With the components in place, the chassis moves to the commissioning station. There a laptop computer is used to program the onboard computers that control vehicle operation.
As a final step, the hybrid chassis is placed on a dynamometer. There the truck runs through a New York Trace test, a series of starts and stops that simulates a delivery route. In addition to simulated local delivery, the test includes revving the truck up to highway speeds. Test results are displayed and captured here.
Three small fans take the place of the single large OEM fan. One, two, or three of the electrically powered fans can be activated, depending upon what the hybrid controller determines the heat load to be. The design saves electrical energy compared to operating one large fan. All subassemblies are produced in this defined area.
Hosing station is part of the hybrid assembly process. Hoses carry the low-temperature coolant that the electric power system requires.
The 280-volt electric motor is mounted to the crossmember. Orange is the industry standard color code indicating the presence of high-voltage wiring.
The hybrid components require their own cooling system. Compared to that of the gasoline engine cooling system, hybrid cooling system is low-temperature. However, the frontmounted radiator is still required to make sure the electric components do not overheat.
Read the feature article that goes along with this photo gallery: Azure Dynamics and Utilimaster converting Ford E-Series into hybrid commercial vehicles
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