A state-of-the-art prototype fire apparatus was recently unveiled by Emergency One Inc. of Ocala, FL. The Concept-2000 fire truck has been a joint venture between Emergency One, GE (General Electric) Plastics, Spartech Plastics and Thermoform Plastics Inc. (TPI). This apparatus utilizes newly created advanced plastics technology designed specifically for outdoor vehicles.
After listening to the wants and needs of more than 4,000 fire chiefs, officers, members of fire departments, mechanics and industry focus groups each year, Emergency One embarked on a plan to design, manufacture and deliver a vehicle engineered as a total system rather than separate components, and as a state-of-the -art package, not a combination of old and new technologies. This project had several goals in mind. Starting with the Emergency One motto, "No alternative to innovation," the goals included: the apparatus must be aesthetically pleasing, better ergonomics than current products today, safer vehicle, lower maintenance costs, easier serviceability and trouble shooting and easier to maintain.
Design of the prototype vehicle created on a computer was partially influenced by a contest sponsored by the Fire Apparatus Manufacturers Association (FAMA) and Firehouse® Magazine. The winners of the contest were published in the April 1993 issue of Firehouse.
LEXAN resin manufactured by GE Plastics is featured on the cab of the apparatus. Emergency One built the cab made of body panels thermoformed by TPI. TPI used a Millennium™ III sheet, a three- layer coextrusion from Spartech Plastics. The core layer of the sheet is made of glass-reinforced LEXAN resin while the outer layers are made of unreinforced LEXAN resin. This material was selected for its light weight (increases payload); paintability (provides a high-gloss finish); and durability. The Millennium III sheet features a unique co-efficient of thermal expansion which allows the sheet to be used successfully in combination with metals such as aluminum and steel. The cab is constructed of an all-aluminum roll cage. The cab and body panels of the apparatus are constructed with Millennium III rigid sheets attached to an all-aluminum frame. This gives the apparatus structural strength, stiffness and durability. The use of an adhesive bonding with Millennium III and the large flat areas of the body panel were designed to provide many square inches of adhesive to attach itself. This spreads the load over a greater area, giving greater strength to the structure and cab frame. The adhesive used is the same one used in the installation of over 130 million windshields since 1963.
Some of the highlights of the new material include corrosion-resistant materials that do not oxidize through electrolytic corrosion and are not affected by dissimilar metal contact. Materials are elastic and allow for flexing instead of breaking and cracking. The materials bounce back when struck and repel small projectiles such as stones and gravel. Impact resistant, it will not dent or ding. The composite material reduces apparatus weight by 20% when compared to traditional trucks. This weight savings allows a department to carry more equipment, spec a truck with lower gross vehicle weight (GVW) rated axles or add a bigger tank.
The panels are exact in dimension. Replacement parts too are exact, making the unit easier to repair and reducing down time.
Among the functional items that Emergency One has focused on for user-friendly technology are:
Photo courtesy of Emergency One Inc. Fold-down steps were installed in compartments for easy reach to the top shelves, eliminating the need for slide-out steps.
- Cab access and seating. The driver's and officer's doors are mounted on the B-posts, a type of access common with agricultural equipment. This allows a more natural entry and exit to and from the cab seat. The placement of the pedals, seats and steering wheel also were addressed. A three-point seat belt mounting configuration permits fewer structural posts and a more comfortable ride. The steering wheel is a more automotive style, rather than a bus type.
- Driver visibility. The apparatus features a flat windshield, eliminating blind spots and allowing the windshield wipers a larger sweep. The style of the mirrors also was updated to improve visibility.
- Turning radius. Emergency One worked with component manufacturers to reduce the turning radius, making the truck more maneuverable and better handling in areas such as cul-de-sacs. Also, the steering angle was increased by 15-20%.
- Cab instrumentation. An overhead console and wraparound dash and switch console plus panels for radios and switch heads for the driver and officer. With the use of electronic engines, electronic data is available and can be provided to the cab and pump panels. The instrument panel is more automotive, allowing the driver's eyes to fall easily onto the displays.
- Electronic needs. The large wiring harnesses have been reduced in size. The apparatus utilizes a new technology to include multiplex wiring systems that send multiple signals over a few wires, instead of using numerous wires and creating larger and larger wiring harnesses. This will also reduce electric trouble-shooting.
- Bumper and headlights. The bumper and lower trim are molded in with structural steel beam behind. If an object strikes the bumper, it will bounce off. A module contains the headlights for easy access.
- Sound-proofing. The use of the new material should provide a better seal, letting less heat and noise into the cab. Scotchlight trim is used around the vehicle. The apparatus can handle any type of engine, ranging from 250 hp up to 450 hp.
Other features developed in the Concept-2000 vehicle include a lower, European-style door step, allowing a firefighter to step into the compartment for greater reach and eliminating a slide-out step. A lower hosebed is made possible by installing the water tank in a forward location. To improve access to the top of the truck, a ladder has been added on the rear of the vehicle.
Although the new material will cost more than aluminum, savings will be accomplished through less preparation work on materials by labor.
The prototype apparatus, one of four that will be built, is to undergo several tests in the near future, including a crash test and off highway performance. Engineering installation reviews and other specific testing will be evaluated.
Emergency One and the cooperation with other industry leaders created a win-win situation for all involved to bring a technologically superior product to the marketplace quicker. GE Plastics is the industry leader in engineered plastics. Spartech is the largest producer of custom extruded sheet and rollstock of composite materials in the United States. TPI is the industry leader in its market. The partnership allowed state-of-the-art materials, processes and manufacturing technologies to be used during the design phase of the project.
Emergency One has listened to the wants and needs of its customers. It worked on combining ideas and technology to improve fire apparatus. Now company officials wait to hear the comments and feedback after the product is previewed on their latest venture to fine tune the Concept-2000 vehicle for delivery near the next millennium.
