SUNCAR and Rosenbauer develop high-voltage power distribution systems for the fully electric airport fire truck PANTHER electric
As part of a multi-year development project, SUNCAR AG, in close cooperation with Rosenbauer International AG, developed the high-voltage power distribution systems for the new PANTHER electric—the first fully electric airport fire truck in the renowned PANTHER series.
Fundamentals and project structure
In the early project phase at the beginning of 2022, initial acquisition discussions were held. Detailed audits followed prior to commissioning in order to precisely capture the technical and regulatory requirements of the various target markets. On this basis, robust specifications and well-founded contractual frameworks were developed collaboratively, enabling structured and targeted project execution.
Development consistently followed proven automotive processes and international standards. Validation, documentation, and quality assurance were implemented in line with established standards to ensure the system’s suitability for series production.
Scope of services
A key component of the high-voltage system is the energy distribution systems developed by SUNCAR for high-voltage technology (HVDUs) and DC fast charging. SUNCAR assumed both the customer-specific development and the series production of these systems. A total of six HVDUs are installed per vehicle: two main HVDUs (MAIN), two for power supply (PS), and two auxiliary (AUX) HVDUs. All units are designed for voltage levels up to 1000 VDC to ensure maximum performance and operational safety in service.
The main HVDU is equipped with two high-performance DC contactors that enable safe disconnection and switching of the batteries as well as reliable supply of the drive systems. An integrated insulation monitoring device further increases safety, while all connectors are integrated into the safety circuit (interlock). Additional safety features, such as short-circuit links, underscore the high quality and safety standards.
The design of the AUX and PS HVDUs was implemented with particular efficiency: both types are based on the same platform, reducing variant diversity and lowering production costs without compromising functionality.
The HVDUs meet the highest requirements in terms of service life and operational availability. Extensive thermal stress tests were carried out both internally and in external laboratories to ensure reliability under various load cases at inputs and outputs. The HVDUs withstand temperatures from –40°C to +60°C, are rated to water and dust protection class IP67 / IP6K9K, and remain functional at altitudes from –80 to 4,000 m. In addition, short-circuit tests with currents above 18 kA were successfully completed.
In addition, two standard SUNCAR products—INTERFLOW500 DC fast-charging interfaces—and charging controllers with CCS communication are installed per vehicle. The same high requirements apply here as for the customer-specific high-voltage power distribution systems.
SUNCAR’s energy distribution systems were designed for the extreme requirements of an emergency vehicle with 1,200 hp and a top speed of 120 km/h. In all-electric operation, the PANTHER 6×6 accelerates from 0 to 80 km/h in up to 25 seconds. Boost mode, in which additional electric drive energy is provided by an EnergyBackupSystem installed in the vehicle, enables the PANTHER electric to accelerate from 0 to 80 km/h in less than 20 seconds. Power is supplied by HV batteries with a nominal energy content of 256 kWh, supplemented by an EnergyBackupSystem for maximum operational flexibility. The system also supports a maximum charging power of 250 to 300 kW (DC). This means that the energy sufficient for a typical airport deployment of this vehicle can be provided in approx. 20 minutes.
Global series production and target markets
In addition to the high technical requirements, the international nature of the project added further complexity. Together with numerous partners, a global supply chain was established that meets both worldwide series production needs and country-specific requirements—with a particular focus on requirements for the US market. The main target markets for the PANTHER electric are Europe as well as the USA and Asia, where the diesel-powered series is already successfully in service in over 100 countries, now in its 4th generation.
More info: https://www.rosenbauer.com/de
