The Hybrid Commercial Vehicle (HCV) project aims to develop urban buses and delivery vehicles with advanced second generation of energy efficient hybrid electric powertrains.

Sub-Project 5000 - Hybrid Van demonstrator

Partner's main objectives in SP5000 are to demonstrate the following improvements for the advanced second generation 6-ton hybrid van compared to the early second generation 5,6 t minibus and to second generation 3,5 t van:

  1. 5% fuel consumption reduction on urban cycle
  2. Payload improvement
  3. Cost reduction of at least 40% of hybrid drive train specific components
  4. Improved driveability and performance
  5. Electric air conditioning integration
  6. Noise reduction

In SP5000 data from real service usage of second generation hybrid van will be evaluated and analysed, Results from testing and extended field tests will be used to improve specific hybrid components and to optimise hybrid control strategy.

The hybrid powertrain will be optimised with focus on fuel consumption reduction, improved reliability and lower cost. Two new energy storage systems, lithium technology and supercap technology, updated electric drive system, as well improved AMT and electric auxiliaries will be developed and integrated on the demonstrator.

An electric driven air conditioning compressor will be integrated as well an optimised air conditioning system, in order to improve driver and passengers comfort without significant increasing in fuel consumption. With a smart control strategy, system energy consumption will be lowered and recovery braking energy use will be maximised for air conditioning functionality.

Specific hybrid sw parameters tuning will be performed on demonstrator to optimise driveability, noise and comfort and to maximise recovered energy during braking as for improved storage system performances in recharging phase.

The new hybrid demonstrator will be tested on road in real traffic in Genoa, Turin and Rome. Testing will be performed in order to understand the total system potential with special attention to new storage system capability and air conditioning performances.

Involved partners and activities

Altra (leader)

  • SP and WP management
  • Second generation Van testing
  • System and subsystems specifications
  • Demonstrator van development and build up
  • Hybrid control strategy optimisation
  • Demonstrator tuning and testing


  • Development and delivery of prototype electric drive system including inverter and DC/DC converter as well mechanical parts and housing with cooling
  • Focus on improved system functionality/performance and cost reduction


  • Based on results in SP2000: Electric air conditioning system development and delivery
  • Electric air conditioning system integration support, tuning and testing


  • Based on results in SP3000: Supercap storage system control improvements
  • Development and delivery of the prototype supercap storage system
  • Focus on the performance characteristics, reliability (abuse tolerance) and cost reduction


  • Extended field tests on second generation Van
  • Development and delivery of specific Diesel engine and AMT, delivery of 6 ton Diesel van
  • Demonstrator testing and evaluation

Magna Steyr Battery systems

  • Based on results in SP3000: Lithium Storage system control improvements
  • Development and delivery of the prototype battery system
  • Focus on the performance characteristics, reliability (abuse tolerance) and cost reduction
Info master Last edited on 2014-11-14