Introduction
The project focused on integrating a next-generation traction battery system into both serial production vehicles and vehicles already in operation, taking into account retrofit requirements and the need to maintain a high level of backward compatibility.
The scope covered several bus models of different lengths, as well as multiple existing vehicle configurations. This required the development of a solution that would not only meet the requirements of the new battery system, but could also be implemented across different vehicle variants with a limited scope of changes.
The project included the development of a new adaptive frame for the traction battery, integration of cooling, electrical, fire suppression and detection systems, as well as adaptation of the surrounding components to the new packaging conditions.
Work scope
Our scope of work included:
- analysis of the existing solution and current vehicle layout variants,
- verification of the available installation space and the possibility of adapting selected components,
- analysis of the new supplier’s technical documentation and operating conditions,
- development of the integration concept for the new traction battery,
- design of adaptive solutions taking different vehicle variants into account,
- verification of the developed solution in terms of integration, feasibility and future adaptability,
- preparation of technical documentation,
- support during adaptation and commissioning of the solution.
Results
The outcome of the project was the development of a solution enabling the integration of the next-generation battery system both in new vehicles and in vehicles already in operation.
The adopted approach made it possible to limit the scope of changes required to implement the new battery system, while maintaining the flexibility needed to work across different vehicle and packaging variants, which significantly supported its use in retrofit scenarios as well.
Summary
The project required combining the requirements of the new battery system with the limitations of the existing vehicle architecture and the need to maintain compatibility with the existing fleet.
The result was a solution developed not for a single variant only, but with broader application in mind – both for new vehicle configurations and retrofit implementations.