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This report summarizes work done on Phase 2, ``Prototype Hardware Development`` of Southwest Research Institute (SwRI) Project No. 03-6871, ``Development of an Ultra-Safe, Ultra-Low-Emissions Alternative-Fueled School Bus``. A prototype school bus was designed and constructed. This bus incorporated many new technologies to increase the safety of the bus passengers as well as pedestrians boarding and leaving the bus. These technologies emphasized increased visibility between the bus driver and pedestrians or vehicles, and included the use of high intensity discharge lighting, pedestrian and vehicle detection systems, and remote-mounted cameras. Passenger safety was also stressed, with the application of seat belts and improved emergency exits and lighting. A natural gas-fueled engine was developed for powering the bus. The development process focused primarily on improvements to the lean operation of the engine and control system advancements. The control system development included investigations into alternative control algorithms for steady-state and transient operation, various fuel metering devices, as well as new methods for wastegate control, knock and misfire detection, and catalyst monitoring. Both the vehicle and engine systems represent state-of-the-art technologies. Integration of the vehicle and engine is planned for the next phase of the project, followed by a demonstration test of the overall vehicle system

Development of an ultra-safe, ultra-low-emissions natural gas-fueled school bus: Phase 2, prototype hardware development