Electric luggage cart project

/ ELECTRIC VEHICLES /

Develop an eco-responsible solution to upgrade the fleet of tractors used to tow baggage carts at airports.

A PROJECT BY

AvJet has chosen an eco-responsible solution to upgrade its fleet of tractors used to tow baggage carts at Montréal–Trudeau International Airport and at other airports in Quebec. This solution, both innovative and sustainable, aligns with AvJet’s commitment to reduce its environmental footprint and to comply with future electrification requirements for operations at YUL airport.

This project was carried out in collaboration with Ingenext, a firm specialized in electric conversions based on reusing components from electric vehicles. AvJet — which expects to have completed the conversion of its 100-tractor fleet by 2025 — is a pioneer in its sector.

Project objectives

• Demonstrate the feasibility of adapting cutting-edge electric technology to a 1980s gasoline vehicle;
• Carry out the upgrade at a reasonable price (comparable to or lower than the price of a new vehicle);
• Test the range and reliability as well as performance (ability to tow 10,000 lb);
• Ensure the vehicle will be adapted to Quebec’s winter conditions;
• Eliminate or reduce greenhouse gas (GHG) emissions caused by fuel consumption;
• Reduce maintenance costs;
• Rely on a solution that favors reuse of components from crashed vehicles (Chevrolet Bolt);
• Extend the service life of the tractors and thus delay the scrapping of these vehicles;
• Collaborate with a Quebec-based (supplier) company;
• Improve employee health and safety (emissions, noise, etc.); and
• Facilitate change management for staff (familiarity with the vehicle).

Project stages

In 2020, AvJet and Ingenext began discussions to convert to electric the fleet of tractors used to tow baggage carts. The company selected this type of equipment to start the conversion process of its equipment fleet, since the new models currently available on the market do not meet the company’s needs. Also, the tractors — which make up the majority of the fleet — are among the most used, the most energy-consuming (gasoline) and the most expensive in maintenance costs.

In March 2021, the team decided to move forward with the project. It aims to upgrade AvJet’s fleet of 100 tractors by replacing the fuel (gasoline) drive components with electric motor components taken from heavily damaged Chevrolet Bolt cars.

A feasibility study was conducted and research for developing the preliminary concept of the prototype was launched. An application was submitted to the Ministry of Transport and Sustainable Mobility to obtain financial support from the program for maritime, air and rail transport efficiency (PETMAF).

The team then moved on to the detailed design, assembly, testing and prototyping phases. The conversion posed certain technical challenges, notably regarding modifications to the engine and components to adapt them to the tractor, the assembly of the battery and the electrical and electronic architecture according to the new configuration, programming as well as mechanics (this aspect required many hours of engineering).

Completed in fall 2021, the prototype was used by AvJet for one year to test the vehicle in real conditions. The results were conclusive.

Conversion of the first 30 vehicles (all of the same model) began in November 2022 to end in (month) 2023.

The conversion of the other 70 vehicles will be completed by the end of 2025. This will require certain adjustments depending on the tractor manufacturer. However, 75% of the work — already completed as part of the initial project — is applicable to the other models.

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Pre-project methodology

The AvJet and Ingenext teams worked closely together in planning this project in order to take into account parameters such as:

• Regular supply of components;
• Adapting the vehicles to weather conditions, particularly difficult in winter;
• Logistics of charging spaces according to the required duration;
• Installing a sufficient number of charging stations;
• Developing a contingency plan in case of electrical failure or equipment breakdown;
• Meeting the schedule set by YUL airport (end of 2025);
• Choosing the best time to carry out this initiative (a quieter period due to reduced air traffic during the pandemic).

Financing

A funding application was submitted to theMinistry of Transport and Sustainable Mobility to obtain financial support under theprogram for maritime, air and rail transport efficiency (PETMAF). This fund can finance 75% of the prototype implementation costs, i.e. an amount of $150,000.

Results achieved

High-performing eco-responsible solution

This conversion to electric transportation offers a solution that is both eco-responsible and high-performing:

• Elimination or reduction of fuel-related emissions (GHG). The electric conversion saves 10 tonnes of GHG. In addition, it prevents the emission of 15 tonnes of GHG per year for each gasoline vehicle converted to electric;
• Reduction of environmental noise;
• Extending the tractors’ lifespan by 20 years (total of 50 years);
• Increased efficiency: reduction of xx% to xx% of the time required to repair failures of fuel components;
• Significant reduction in maintenance costs;
• Improved performance;
• Conversion cost 50% lower compared to purchasing a new vehicle.

Current electric vehicles on the market do not adequately meet Quebec’s winter conditions. This solution helps address this problem and ensures optimal on-site performance. It also provides AvJet with a reliable supply of vehicles (delivery times for new vehicles are long).

Furthermore, using gasoline vehicles poses several environmental and public health problems, since they emit air pollutants that contribute to climate change.

Health and safety

The reduction of emissions and noise represents an important factor for the health of employees and airport workers.

Adaptability

This solution can be adapted to different tractor models without incurring significant costs. The work carried out as part of the project is 75% applicable to other models.

Lessons learned

Success factors

• Financial support to build the prototype;
• Collaboration between two local companies (proximity);
• Early involvement of the AvJet team;
• The choice of high-performing and reliable products;
• The possibility of applying the work done in the project to other cart models;
• The reuse of proven and tested automotive components (compared to parts imported from elsewhere);
• Access to a local (mainly Quebec and Ontario) and reliable supply (the Chevrolet Bolt is still on sale), able to meet the needs (volume);
• Choosing a vehicle (tractor) whose manufacturing methods have not changed much over the years;
• Electric range (3 days or more);
• Staff adaptation to the new electric vehicle (driving knowledge acquired);
• Sustained collaboration between AvJet and Ingenext teams;
• Choosing the right time to carry out this project (a quieter period due to reduced air traffic during the pandemic);
• The courage to choose and promote Innovation and Sustainability (alignment with needs);
• Transparency and information sharing.

Practical advice for carrying out such a project

• Ensure needs are well understood by involving the team from the start;
• Rely on a decision-making process compatible with AvJet’s eco-responsible vision;
• Validate the vehicle’s technology, performance and reliability upfront;
• Ensure the technology’s adaptability to all tractor models;
• Ensure sustained long-term support from the supplier;
• Choose high-performance charging stations (similar to those used for cars).

Next steps

AvJet will focus its efforts through 2025 to convert its fleet of tractors to electric. Afterwards, the company will evaluate the possibility of applying this approach to other types of equipment.

Project partners

• AvJet
• Ingenext
• Representatives of theprogram for maritime, air and rail transport efficiency (PETMAF)

Resources

Report on the project

• Radio-Canada | Electrified airport tractors in Trois-Rivières (August 4, 2023)