Turkey
- Systems We Provided: battery packs, PDU (with BMS), BTMS, EVCC
Project Introduction
In response to Turkey’s growing environmental initiatives, a well-established Turkish commercial vehicle manufacturer embarked on an electric bus project, focusing on 8-meter and 12-meter models. Leveraging our expertise in electric bus battery systems, we delivered a tailored solution that included a 280 kWh battery system, a custom BMS, and a cooling unit. This case study outlines our approach to overcoming technical challenges and providing comprehensive support throughout the project.
Client Background
The client, a prominent commercial vehicle manufacturer in Turkey, has a strong reputation for producing traditional fuel-powered buses. In 2022, motivated by Turkey’s environmental policies, the company shifted its focus to electric buses, initiating a new product for 8-meter and 12-meter electric models. Given our history as their supplier of EHPS and air brake compressors, they entrusted us with developing a high-quality electric bus battery system for their new fleet.
Challenges
- Customized Battery System Design: The 8-meter and 12-meter electric buses required different battery capacities and layouts, necessitating a bespoke approach for each vehicle size.
- Unique Voltage Requirements: The battery-electric buses were equipped with a 700 V high-voltage motor, which is not a common voltage for battery packs, posing a challenge in designing a compatible system.
- Space Optimization: The battery packs needed to be efficiently integrated into the limited space within the buses while meeting energy requirements.
How We Worked
- Initial Consultation and Design
- Conducted detailed simulations and calculations based on the client’s vehicle specifications, including speed, range, and certification requirements.
- Designed custom battery packs with different capacities to meet the distinct needs of the 8-meter and 12-meter buses.
- Technical Development
- Developed a specialized BMS tailored to the buses’ specifications.
- Created circuit diagrams and optimized the internal and external wiring to fit the vehicle layouts.
- Carefully selected connectors, considering power currents and interlock requirements.
- Ensured compatibility between the charging infrastructure and the battery system, adhering to European standards.
- Testing and Validation
- Conducted joint testing with the client to verify the charging system’s functionality.
- Provided technical support during the installation and initial operation phases, including software updates and remote troubleshooting.
Systems We Provided
- Battery modules
- BMS
- PDU
- Power output wiring harness
- Vehicle communication wiring harness
- CCS charging seat wiring harness
- Battery input harness
- Power wire harness between the battery boxes
- Communication wiring harness between the battery boxes
- EVCC
- Charge harness
Battery Packs Used in This Project
Other Systems in This Project
Brogen Standard EV Battery Pack Solution
- Independent secondary control: facilitates easy installation and maintenance.
- Integrated liquid cooling: strong adaptability to high-temperature environments.
- Full aluminum casing: lightweight design.
- High energy density.
- Protection level: IP67.
- Standard charging: 1C.
- Standard equipped with heating film.
| Parameters | C Box | C Box | C Box | C Box |
| Dimension | 1060*630*240 mm | |||
| Battery cell | 105 Ah | 173 Ah | 230 Ah | 280 Ah |
| Grouping | 2P48S | 1P63S | 1P48S | 1P36S |
| System capacity | 210 Ah | 173 Ah | 230 Ah | 280 Ah |
| Rated system voltage | 153.6 V | 202.86 V | 153.6 V | 115.2 V |
| System energy | 32.256 kWh | 35.095 kWh | 35.328 kWh | 32.256 kWh |
Battery System Configuration Example Based on Our Standard Battery Packs
| Battery System | Parameters | Note | |
| System nominal voltage | 614.4 V | The monomer is 3.2 V | |
| System operating voltage range | min | 480 V | Monomeric 2.5 V~3.65 V |
| max | 700.8 V | ||
| System rated capacity | 460 Ah | 25 ± 2℃, 1 / 3C, 100% DOD, the shipment capacity is not less than 98% of the rated capacity | |
| System storage energy | 282.62 kWh | 25 ± 2℃, 1 / 3C, 100% DOD, the shipped power is not less than 98% of the rated power | |
| System life end remdual capacity | ≥368 Ah | 5 years, not less than 80% of the rated capacity | |
| System group mode | 2P192S | Series and parallel connection | |
| Battery system weight | About 1920 kg | ||
| Specific energy of the system | About 150 Wh/kg | ||
| Maximum continuous charging current | 230 A | Maximum duration of 0.5C | |
| Maximum pulse charging current (30s) | 460 A | 30s max. 1C | |
| Maximum continuous discharge current | 460 A | Maximum duration of 1C | |
| Maximum pulse discharge current (30s) | 920 A | 30s maximum of 2C | |
| Maximum allowable feedback charging current (10s) | 920 A | 50% SOC, 20 – 55℃ / 10s max 2C | |
| SOC working range | 10~100 % | ||
| Insulation requirements | ≥200 MΩ | 500 VDC, total positive / negative against the shell | |
| Protection level of the battery box body | IP67 | ||
| System cooling mode | water cooling system | ||
| System heating mode | water cooling system | ||
| Charge on shipment (SOC) | 20%~50% | The SOC status is consistent with the same batch of shipment | |
Contact Us
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Whatsapp: +8619352173376
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