A high-efficiency powertrain through a self-developed two-speed planetary gearbox

In 2021, following the launch of our drivetrain for aircraft stairs, we got in touch with Aviaco GSE. Aviaco GSE focuses on refurbishing and selling existing GSE equipment. Even then, Aviaco and XYZ recognized the potential in converting existing GSE equipment, with benefits such as:

• Cost-effectiveness

• No forced write-off of GSE equipment

• Extended lifespan of GSE equipment

• The ability to actually start the transition, since handlers are no longer dependent on the supply from the GSE manufacturer.

A Minimum Viable Product leading to improvement

XYZ and Aviaco then began developing a retrofit drivetrain for a TMX 150 pushback tractor. Why specifically a TMX 150? We'll discuss that another time! In any case, the goal was clear: in November 2021, XYZ and Aviaco GSE wanted to show a prototype at the InterAirport show in Munich. No sooner said than done — in Munich, the response was hugely positive, given the cost-effectiveness and lifespan extension of the GSE equipment.

After the InterAirport show, we began testing the pushback at various locations in collaboration with different handlers across Europe. These demos and tests were successful and valuable. A lot of quality data was collected, and the overall conclusion was: "the drivetrain can be 30% to 40% more efficient."

An improvement that leads to the following:

• 30% to 40% more pushes with the same amount of energy capacity.

• A lower load on the airport's charging infrastructure.

The end result for the user

That all sounds great, but what does it actually deliver for the user? 20 – 25 pushes on a single battery charge! Assume that a pushback needs to perform an average of 10 – 15 pushes per day. That means that, in a good scenario, the pushback only needs to be charged once every 2 days.

How did we achieve this result? By replacing the manufacturer-installed torque converter with a self-developed transmission box. The transmission box is a "two-speed planetary gearbox," with a low and a high gear:

• The low gear results in a low speed (5 – 6 km/h) but delivers a high amount of torque to actually perform the push.

• The high gear results in a higher speed (20–25 km/h) to move quickly across the airport.

Would you like to know more about this transmission box and the full retrofit package? Feel free to get in touch with us!