Bus Testing Program

1. Federal Transit Administration’s Bus Testing Program Steering Committee Meeting March 28th, 2013 University Park, PA Operated by: Thomas D. Larson, Pennsylvania Transportation Institute Altoona Bus Testing and Research Center Pennsylvania Transportation Institute College of Engineering The Pennsylvania State University

2. Purpose of Meeting • Steering committee members include: • Transit bus manufactures • Transit industry manufacturers • Transit agency professionals • Experts from national labs • FTA Personnel • Meeting objectives: • Review current program • Suggest improvements to tests, policies and procedures • Present and discuss MAP-21 changes

3. Altoona Bus Research and Testing Center 2237 Old Route 220 N Duncansville, PA

4. LTI’s Full-Scale Research Facility (Test Track) Brake Slope Rail-Guided Crash Test Facility Vehicle Handling Area Large Impact Pendulum Vehicle Durability Track Bus Lane Dynamometer Vehicle Testing Laboratory Pavement Durability Track Rock Road Entrance (Test Track Road) Research Laboratory and Office

5. The Bus Testing Law • STURRA • Established center (1989) • Required testing of new model buses to be purchased with Federal funding • Established test categories (based on early 1980’s First Article Bus Testing Plan, i.e., White Book) • ISTEA • Provided 80% test fee funded by FTA • Provided 20% test fee funded by entity having vehicle tested • Expanded test categories • TEA21 • Provided funding until 2004 • SAFETEA-LU • Provides continued funding • MAP-21 • Establishes pass/fail requirement

6. Definition of a Bus? • 49 Code of Federal Regulations, part 665.5 • “a rubber-tired automotive vehicle used for the provision of mass transportation service by or for a recipient.”

7. Testing Determinations • Independent of testing center • Made by FTA • FTA Program Manager: Mr. Greg Rymarz • Reasonable approach based on “family of vehicles” • Consistent, qualified engineering support • Booz Allen & Hamilton

8. Full Testing • Explicitly required when a new bus model has not been tested previously at the Altoona Bus Research and Testing Center

9. Partial Testing • Applies to previously-tested models only • Required for • “Major change in chassis or components” • Might be required when a change • Potentially impacts structural integrity • Potentially impacts safety characteristics

10. Altoona’s Testing Plan • Standardized • Based on minimum expected vehicle service life or mileage • Minimum performance criteria proposed • Mandated pass/fail provision • In addition to FMVSS requirements

11. The Tests • Eight evaluation categories • Maintainability • Reliability • Safety-Braking • Performance • Structural Integrity and Durability • Fuel Economy • Noise • Emissions

12. Data Reported • Comprehensive Final Test Report • Comprehensive report for each model tested • Format standardized for ease of comparison between competing models • Objective results • Pass/fail provision mandated by MAP-21 • Descriptions of all problems/failures encountered • Data intended for use during procurement process

13. Test Report Format

14. Web Dissemination of Test Results • Web-based Information Management System • Currently maintaining web presence • Contains test data from all reports • Queries for specific, cross-referenced data • Allows statistical analysis www.altoonabustest.org

15. Web Update • Administrative site allows timely updates by authorized personnel.

16. Web Presence

17. Web Database • Capabilities include the ability • To select and compare bus models • To apply multiple filters to a search

18. Bus Models Tested As of March 31, 2008 Since its inception, the test center has completed testing of 410 buses.

19. Electric/HEV Buses Tested • Hybrid-Electric • Advanced Vehicle Systems (AVS)(Capstone Turbine) • Ebus (Capstone Turbine) • Northrup Grumman Advanced Technology Transit Bus (ATTB) • Orion VI (BAE Systems) • Transteq (Ecomark Shuttle) • Vehicle performance severely limited testing • New Flyer/Allison • Gillig/Allison • Trolley Enterprises/SK International • New Flyer/ISE Research • Azure • Orion • Gillig • DesignLine • Battery-Electric • Advanced Vehicle Systems (AVS-22) • Ebus • Proterra • Dual-Mode • Neoplan Dual-Mode DMA/Skoda

20. Failures Encountered • Majority of failures encountered • Chassis/structure • Suspension • Engine/drive train • Exhaust/emissions • Electrical • Air conditioning/heating • Brakes • Steering • Fuel Systems • Seats/Lifts/Doors/Windows

21. Examples of Failures

22. Examples of Failures

23. Quantity and Class of Failures As of March 31, 2008 Based on data from 410 buses completing structural durability test.

24. An Ambitious Beginning • Technical and regulatory changes since 1990(ADA, Clean Air, etc.) • Deployment of new technologies • Alternative fuels/Fuel cells • Battery and hybrid-electric buses • Advanced materials-SS and light weight composites • Electronic controls/multiplexed systems • Advanced engines (diesel, gas, turbine, etc.) • Advanced after-treatment including urea injection, SCR catalysts, etc. • Evaluating new technologies • Bus testing played prominent role • Identifying “teething” problems • Helping to correct problems early in production cycle • Emissions testing • Brake testing • Pass/fail criteria

25. Safety Benefits • Detect defects directly related to safety of transit-riding publicExamples: • Bus Fires • Cracked CNG cylinder support brackets • High-pressure fuel cylinder detachment • CNG fuel system cracks/leaks • Fuel tank leaks • Fire detection/suppression system failures • High current electrical short circuits • Broken steering/suspension components • Loss of vehicle control

26. Making a Positive Impact • Testing raises the bar • Requires better reliability and performance • Manufacturers • Opportunity to correct deficiencies (without public disclosure) • Transit agencies • Use test results to • Manage risk during procurement • Modify maintenance schedules

27. Expansion of Testing Program • Facility Modifications Since 2000 • Accommodate new tests • Accommodate advanced technology buses • New Facilities • Brake slope • Emissions Lab • Battery testing/simulation • Power processing systems • Hydrogen fueling station • Completed spring 2006

28. Bus Maintenance and Testing Facility • Vehicle Testing Laboratory (2004) • 10,000 ft2 heated maintenance/testing area • Large-roll (72-in diameter) dynamometer • Schenck-Pegasus (Horiba Automotive Test Systems) • Electronic inertial simulation • Battery/electric drive test area • Aerovironment AV-900 power processing system • Environmental Chamber for full-scale Battery pack testing • Emissions testing laboratory

29. Regulatory Changes • FTA Final Rule Published October 5th 2009 Testing of Overloaded Buses Emissions and Brake Testing • FTA Withdrew the 175lb per person requirement in December 2012 • MAP-21 Requires Pass/Fail • Federal Register: 49 CFR Part 665 • Go to : www.regulations.govto view or post comments to the docket

30. Proposed Changes to tests • Perform fuel economy tests on chassis dynamometer. • Replace current fuel economy cycles (CBD, Arterial, Commuter) with cycles used for emissions tests: (Manhattan, Orange County, and UDDS)

31. Bus Testing—Into the Future • Predicting continued significant advancement in new bus technologies (i.e., Bus Rapid Transit) • Driving Factors • Safety and security • Better performance, efficiency, reliability • Enhanced service • Advancements in materials systems • Increased integration of advanced systems • Anticipating future changes in industry • Looking forward to meeting challenges • Bus Testing Steering Committee

32. Information Greg Rymarz, FTA Program Manager Phone: 202-366-6410 Email: gregory.rymarz@dot.gov • David J. Klinikowski, Program DirectorPhone: 814-863-1898Email: dklinikowski@engr.psu.edu • Robert R. Reifsteck, Altoona ManagerPhone: 814-695-4067Email: rreifsteck@engr.psu.edu

33. Brake Testing Update Larson Transportation Institute Bus Research and Testing Center Steering Committee Meeting Allen Homan27 March 2013

34. Mid-Sized Buses

35. Full-Size Buses

36. Current Equipment

37. Proposed System

38. Questions? Allen Homan(814) 863-8011ahoman@engr.psu.edu

39. Emissions Testing Update Larson Transportation Institute Bus Research and Testing Center Steering Committee Meeting Dr. Suresh Iyer27 March 2013

40. Overview • 2005 – Decided on concept of full scale dilution tunnel • 2006 – Finalized specifications • 2007 - Identified potential suppliers • 2008 – Placed orders • 2009 – Modified facilities, equipment delivered and commissioned • 2010 – Started emissions tests on buses • 2011 – Received ISO 17025 laboratory accreditation from A2LA • 2010 to 2012 – Performed emissions tests on 44 buses

41. Buses Tested 2010-2012

42. Specifications Chassis Dyno • 300 HP (absorb/deliver) • Large roll (72 inches) • 25 tons inertia • 80 mph • Simulated road load Emissions Equipment • Full scale dilution • CO2, CO, Nox, NO, THC, CH4, particulates • Diesel, gasoline, CNG, propane, LNG, ethanol, hybrid energy • Driver aid

43. Capabilities • Gaseous Emissions (dilute continuous, dilute bag, and raw) • CO2 • CO • THC and CH4 • NOx and NO • Particulates (PM) • Secondary air conditioned for dilution • Up to 3 phases in one test • Fuel consumption by carbon balance

44. Advantages • Less sensitive to ambient conditions • Conditioned air to dilution tunnel • Conditioned air to engine intake • Two banks of emissions analyzers • Simultaneous dilute and raw exhaust measurements (check) • Reliability • Large roll (dyno) reduces tire flexure (and tire heating) during tests • Absorbed power (dyno) is fed back into the grid

45. Heavy-Duty Dynamometer

46. Emissions Testing Facility-Overview

47. Midsize Bus under Test

48. Midsize Bus under Test

49. 40’ Bus under Test

50. 40’ Bus under Test