Clean Air for London - Equipmake Converts Double-Decker Buses to Electric

The electric version of the New Routemaster operated by Metroline is currently being tested for six months in London. The program is expected to provide valuable testing data as Transport for London (TfL) continues to evaluate a range of clean technologies, including repower systems like Equipmake's ZED. The charging infrastructure at the Metroline depot in Holloway and the battery data analysis for the bus are provided by Zenobē, a specialist in EV fleets and battery storage.

Repowering from Snetterton

The New Routemaster developed by Equipmake in Snetterton, Norfolk, features a 400-kWh battery that enables an expected range of nearly 250 kilometers - more than enough for a day. The development of the all-electric New Routemaster was made possible through a program co-funded by the UK's Advanced Propulsion Centre (APC).

"Repowering is an important, cost-efficient transition technology that can bridge the gap between diesel and a new electric bus fleet," explains Ian Foley, CEO of Equipmake. "We are excited to present our latest repowering system in the form of an emission-free version of the iconic New Routemaster double-decker bus here today at the Euro Bus Expo."

The ZED used in the New Routemaster can be installed in any existing hybrid or diesel bus, quickly upgrading the vehicle with a state-of-the-art battery powertrain.

Maximizing Range Through Efficient Thermal Management

According to Foley, one of the key features of the ZED is Equipmake's patented, highly efficient thermal management system. It keeps all three key components of the ZED - battery pack, motor, and inverter - at an optimal operating temperature, thereby maximizing the vehicle's range.

The system features a water-glycol cooling circuit and has the added advantage of heating the interior with captured thermal energy during cold temperatures. When the battery is depleted at the end of a full operating cycle, it can be recharged overnight at a CSS DC charging station in the depot. Under the hood of the New Routemaster is also Equipmake's HTM 3500 electric motor. The motor is seamlessly integrated into the driveshaft, without the need for a separate gearbox. It generates 3,500 Nm of torque at a motor speed of only 1,000 rpm and delivers a maximum power of 400 kW.

Cost-Effective and Environmentally Friendly

Apart from the environmental benefits, the repower program is also cost-effective, as each conversion costs less than half the price of a new electric bus. And since most buses are expected to remain in service for 14 years or more, operators can still achieve significant efficiency gains by repowering a bus halfway through its lifespan. Vehicles that would have to be decommissioned due to new environmental regulations can be re-integrated into the fleet through repowering.

“We know that there is a clear interest in repowering technology, with strong demand from operators leading to the expansion of our facilities in Norfolk,” Foley continues, “The changes in subsidies for bus companies mean that repowering is being promoted, and the DfT's consultation on proposals to end the sale of new, non-emission-free buses means that the demand for our technology will only increase. Considering the financial benefits that come from converting a bus, it becomes clear why such vehicles can quickly improve air quality in cities across the UK."