Airport Ground Support Equipment Electrification - Key Insights and Solutions

Why Airports Are Ideal for Electrification

Airports are widely recognized as the perfect environment for electrification, with airport ground support equipment (GSE) standing out as an ideal application for electrification technology. Airports offer nearly optimal conditions: enclosed areas with predictable routes, consistent daily distances, flat terrain, and low-speed limits (usually under 30 km/h). Additionally, professional drivers, strict safety regulations, and a strong culture of routine maintenance further enhance the viability of electrification in this setting.

Experts in the industry agree that transitioning airport vehicles from diesel to electric is a clear and sensible choice. This is already being realized by airports that have adopted electrified vehicles, which report positive outcomes and emphasize the importance of integrating effective charging infrastructure to unlock the benefits of electrification fully.

Given the unique operational needs of airport GSE, where safety and reliability are paramount, a thoughtful and strategic approach is essential for a smooth transition. This article will explore the key considerations in electrifying airport vehicles and provide insights to ensure successful implementation.

Key Technical Issues in Airport GSE Electrification

(1) Lead-acid Batteries vs. Lithium Batteries

Conclusion: Lithium batteries are the optimal choice for airport vehicles.

Explanation:

Historically, baggage tractors were the first airport GSE to go electric, primarily using lead-acid batteries due to their earlier adoption, safety concerns about lithium batteries, and their higher costs at the time. However, with the proven safety and declining costs of lithium iron phosphate (LFP) batteries, the industry has now largely standardized on LFP batteries. The following table highlights why LFP batteries outperform lead-acid batteries in every metric, marking a complete transition to lithium batteries for airport GSE:

Thanks to advancements in lithium technology, LFP batteries are now the first choice for electric commercial vehicles.

(2) LFP Batteries vs. NMC Batteries

Conclusion: LFP batteries are preferred due to their superior safety compared to nickel-manganese-cobalt (NMC) batteries.

Explanation:

• LFP batteries are inherently safer: NMC materials begin to decompose at 200°C, potentially causing fires, while LFP decomposes only at 700-800°C.
• NMC batteries, with their higher energy density, are more suitable for smaller, lightweight vehicles like passenger cars. In contrast, LFP batteries are used in electric buses and larger vehicles, prioritizing safety over size.
• In China, over 98% of electric buses use LFP batteries, demonstrating their proven safety in large-scale applications.

(3) Low Voltage (80V) vs. High Voltage (300-600V)

Conclusion: High-voltage systems (300-600V) are recommended.

Explanation:

From an electrical efficiency perspective, higher voltage results in less loss, leading to better efficiency. However, if the voltage is too high, it can create challenges in terms of insulation protection. Additionally, lead-acid batteries are not suitable for large numbers of cells in series.

Considering these factors and the accumulated experience in the electrification industry, lead-acid battery systems typically use an 80V voltage, while lithium battery systems typically use a voltage range of 300V-600V.

• 80V low voltage is the preferred voltage for lead-acid battery systems. Most lead-acid battery-powered vehicles opt for 80V because the nominal voltage of a lead-acid cell is 2V, so 80V requires 40 cells connected in series. However, due to the inconsistent performance of lead-acid batteries, especially flooded lead-acid types, 40 cells in series is the maximum number that can maintain good characteristics. Electric forklifts, sightseeing vehicles, golf carts, and electric tow tractors using lead-acid batteries generally have a total battery voltage of 80V. This is a limitation imposed by the technology of lead-acid batteries.
• Lithium batteries, due to better consistency and the presence of a sophisticated battery management system (BMS), typically operate within a voltage range of 300V-600V.

(4) Charging Infrastructure

Conclusion:

• The optimal solution is a distributed charging model with charging points located close to parking spaces.
• National standard charging equipment should be adopted (including charging voltage, protocols, and interfaces).
• The goal is to ensure compatibility: “Vehicles should not be selective about chargers, and chargers should not be selective about vehicles.”

Explanation:

1. For airport electric ground support equipment, a distributed charging model near parking spaces is the most suitable. This is because airport GSEs are diverse in type and often have unique designs, making battery swapping impractical. As such, a battery-swapping model is not feasible.
2. Most airport GSEs have relatively short driving ranges, which makes "long-distance" battery swapping or charging inconvenient. Therefore, a centralized charging model is also unsuitable.
3. Based on these considerations, establishing 2-3 battery maintenance stations within the airport is a good solution. Vehicles can stay within the airfield while receiving regular battery inspections and maintenance. This approach is particularly effective for new airport construction projects, offering an efficient way to manage battery upkeep.

(5) Motors and Controllers

Conclusion: Permanent magnet brushless motors are optimal, and integrated controllers are the standard.

Explanation:

• Permanent magnet motors offer the highest efficiency among motor types, thanks to their use of magnets for excitation.
• Integrated controllers, which combine control systems for multiple motors (e.g., for driving, hydraulic systems, air systems, and air conditioning), have replaced standalone controllers for each motor. These compact, water-cooled units with IP67+ protection offer better reliability, electromagnetic compatibility, and cost-effectiveness.

Brogen Solution for Airport GSE Electrification

At Brogen, we offer electrification solutions specifically designed for airport GSE. Our portfolio includes high-efficiency motors, advanced controllers, distributed e-axles, and lithium battery systems, all engineered to meet the unique demands of airport operations. Whether it's powering pushback tractors, cargo loaders, or passenger shuttle buses, our solutions ensure reliability, efficiency, and sustainability.

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