When Menzies Aviation was looking for help in reducing emissions within their operations teams based in the U.S., the ground service provider looked for ways to convert is fleet of baggage tractors and belt-loaders to an electric powertrain.
A&V Rebuilding was able to provide up-cycled lithium electric powered baggage tractors and belt-loaders with a fully integrated battery management system (BMS) and additional safety features.
“Not only are these units allowing us to move closer to our aim to be carbon neutral by 2033, Menzies’ 200th anniversary, the advanced safety features of both the belt-loaders and the baggage tractors will ensure a safer work environment for our employees,” says Scott Bellamy, director of GSE-Americas for Menzies Aviation.
When approaching the project, A&V relied on its history of building internal combustion engine (ICE) powered remanufactured GSE and expanded on it with the new Lithium technology.
“We have known for many years that there was a need for electric baggage and cargo tractors that could be used as effectively as their internal combustion engine counterparts,” explains Gerry Hoadley, owner of A&V Rebuilding.
“We were one of the first to develop a lithium power package to replace the ICE engine in a baggage tractor back in 2011,” he continues. “Our early development was ahead of its time and unaffordable due to the very high cost of lithium batteries at that time.”
After early attempts at converting GSE to lithium power, the project was revisited when Chris Shaeffer of Airport Terminal Services (ATS) approached A&V about developing a repowered baggage tractor with a lithium electric drive system. This initiative ultimately led to A&V’s partnership with LevCon to deliver an electric drive system that is now in use by Menzies.
The LevCon package has been well received, prompting A&V to expand its use. Now through its subsidiary, AV GSE, the LevCon package is also being utilized by Taylor-Dunn to power its redesigned Tiger TC series of baggage and cargo tractors.
“Like other A&V electric equipment, the new lithium electric powered Tiger TC series tractors are equipped with the LevCon drive system and feature their patented anti-rollover safety feature,” Hoadley explains.
Officials at A&V were working on ATS’s eGSE project prior to the pandemic. But as business slowed down, more focus could be directed to building prototypes and performing tests.
“In all honesty, the pandemic was a big help,” Hoadley recalls. “We worked nearly two years developing and testing our tractor package. After thorough in-house testing, we enlisted the help of our customers for on airfield testing.”
ATS was the first company to test the tractor on the ramp, using it in daily operations at John Wayne Airport (SNA) in Santa Ana, Calif., alongside its existing fleet of eGSE.
“Most of their ramp agents liked it because it was more of a traditional tractor like they were used to, where you sat up high on the tractor and you could see everything,” Hoadley says.
Menzies became A&V’s second testing partner. After placing an order for the lithium baggage tractors to be used at Ontario International Airport (ONT), A&V sent the ground handler a lithium repowered belt-loader equipped with its Plane-Safe Collision Deterrent system for testing.
“They promptly ordered two of these for ONT as well,” Hoadley notes, adding the units run-time offered advantages. “We have now sold Menzies lithium powered equipment for multiple stations and are working with them to hopefully supply many more.”
The LevCon solution fits within the footprint of existing tractors with minimal modification. Being able to utilize the existing steel and other materials of the tractor itself has environmental benefits, too.
“The fact that these units are built around refurbished chassis means less materials are ending up at landfills,” Bellamy notes.
In addition to emission benefits, a reduction in fuel and maintenance costs can also be achieved.
“Other than an occasional gear oil replacement in the drive axle, and basic lubrication, there is very little to service. Even brake pads last longer due to our programmable regenerative braking system that uses the AC induction motor to do most of the stopping,” he says.
Hoadley says modern LiFePO4 batteries are forecasted to last 10-12 years, or more, with proper charging.
“The biggest challenge anyone faces when thinking of going electric is the charging infrastructure,” Hoadley explains, noting his equipment can be charged multiple ways.
“If the customer has access to fast chargers with communication pins, we can supply the equipment with the necessary battery identifier modules to communicate with their chargers,” he continues. “For customers without charger infrastructure available, our equipment can be fitted with on-board chargers that can charge using a 110v or 220v outlet. This type of charging is done through a J1772 charge connector and an EVSE equipped power cable. We have also developed a charge cart, which can charge our equipment using 400hz aircraft bridge power or a GPU if necessary.”
Hoadley credits working with people familiar with the ramp environment to gather input during the development stage. As a result, he says feedback has been positive. Specifically, he says one ramp manager raved about the Plane-Safe Collision Deterrence technology and the peace of mind that comes with knowing operators cannot accidentally collide with aircraft.
A&V plans to work with LevCon to increase the lithium repower package offerings for the GSE industry. In addition to working with Taylor-Dunn on its Tiger tractors, plans to move into larger types of GSE are also on the horizon.
