REVOLUTIONIZING TRANSPORT WITH ELECTRIC AND HYBRID INNOVATION
Series Hybrid City Bus
Explore how Astauto is pioneering the future of commercial vehicles with cutting-edge electrification technology, designed to reduce emissions and enhance efficiency.
Case study: Series Hybrid City Bus
AGRALE HYBRID MINI BUS FOR BRAZIL
Series Hybrid City Bus
The Brief
Our client, a leading manufacturer of buses and trucks in South America with production plants in Brazil and Argentina, has been producing electric city buses for several years, catering to major cities across South America.
However, for smaller cities and towns where the local electric grid cannot support the required charging infrastructure, the client commissioned Astauto to conduct a study on developing a city bus with a Series Hybrid propulsion system, aiming for production by 2025.
Our approach
Astauto’s methodology for this project included the following steps:
- Defining specifications and attributes of the current vehicle: We modeled and simulated the current Diesel bus to identify key attributes and performance metrics.
- Analyzing power and energy needs for typical operations: We conducted a comprehensive analysis of power and energy requirements for various drive cycles and operating conditions while maintaining the vehicle’s size and weight.
- Developing a virtual model of the electric/hybrid propulsion system: Using advanced modeling tools, we created a detailed virtual model of the power system and vehicle characteristics, simulating performance and efficiency.
Deliverables
Astauto delivered a complete set of electric/hybrid power system specifications, validated by simulation results. These specifications included:
- Traction motors.
- The internal combustion engine for powering the generator.
- The generator itself.
- Battery systems.
- Hybrid control system logic.
Based on the simulation results, we developed and validated propulsion system specifications to ensure they met the desired performance criteria.
In collaboration with suppliers, Astauto also conducted cost estimations and prepared a detailed bill of materials to support the construction of the first prototype. The goal is to have a fully developed prototype ready by the second half of 2025.
What Our Clients and Partners Say
“Since 2016, Sergio and his team have been invaluable partners in our expansion into the South American market for electric buses. Their deep expertise and strategic insights helped us navigate this evolving sector while also playing a crucial role in the design and development of electric buses tailored for both South America and the UK. Now, as we venture into agricultural machinery electrification for the global market, their continued support and innovative thinking remain instrumental in driving forward our vision.
Their dedication, technical knowledge, and ability to adapt to emerging opportunities make them an outstanding collaborator in shaping the future of sustainable transportation.”
Ian Foley
Chief Executive Officer
Equipmake Ltd
“From the very beginning of our journey developing the REE Corner and REE Platform, Sergio and Astauto have been invaluable partners to our R&D efforts. Their expertise in vehicle performance analysis, combined with advanced simulation tools, allowed us to make informed decisions on critical components—including motors, batteries, tyres, and aerodynamics. Thanks to their support, we rigorously evaluated our small to medium electric delivery trucks across a variety of drive cycles and typical mounting roads, ensuring optimal performance and efficiency. Their contributions have been instrumental in shaping our vehicles into cutting-edge solutions for the industry.
We couldn’t have asked for a more dedicated and insightful partner”
Ahishay Sardes
Director & Chief Technology Officer
REE Automotive Ltd.
“Over the years, AVL has been proud to collaborate with Astauto, a dedicated and innovative user of our simulation software. Their invaluable feedback and commitment have significantly contributed to the evolution and refinement of our tools, ensuring they meet the highest industry standards. Astauto’s proactive approach to leveraging our technology has not only enhanced their own projects but has also played a key role in advancing simulation capabilities for the broader Automotive and Motorsport engineering community. Together, we have fostered a relationship rooted in mutual growth, technical excellence, and shared vision for innovation.”
Mario Oswald
Team Leader
Engineering & Technology Powertrain Systems
AVL List GmbH
“Sergio’s contributions to Agrale have been instrumental in driving innovation and excellence. His expertise, dedication, and visionary approach have consistently elevated the team and its achievements.”
Edson A S Martins
Director
Agrale S.A.