Alexander Dennis
Superlo 500 EV conversion
The aim of this project was to convert two diesel double decker buses to full EV, in order to test a prototype driveline out in the field.
This was carried out in the following steps:
1. Request full cad data package of bus & batteries
2. 3d laser scan the chassis’ & compare with received CAD within ADL’s supplied data package
Raw scan data
Deviation analysis, used to calculate system adjustability requirements
3. Dictate battery cartridge space envelopes, reinforce chassis, & weatherproof battery compartment
Adjustable chassis reinforcement and wheel arch liners
Wheel arch liners
FEA of reinforced chassis section
Structural reinforcement metal work installation process
Installed metal work
Finished battery compartment
4. Create battery cartridges with a simple installation/removal process
Battery stack and cassette frame
Cassette frame FEA
Cassette frame plus forklift tool
5. Provide project management for procurement & build, including on-site installation at both the testing & development HQ, & Millbrook proving ground.
Completed CAD exploded assembly
Completed CAD model
Battery cassettes installed and wired
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