Electrification Simplified™. It’s not just a tag line at BAE Systems, it’s what we do. We’ve tackled the complexity of electrification to make it easier for both vehicle manufacturers and their operators to transition their buses and heavy-duty trucks to operate on electric power.
By using a modular architecture, our propulsion system is flexible enough for multiple platforms and can accommodate fuel-cell, battery-electric, and hybrid-electric power. Our latest propulsion system increases operational efficiencies and unlocks new capabilities with the additional power we harness. It was crafted to drive the expansion of electrification beyond transit city buses.
In doing so, BAE Systems engineers pioneered ground-breaking power electronics technology that can streamline vehicle electrification systems while expanding the range of power solutions available.
How exactly did we do this? Our innovative technologists designed scalable power electronics known as our propulsion power system (MPCS) and our accessory power system (MAPS). These systems employ sectional building blocks, each serving a distinct function. This approach allows for flexible and efficient customization, to meet diverse application requirements across numerous platforms and reducing the need for additional development efforts.
Each building block, or ‘slice’ as we refer to them, has a unique role. One of our ‘slices’ converts power from high voltage to low voltage, while another converts DC (direct current) to AC (alternating current) power. Each capability is packaged into a slice thinner than the size of a personal size pizza box, at only 1.5 inches thick. The slices can be stacked to make one scalable, compact component – instead of several components, like many of our competitors.
Rob Vovos, lead engineer in the development of our new flexible power systems, notes, “with fewer components, we have fewer connections and cables, simplifying the process. Our ‘slice’ approach offers customization by enabling us to combine slices according to the vehicle’s power needs, ensuring we avoid adding unnecessary capabilities.”
Let’s consider a sanitation truck in a city that has gone electric. The truck is equipped with the capabilities and requirements to do its job, including automated front loaders or side loaders, air conditioning, batteries, heating, and trash compacting. To support the truck’s electric operation, we would include a slice to power the loaders, a slice to support the batteries, a slice for propulsion of the vehicle, and so on – we are able to provide all the power for this vehicle with just a few slices.
Combining functions within one component, versus creating separate components, means 25-40 percent fewer parts than our competitors, streamlining integration. As the industry progresses, we’re finding vehicle manufacturers are looking for more accessory power than ever before. Fortunately, our systems can supply more than ample power to them, without sacrificing space or adding excess weight.
If you were to examine a competitor’s electric drivetrain solution, you might see an entanglement of undecipherable connections – posing safety concerns as well as difficulty in servicing the vehicle. In contrast, with our simplified approach, it’s much easier to follow the connections to driveline components.
Our customers value the efficiency our consolidated approach offers. By integrating cutting-edge electronics and switching technology, we significantly enhance performance. We’re using silicon carbide for faster switching, and gallium nitride to lower heat and resistance.
Due to its myriad benefits, electrification is a goal for today and the state of the future. With our flexible and compact approach, our power electronics design is destined to become the benchmark for Electrification Simplified™.
By Carol Gorenflo, Communications