Providing Electric Drive Systems for Rapidly Expanding e-Bus Fleets in North America

Gen3 power management technology will deliver clean, efficient, and reliable operation for zero-emission fleet

BAE Systems, a leader in heavy-duty electric propulsion, will supply up to 541 Gen3 electric power and propulsion systems for the Toronto Transit Commission’s (TTC) new fleet of battery-electric buses, allowing them to run free of emissions. It marks the latest in a flurry of such orders, now even involving fuel cell systems.

BAE Systems’ electric propulsion technology has been operating in TTC buses since 2006. The company’s Gen3 offering builds on those proven components and technical expertise that has powered more than 1,000 hybrid-electric buses in Toronto. The system will advance the TTC’s goal of transitioning to a zero-emissions fleet by 2040.

“Delivering leading-edge technology to help Toronto realize its green transit initiatives is a shared vision for BAE Systems and the TTC,” said Bob Lamanna, vice president and general manager of Power & Propulsion Solutions at BAE Systems. “The TTC has consistently embraced sustainable transportation, and our systems will help make our vision a reality through reliable, efficient operation.”

BAE Systems’ Gen3 system includes an electric motor and innovative power electronics to create a clean, integrated power management solution for the buses. Gen3 uses advanced materials such as silicon carbide (SiC) to increase power density and electrical efficiency, allowing buses to travel longer distances on a single charge. Its compact design allows for reduced size and weight to deliver best-in-class reliability and performance.

Using a modular architecture, the same core technology used for hybrid buses, makes it easier for transit agencies to transition to all-electric operation. The system also requires fewer components and connections, which contributes to reduced operational costs and maintenance requirements to maximize fleet productivity.

BAE Systems’ proprietary Intuitive Diagnostic Software (IDS), already in use at TTC for its hybrid bus fleet, will provide powerful, in-depth, full electric propulsion and accessories power management system diagnostics and troubleshooting capabilities. IDS updates cover all Gen3 system components.

Building on 25 years of innovation, BAE Systems has more than 16,000 propulsion systems in service on transit buses worldwide. Its electric propulsion technology is developed and serviced at its facilities in Endicott, New York and Rochester, U.K.

In March, BAE received an order to supply its Gen3 electric drive system for three hydrogen fuel cell buses in Rochester, New York manufactured by ElDorado National-California, a unit of specialty vehicle conglomerate Revco Group. The buses will advance Rochester-Genesee Regional Transportation Authority’s goal of reducing its carbon footprint and transitioning to a zero-emission fleet. They will be the first hydrogen fuel cell buses to use the Gen3 system, to be integrated with a 125kW Progen hydrogen fuel cell engine from Plug Power. 
In June, BAE announced an order from Nova Bus for integration of its electric drive system into the largest electric bus order to date in North America. The ten transit authorities members of the Association du Transport Urbain du Quebec ordered up to 1,229 battery-electric buses to serve their routes for the province.