FEDERAL TRANSIT BUS TEST

Transcription

1 FEDERAL TRANSIT BUS TEST Performed for the Federal Transit Administration U.S. DOT In accordance with CFR 49, Volume 7, Part 665 Manufacturer: Proterra, Inc. Model: Catalyst E2 Submitted for Partial Testing September 2017 Report Number: LTI-BT-R1706-P The Thomas D. Larson Pennsylvania Transportation Institute 201 Transportation Research Building The Pennsylvania State University University Park, PA (814) Bus Testing and Research Center 2237 Old Route 220 North Duncansville, PA (814)

2 FEDERAL TRANSIT BUS TEST Performed for the Federal Transit Administration U.S. DOT 1200 New Jersey Avenue, SE Washington, DC In accordance with CFR 49, Volume 7, Part 665 Manufacturer: Proterra, Inc. Manufacturer s address: 1 Whitlee Ct. Greenville, SC Model: Catalyst E2 Submitted for Partial Testing Report Number: LTI-BT-R1706-P 1706-P Page 2 of 30

3 TABLE OF CONTENTS Page EXECUTIVE SUMMARY... 4 ABBREVIATIONS... 5 BUS CHECK-IN PERFORMANCE TESTS 4.1 PERFORMANCE - AN ACCELERATION, GRADEABILITY, AND TOP SPEED TEST FUEL ECONOMY TEST - A FUEL CONSUMPTION TEST USING AN APPROPRIATE OPERATING CYCLE P Page 3 of 30

4 EXECUTIVE SUMMARY Proterra, Inc. submitted a model Catalyst E2, electric powered 39 seat (including the driver) 42 foot, 7 inch bus, for a partial STURAA test. The Federal Transit Administration determined that the following tests would be performed; 4.1 Performance Test and 6. Fuel Economy Test. This is based on a previously tested 12 year / 500,000 mile bus model bearing report number LTI-BT-R The odometer reading at the time of delivery was miles. Testing started on June 2, 2017 and was completed on July 27, The Check-In section of the report provides a description of the bus and specifies its major components. The interior of the bus is configured with seating for 39 passengers including the driver. Eight seats fold away for 2 wheelchair positions. The manufacturer passenger placard indicates that the test bus can accommodate 42 standing passengers. At 150 lbs per person, this load results in a measured gross vehicle weight of 43,540 lbs which exceeds the gross vehicle weight rating of 42,000 lbs by 1,540 lbs or approximately 10 people. At this load, the front gross axle weight rating is also exceeded. All testing performed under this partial test was performed at a seated load weight of 37,230 lbs. The performance of the bus is illustrated by a speed vs. time plot. Acceleration and gradeability test data are provided in Section 4, Performance. The average time to obtain 50 mph was seconds. The maximum gradeability at 10 mph was only 8.9%, while the maximum gradeablity at 40 mph was 3.3%. Top speed obtained on the dynamometer was 65.7 mph. An Energy Economy and Range Test was run on simulated transit test cycles: Manhattan cycle, Orange County Bus cycle and the Heavy-Duty Urban Dynamometer Driving Schedule (HD-UDDS). The energy consumption and range for the three test cycles were as follows: Test Cycle AC Energy Wh/mile Range Miles Manhattan 2, Orange County 2, HD-UDDS 1, The driver noticed that the acceleration was not enough to keep up with certain segments of the HD-UDDS driving cycle. This occurred at four time intervals into the cycle, namely 98 seconds-104 seconds, 422 seconds-428 seconds, 561 seconds-567 seconds, and 904 seconds-910 seconds. It is interesting to note that the required acceleration at all these instances was from approximately 29 mph to about 32 mph within 6 seconds P Page 4 of 30

5 ABBREVIATIONS ABTC - Altoona Bus Test Center A/C - air conditioner AC - alternating current ADB - advance design bus ATA-MC - The Maintenance Council of the American Trucking Association CBD - central business district CW - curb weight (bus weight including maximum fuel, oil, and coolant; but without passengers or driver) db(a) - decibels with reference to microbar as measured on the "A" scale DIR - test director DC - direct current DR - bus driver EPA - Environmental Protection Agency FFS - free floor space (floor area available to standees, excluding ingress/egress areas, area under seats, area occupied by feet of seated passengers, and the vestibule area) GVL - gross vehicle load (150 lb for every designed passenger seating position, for the driver, and for each 1.5 sq ft of free floor space) GVW - gross vehicle weight (curb weight plus gross vehicle load) GVWR - gross vehicle weight rating MECH - bus mechanic mpg - miles per gallon mph - miles per hour PM - Preventive maintenance PSTT - Penn State Test Track PTI - Pennsylvania Transportation Institute rpm - revolutions per minute SAE - Society of Automotive Engineers SCH - test scheduler SA - staff assistant SLW - seated load weight (curb weight plus 150 lb for every designed passenger seating position and for the driver) STURAA - Surface Transportation and Uniform Relocation Assistance Act TD - test driver TECH - test technician TM - track manager TP - test personnel Wh - watt hour 1706-P Page 5 of 30

6 TEST BUS CHECK-IN I. OBJECTIVE The objective of this task is to log in the test bus, assign a bus number, complete the vehicle data form, and perform a safety check. II. TEST DESCRIPTION The test consists of assigning a bus test number to the bus, cleaning the bus, completing the vehicle data form, obtaining any special information and tools from the manufacturer, determining a testing schedule, performing an initial safety check, and performing the manufacturer's recommended preventive maintenance. The bus manufacturer must certify that the bus meets all Federal regulations. III. DISCUSSION The check-in procedure is used to identify in detail the major components and configuration of the bus. The test bus consists of a Proterra, Inc., model CATALYST E2. The bus has a front door, forward of the front axle and a rear door forward of the rear axle. The front passenger door is equipped with a LIFT-U model U electric bi-fold wheelchair ramp. Power is supplied by a model UOM electric motor coupled to an Eaton model EEV 7202 transmission. The measured curb weight is 14,000 lbs. for the front axle and 17,360 lbs. for the rear axle. These combined weights provide a total measured curb weight of 31,360 lbs. There are 39 seats including the driver, and this test bus is designed to accommodate 42 standing passengers, for a total of 81 passengers. Gross load is 150 lbs. x 81 = 12,150 lbs. At full capacity, the measured gross vehicle weight is 43,540 lbs. The measured seated load weight is 37,230 lbs P Page 6 of 30

7 VEHICLE DATA FORM Page 1 of 7 Bus Number: 1706-P Date: Bus Manufacturer: Proterra, Inc. Vehicle Identification Number (VIN): 1M9TH16JXGS Model Number: CATALYST E2 Chassis Mfr./Mod.#: Personnel: S.R., T.S., E.D. & E.L. Starting Odometer Reading: WEIGHT: Individual Wheel Reactions: Weights (lb) Front Axle Middle Axle Rear Axle Curb Street Curb Street Curb Street CW 6,740 7,260 8,790 8,570 SLW 7,570 8,290 10,620 10,750 GVW 9,400 9,740 12,280 12,120 Total Weight Details: Weight (lb) CW SLW GVW GAWR Front Axle 14,000 15,860 19,140 16,094 Middle Axle Rear Axle 17,360 21,370 24,400 25,906 Total 31,360 37,230 43,540 42,000 (GVWR) Dimensions: Length (ft/in) 42 / 7 * Width (in) 102 Height (in) 133 Front Overhang (in) Rear Overhang (in) Wheel Base (in) Wheel Track (in) Front: 86.8 Middle: Rear: 77 *Test Bus submitted measures with a 4 removable bike rack mount. Bus length measurement above is bumper to bumper P Page 7 of 30

8 VEHICLE DATA FORM Page 2 of 7 Bus Number: 1706-P Date: CLEARANCES: Lowest Point Outside Front Axle Location: Protective Skid Plate Clearance(in): 6.0 Lowest Point Outside Rear Axle Location: Guard on Transmission Clearance(in): 8.3 Lowest Point between Axles Location: Body Clearance(in): 8.7 Ground Clearance at the center (in) 8.7 Front Approach Angle (deg) 8.3 Rear Approach Angle (deg) 8.6 Ramp Clearance Angle (deg) 3.4 Aisle Width (in) Front: 24.0 Rear: 23.1 Inside Standing Height at Center Aisle (in) Front: 91.1 Rear: 74.5 BODY DETAILS: Body Structural Type Frame Material Body Material Floor Material Roof Material Semi Monocoque Fiberglass composite Fiberglass composite Fiberglass composite Windows Type Fixed Movable Window Mfg./Model No. AROW / AS3 DOT 411 Number of Doors 1 Front 1 Rear Mfr. / Model No. Ventura Pilkington / 43-R Dimension of Each Door (in) Front: 32.7 W x 75.0 H Rear: 43.8 W x 78.1 H Passenger Seat Type Cantilever Pedestal Other (explain) Driver Seat Type Air Spring Other (explain) Mfr. / Model No. Number of Seats (including Driver) Recaro / Ergo Metro Seat 8H VCC11 39 or 31 and 2 wheelchair positions 1706-P Page 8 of 30

9 VEHICLE DATA FORM Page 3 of 7 Bus Number: 1706-P Date: BODY DETAILS (Contd.) Free Floor Space ( ft 2 ) 66.4 Height of Each Step at Normal Position (in) Front Middle Rear Step Elevation Change - Kneeling (in) Front: 2.8 Rear: 2.9 ENGINE Type C.I. Alternate Fuel S.I. Other - Electric Mfr. / Model No. UOM / SN Location Front Rear Other (explain) Fuel Type Gasoline CNG Methanol Diesel LNG Other Battery Powered Fuel Induction Type Injected Carburetion Alternator (Generator) Mfr. / Model No. Maximum Rated Output (Volts / Amps) Air Compressor Mfr. / Model No. Hydrovane / Maximum Capacity (ft 3 / min) Max Bar 1450 rpm Starter Type Electrical Pneumatic Other (explain) Starter Mfr. / Model No P Page 9 of 30

10 VEHICLE DATA FORM Page 4 of 7 Bus Number: 1706-P Date: TRANSMISSION Transmission Type Manual Automatic Load Sensing Adaptive Mfr. / Model No. Eaton / EEV7202 Control Type Mechanical Electrical Other Integral Retarder Yes No SUSPENSION Number of Axles 2 Front Axle Type Independent Beam Axle Mfr. / Model No. Axle Ratio (if driven) ZF / RL 75 EC Suspension Type Air Spring Other (explain) No. of Shock Absorbers 2 Mfr. / Model No. Sachs / Middle Axle Type Independent Beam Axle Mfr. / Model No. Axle Ratio (if driven) Suspension Type Air Spring Other (explain) No. of Shock Absorbers Mfr. / Model No. Rear Axle Type Independent Beam Axle Mfr. / Model No. ZF / AV Axle Ratio (if driven) 7.36 Suspension Type Air Spring Other (explain) No. of Shock Absorbers 4 Mfr. / Model No. Sachs / P Page 10 of 30

11 VEHICLE DATA FORM Page 5 of 7 Bus Number: 1706-P Date: WHEELS & TIRES Front Wheel Mfr./ Model No. Alcoa / 22.5 x 8.25 Tire Mfr./ Model No. Michelin XZU2 Rear Wheel Mfr./ Model No. Alcoa / Tire Mfr./ Model No. Michelin XZU2 BRAKES Front Axle Brakes Type Cam Disc Other (explain) Mfr. / Model No. Knorr Bremse / SN7 Middle Axle Brakes Type Cam Disc Other (explain) Mfr. / Model No. Rear Axle Brakes Type Cam Disc Other (explain) Mfr. / Model No. Knorr Bremse / SB7000 HVAC Heating System Type Air Water Other Capacity (Btu/hr) 54,594 Mfr. / Model No. Eberspächer / AC136 AE G3 Air Conditioner Yes No Location Roof Capacity (Btu/hr) 95,540 A/C Compressor Mfr. / Model No. Eberspächer / AC136 AE G3 STEERING Steering Gear Box Type Mfr. / Model No. Hydraulic gear Ross / Hydrapower Steering Wheel Diameter 18.0 Number of turns (lock to lock) 4 Control Type Electric Hydraulic Other (explain) 1706-P Page 11 of 30

12 VEHICLE DATA FORM Page 6 of 7 Bus Number: 1706-P Date: OTHERS Wheel Chair Ramps Location: Front Passenger Door Type: Electric bi-fold Wheel Chair Lifts Location: Type: Mfr. / Model No. Emergency Exit LIFT-U / U Location: Windows Doors Roof Hatch Number: CAPACITIES Fuel Tank Capacity (gallons) Engine Crankcase Capacity (gallons) Transmission Capacity (gallons) Differential Capacity (gallons) 4.49 Cooling System Capacity (gallons) 18.5 Power Steering Fluid Capacity (quarts) 12 Battery / Thermal Management System Batteries Mfr. / Model No. Battery Thermal Management System Mfr. / Model No. 4 - Proterra / ASY, HV Battery Standalone: Grayson / HP Secondary: Eberspächer / AC136AE G3 (using HVAC chiller system) 1706-P Page 12 of 30

13 VEHICLE DATA FORM Page 7 of 7 Bus Number: 1706-P Date: List all spare parts, tools and manuals delivered with the bus. Part Number Description Qty P Page 13 of 30

14 COMPONENT/SUBSYSTEM INSPECTION FORM Page 1 of 1 Bus Number: 1706-P Date: Subsystem Checked Initials Comments Air Conditioning Heating and Ventilation E.D. None Noted. Body and Sheet Metal E.D. None noted. Frame E.D. None noted. Steering E.D. None noted. Suspension E.D. None noted. Interior/Seating E.D. None noted. Axles E.D. None noted. Brakes E.D. None noted. Tires/Wheels E.D. None noted. Exhaust E.D. None noted. Fuel System E.D. None noted. Power Plant E.D. None noted. Accessories E.D. None noted. Lift System E.D. None noted. Interior Fasteners E.D. None noted. Batteries E.D. None noted P Page 14 of 30

15 CHECK - IN PROTERRA, INC. MODEL: CATALYST E2 VIN TAG 1706-P Page 15 of 30

16 CHECK - IN CONT. OPERATOR S AREA ELECTRIC MOTOR AND TRANSMISSION 1706-P Page 16 of 30

17 CHECK - IN CONT. INTERIOR FROM FRONT INTERIOR FROM REAR 1706-P Page 17 of 30

18 4.0 PERFORMANCE 4.1 PERFORMANCE - AN ACCELERATION, GRADEABILITY, AND TOP SPEED TEST 4.1-I. TEST OBJECTIVE The objective of this test is to determine the acceleration, gradeability, and top speed capabilities of the bus. 4.1-II. TEST DESCRIPTION In this test, the bus will be operated at SLW on a chassis dynamometer. The bus will be accelerated at full throttle from a standstill to a maximum geared, maximum governed, or maximum safe speed not exceeding 80 mph. The maximum geared speed is defined as the limited output capabilities of the test vehicle s engine and drivetrain. The maximum governed speed, if applicable, is the top speed as limited by the engine control system. The maximum safe speed is defined as the maximum speed that the dynamometer is limited to. The test vehicle speed will be measured using a speed encoder built in the chassis dynamometer. The time intervals between 10 mph increments will be recorded using a Data Acquisitions System. Time-speed data and the top speed attained will be recorded on the Performance Data Form. The recorded data will be used to generate a percent grade versus speed table and a speed versus time curve. 4.1-III. DISCUSSION This test consists of three runs from standstill to full throttle on the chassis dynamometer at simulated seated load weight of 37,230 lbs. Speed versus time data is obtained for each run and results are averaged to minimize test variability. The test was performed up to a maximum speed of 65.7 mph. The maximum gradeability at 10 mph was only 8.9%, while the maximum gradeablity at 40 mph was 3.3%. The fitted curve of velocity vs. time is attached, followed by the calculated gradeability results P Page 18 of 30

19 PERFORMANCE DATA FORM Page 1 of 1 Bus Number: 1706-P Date: Personnel: S.I. & J.S. Temperature ( F): 75.9 Humidity (%): 89 Barometric Pressure (in.hg): INITIALS: Air Conditioning - OFF Checked J.S. Ventilation fans - ON HIGH Checked J.S. Heater pump motor - OFF Checked J.S. Defroster - OFF Checked J.S. Exterior and interior lights - ON Checked J.S. Windows and doors - CLOSED Checked J.S. Recorded Interval Times Speed Run 1 Run 2 Run 3 10 mph mph mph mph mph mph mph Maximum Speed (mph): P Page 19 of 30

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21 1706-P Page 21 of 30

22 6. ENERGY ECONOMY AND RANGE TEST AN ENERGY CONSUMPTION AND RANGE TEST FOR BATTERY ELECTRIC BUSES USING APPROPRIATE OPERATING CYCLES 6-I. TEST OBJECTIVE The objective of this test is to provide accurate comparable energy consumption data on battery electric transit buses produced by different manufacturers. This energy economy test bears no relation to the calculations done by the Environmental Protection Agency (EPA) to determine levels for the Corporate Average Fuel Economy Program. EPA s calculations are based on tests conducted under laboratory conditions intended to simulate city and highway driving. This energy economy test, as designated here, is a measurement of the energy consumed by a vehicle traveling a specified test operating profile, under specified operating conditions that are typical of transit bus operation. The results of this test will not represent actual energy usage, but will provide data that can be used by FTA Grantees to compare buses tested using this procedure. 6-II. TEST DESCRIPTION This test is performed in the emissions bay of the LTI Vehicle Testing Laboratory. The Laboratory is equipped with a Schenk Pegasus 300 HP, large-roll (72 inch diameter) chassis dynamometer suitable for heavy-vehicle emissions testing. The driving cycles are the Manhattan cycle, a low average speed, highly transient urban cycle (Figure 1), the Orange County Bus Cycle which consists of urban and highway driving segments (Figure 2), and the EPA HD-UDDS Cycle (Figure 3). This test is conducted at seated load weight. This test is conducted generally as per the methods described in the SAE standard J The light-duty test cycles specified in this standard are replaced by transit bus test cycles mentioned above. The Multi-Cycle test (MCT) procedure is adopted for this bus. The end of test is determined when the bus cannot maintain 65 mph as recommended by the bus manufacturer. The battery system is recharged to full SOC at the end of the test, following procedures specified in SAE J During the recharge, the DC energy (into the battery system) and the AC energy (into the charger) are recorded. From these data, the average energy consumption (AC & DC) and range for each test cycle is calculated P Page 22 of 30

23 Figure 1. Manhattan Driving Cycle (duration 1089 sec, Maximum speed 25.4 mph, average speed 6.8 mph) Figure 2. Orange County Bus Cycle (Duration 1909 Sec, Maximum Speed 41 mph, Average Speed 12 mph) P Page 23 of 30

24 Figure 3. HD-UDDS Cycle (duration 1060 seconds, Maximum Speed 58 mph, Average Speed mph). 6-III. DISCUSSION The driving cycle consists of three simulated transit driving cycles: Manhattan, Orange County Bus Cycle and the HD-UDDS, as described in 6-II. An extensive pretest maintenance check is conducted including the replacement of all lubrication fluids, if applicable. The details of the pretest maintenance are given in the first three Pretest Maintenance Forms. The fourth sheet shows the Pretest Inspection Form. Finally, the summary sheet provides the average energy consumption and range of bus for the three test cycles. The test was conducted at a seated load weight of 37,230 lbs. The average energy consumption for the Manhattan, OCBC and the HD-UDDS were 2,406.4 Wh, 2,360.3 Wh and 1,842.7 Wh respectively. The range for the three driving cycles were 156 miles, 159 miles and 204 miles respectively. The manufacturer recommended that the transmission temperature may not exceed 120 C. A fan was placed at the rear of the bus to blow air around the transmission in order to prevent the transmission from overheating. The driver noticed that the acceleration was not enough to keep up with certain segments of the HD-UDDS driving cycle. This occurred at four time intervals into the cycle, namely 98 seconds-104 seconds, 422 seconds-428 seconds, 561 seconds-567 seconds, and 904 seconds-910 seconds. It is interesting to note that the required acceleration at all these instances was from approximately 29 mph to about 32 mph within 6 seconds P Page 24 of 30

25 FUEL ECONOMY PRE-TEST MAINTENANCE FORM Page 1 of 3 Bus Number: 1706-P Date: SLW (lbs.): 37,230 Personnel: T.S., S.R. & E.D. FUEL SYSTEM Install fuel measurement system Replace fuel filter Check for fuel leaks Specify fuel type (refer to fuel analysis) OK Electric Remarks: None noted. BRAKES/TIRES Inspect hoses Inspect brakes Relube wheel bearings Check tire inflation pressures (mfg. specs.) Check tire wear (less than 50%) Remarks: None noted OK Done by Manufacturer COOLING SYSTEM Check hoses and connections Check system for coolant leaks Remarks: None noted OK 1706-P Page 25 of 30

26 FUEL ECONOMY PRE-TEST MAINTENANCE FORM Page 2 of 3 Bus Number: 1706-P Date: Personnel: S.R., E.D. & T.S. ELECTRICAL SYSTEMS Check battery Inspect wiring Inspect terminals Check lighting Remarks: None noted OK DRIVE SYSTEM Drain transmission fluid Drive Motor Replace filter/gasket Check hoses and connections Replace transmission fluid Check for fluid leaks Remarks: None noted OK LUBRICATION Drain crankcase oil Replace filters Replace crankcase oil Check for oil leaks Check oil level Lube all chassis grease fittings Lube universal joints Replace differential lube including axles Remarks: None noted OK 1706-P Page 26 of 30

27 FUEL ECONOMY PRE-TEST MAINTENANCE FORM Page 3 of 3 Bus Number: 1706-P Date: Personnel: S.R., E.D. & T.S. EXHAUST/EMISSION SYSTEM Check for exhaust leaks Remarks: None noted OK ENGINE Replace air filter Inspect air compressor and air system Inspect vacuum system, if applicable Check and adjust all drive belts Check cold start assist, if applicable Remarks: None noted OK STEERING SYSTEM Check power steering hoses and connectors Service fluid level Check power steering operation Remarks: None noted OK OK Ballast bus to seated load weight Check brake operation TEST DRIVE Check transmission operation Drive Motor OK Remarks: None noted 1706-P Page 27 of 30

28 FUEL ECONOMY PRE-TEST INSPECTION FORM Page 1 of 1 Bus Number: 1706-P Date: Personnel: E.D. & J.S. PRE WARM-UP Cold tire pressure (psi): Front 120 Middle Rear 120 Engine oil level Battery System coolant level Interior and exterior lights on, evaporator fan on Fuel economy Pre-Test Maintenance Form is complete Fuel economy instrumentation installed and working properly. Fuel line -- no leaks or kinks Bus is loaded to SLW WARM-UP Bus driven for at least 20 min on dynamometer If OK, Initial If OK, Initial 1706-P Page 28 of 30

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30 ENERGY ECONOMY TEST TEST BUS UNDER ENERGY CONSUMPTION TEST CHARGER USED FOR ENERGY CONSUMPTION TEST 1706-P Page 30 of 30