Legacy Department of Trade & Industry
Leyland Trucks and Bucher Municipal are working together to design, develop and build a fully integrated zero emission **Battery Electric Road Sweeper** based on a modified 16 tonne DAF XB electric truck chassis. This will be Bucher's first production representative version of its next generation of electric road sweepers based on an OEM chassis. This will allow the complete vehicle to be homologated through the EU whole vehicle type approval process, thus allowing easier access to EU export markets. The two partners will focus on optimised energy usage and vehicle packaging for this type of vehicle operations.
Leyland Trucks currently do not produce any BEV trucks through primary production processes at their site in Leyland. Current commitment from PACCAR provides the Leyland team with a 10 truck/shift solution which will combine both ICE and battery electric vehicles on one production line. The team believes that, through innovations relating to automation and advanced testing, productivity can be increased and production of BEV trucks can be scaled to 30+ trucks/shift. This activity would put Leyland Trucks at the forefront of innovation within the PACCAR group and would allow them to take their place as the global net zero centre of excellence for BEV truck manufacture across the PACCAR group. This project would help safeguard up to 120 jobs at the Leyland site in the North West of England and enhance the capability at the site for any future projects.
Leyland Trucks, working with its programme partners including NHS, will manufacture and deploy 20 DAF LF Electric Trucks in a Demonstration Battery Electric Truck Trial (BETT) project. It will cover various operations and duty cycles during a 12-month trial to show the benefits of running electric trucks.
The DAF LF Electric has a Gross Vehicle Weight of 19 tonnes and uses a 250kW Permanent Magnet motor powered by high cycle 254kWh Lithium Ferro Phosphate batteries to deliver a targeted range of 220km from a single charge. It can recharge either from an AC charger at 22kW or from a DC charging station at up to 150kW.
All vehicles will be fitted with data logging equipment to allow key vehicle parameters to be logged. Working with data analysis partner CENEX, this operational data will be used to publish reports on vehicles in operation. CENEX will also use the project data to support the generation of a website to inform vehicle operators about the benefits of running battery electric trucks, with the aim of influencing their future vehicle purchasing decisions.
This interactive report and website will cover:
* Explaining how to select the appropriate technical specification for battery electric trucks,
* Defining how operations and duty cycles might influence vehicle selection,
* Supplying information on expected vehicle performance and operation envelopes,
* Details on the 'total cost of ownership' approach and financing,
* Charging infrastructure information including costs and connecting to the grid,
* Defining vehicle charging options, from slow to rapid charging,
* Training requirements for organisations, including management of High Voltage systems,
* Fleet management, repair, and maintenance issues pertaining to Electric Trucks.
As part of the project, all required charging infrastructure will be provided. PACCAR Parts will supply PACCAR-branded charging stations manufactured by ABB. The specific model of charging station will be matched to the customer's specific duty cycles for each of the 20 vehicles and will range from slow 22kW AC wall boxes to rapid 180kW DC charging stations. ABB will manage their installation.
The vehicles will be fitted with a mixture of bodies, from Leyland Trucks manufactured box bodies to Gray & Adams refrigerated bodies meeting NHS Supply Chain specifications. The refrigerated vehicles will be equipped with an e-PTO to export electric power from the vehicle to drive the electrically powered chiller unit.
"The REETR \[Range Extender Electric Truck Research\] project sets out to research and develop Range Extender Electric Truck technology based on the highly successful 19 Tonne \[GVW\] DAF LF chassis. The project is a collaboration between the last UK volume truck manufacturer, Leyland trucks and MAGTEC the UK leading Electric Vehicle drive system manufacturer. Leyland Trucks is part of the PACCAR Inc. Corporation which is one of the world's major manufacturers of heavy trucks, through its DAF, Kenworth and Peterbilt brands.
Increased Air Quality concerns are driving the requirement for the development of new cost effective zero tailpipe emissions technologies, which in the medium term is increasing the level of vehicle electrification. On heavier vehicles, such as trucks, the challenge of reduced energy density of batteries compared to today's diesel technology means that the vehicle driving range / payload and product cost can be compromised. So the Range Extender Electric Vehicle technology delivers the optimum solution of zero tailpipe emissions in the centre of town and city then the range extender feature will allow it to operate from ""out of town"" distribution centres
The project sets out to deliver between 160km and 200km electric only driving and with the IC engine operating this range would approximately double without refuelling. It is planned to deliver a cost effective package of technology which is energy efficient to maximise the electric range on the minimum amount of battery storage. This will be achieved by the development of a new overall system controller, component design and regeneration control."
Magnomatics’ innovative and proprietary magnetic CVT MAGSPLIT integrates a magnetic planetary gear and a highly efficient control motor/generator to enable the realisation of more efficient and compact Plug-in Hybrid Electric Vehicle powertrains. A Commercial Vehicle Intent MAGSPLIT component has previously demonstrated high efficiency and robustness in a compact package, showing the potential to reduce CO2 emissions by 1m tonnes p.a. by 2025. For this project, two 18t DAF LF PHEV demonstrator trucks will be delivered by the UK based consortium and operated in a 1 year trial by Calor, with oversight by DAF LF manufacturer Leyland Trucks. Magnomatics will design, build and test the MAGSPLIT device and electrical traction subsystem; Hewland Engineering, a UK transmission manufacturer, will design and manufacture the MAGSPLIT transmissions and AVID Technology will convert, commission and deliver the vehicles, including proprietary electrified ancillaries to enable zero emission capability. The trial will verify the technology, business case and emissions benefits to the consortium, who represent UK based end user, OEM and Tier 1 suppliers, capable of delivering this high value, innovative powertrain to market from a UK manufacturing base.
The 36 month project will carry out research and develop a completely new chassis system concept for a 7.5 - 12t [G.V.W.] truck. A light weight future truck chassis concept will deliver at least 30% weight saving compared with the current Best in Class truck chassis. The aim of this project is to prove out the feasibility of this concept, so it can be incorporated into future truck chassis designs created at Leyland Trucks. Its design will allow the installation of all the planned next generation of Low Carbon vehicle driveline technologies, from full EV through hybrid vehicles and refined diesel vehicles. Significant weight saving will be achieved by the use of various Aluminium alloys deployed by using diverse manufacturing methods, i.e. extrusions, cast nodes and brackets. The project includes a number of innovations to deliver the weight saving and integrate truck chassis and body under structure.