Battery System Integration for Turkey's 8-Meter and 12-Meter Electric Bus Project
Project Overview
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
1. Customized Battery Design
The 8-meter and 12-meter electric buses required different battery capacities and layouts, necessitating a bespoke approach for each vehicle size.
2. Unique Voltage Requirements
The buses were equipped with a 700 V motor, which is not a common voltage for battery packs, posing a challenge in designing a compatible system.
3. Space Optimization
The battery packs needed to be efficiently integrated into thee limited space within the buses while meeting energy requirements.
How We Worked
1. 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.
2. 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.
3. 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.
This project exemplifies our capability to deliver specialized electric bus battery systems that meet the unique demands of our clients, enabling them to transition smoothly to electric mobility while maintaining performance and reliability.
Systems We Provided
Battery Packs
- System nominal voltage: 614.4 V
- System operating voltage range:480 V – 700.8 V
- System rated capacity: 460 Ah
- System storage energy: 282.62 kWh
- System group mode: 2P192S
- Battery system weight: about 1920 kg
- System cooling mode: water cooling system
PDU (With BMS)
BTMS
- Rated refrigeration volume: 8 kW
- Unit working environment:-20°C – 60°C
- Refrigeration circuit pressure resistance: 3.5 Mpa
- Pressure resistance of the coolant system:0.25 Mpa
- High voltage range: 400 VDC – 750 VDC
- Low voltage range: 18 VDC – 30 VDC
- Low voltage wake up: 18 VDC – 30 VDC
- Maximum input electrical power of the compressor: 4 kW
- Coolant type:50% ethylene glycol+50% water (volume ratio)
- Circulating water: 12 -20 L/min
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