GKN Hybrid Power. :The use of the Gyrodrive hybrid system in bus, truck and off highway vehicles

Transcription

1 GKN Hybrid Power :The use of the Gyrodrive hybrid system in bus, truck and off highway vehicles

2 GKN Hybrid Power Success and Growth Growth of the GKN Hybrid Team This team has developed a leading technology, now moving into production Heads F1 system developed F1 system run Achievements Porsche GT3R Hybrid developed Porsche Hybrid raced & won Audi e-tron Quattro developed; WHP s investment in industrialization Bus & Tram demonstrator contracts; Audi R18 e- tron quattro raced & won Bus demonstrator efficacy proved; Significant increase in interest within bus industry; Audi R18 e-tron quattro 2.0 raced and won Pre-Production Orders for 500+ Bus systems. Alexander Dennis Partnership. Audi R18 e-tron quattro 2.0 raced and won; DSTL contract and..we re now GKN 2

3 Flywheel Hybrid System - Principle of Operation FESS = Flywheel Energy Storage System 1-Power Inverter 2-Motor Gearbox 3-HV Bus 4/5-FESS 3

4 The Mk4 Flywheel Section View Mk 4 Flywheel Assembly Section Phase Connection Sensor Harness Connector Stator Cooling Connection Top Containment Bearing Cooling Connection Upper Bearing Stator Stator Cooling System Carbon Rotor Lower Bearing MLC Bearing Housing Glass Ring Fixings between Containments Rotor End Cap Lower Containment Rotor Shaft Anti Vibration Mount Rotor Nut Flywheel Assy Mounting Screws Mounting Plate (Vehicle) Pressure Burst Discs 4

5 The Flywheel Rotor Filament wound carbon T800 MLC for rotor magnetics Super precision fits and tolerances Carbon Fibre end cap F1 technology 5

6 Electrical Power (kw) Mechanical Energy kj Energy and Power Why Flywheels? A123 Li-ion (Battery) Maxwell Boostcap (Super Cap) GKN HP MK4 Flywheel Cont. input 120 kw Cont. input 120 kw Cont. input 120 kw 240 kg 370 kg 55 kg ~1,000 cycle life ~1,000,000 cycle life >1,000,000 cycle life 390 kj/kg 6.3 kj/kg 30 kj/kg Boost Power up to 120kW for Bus and ~300kW for Msport. Power Delivery / Harvesting for 2-10 seconds 93.6 MJ 2.4MJ 1.6MJ 0.5 kw/kg 0.35kW/kg 2.2kW/kg (6 kw/kg Msport) Power & Energy : 400V Power / Energy Electrical Power (kw) Mechanical Energy (kj) Think about the Mass The Flywheel uses ~80% of its stored energy per cycle. Life costs. Flywheel 15 years Battery 4 years Disposal cost and environmental impact!! RPM 6

7 Flywheel Key Facts 80,000,000 Fibres Population of Germany Rotor surface speed 600 m/s (Mach 1.8) Centrifugal force 250,000 x gravity Mass of 6.5g > 1.6T Centre of balance accuracy 2 um 1/100 diameter of human hair Rotor Energy 1.2 MJ 4 Hobnobs 7

8 Bus & Truck Applications 8 [DOCUMENT NAME] 8

9 Hybrid Bus Programme GKN Motor & Gearbox BRAKING GKN HP Flywheel Re- Gen Braking Saving Up to 25% depending on route ACCELERATING Power Electronics Through the motor / generator in the driveline the Gyrodrive flywheel captures the kinetic energy during braking and reuses it to help accelerate the bus. 9

10 The Gyrodrive Cubicles Cooling and Oil Circulation Mk 4 Flywheel Power Inverters FW / MGU System Controller HV Power Vacuum System 10

11 Bus Installation FESS and MGU Motor and Gearbox Unit WRIGHTBUS Installation Design..... Develop. Realise FESS Concept Design Alexander Dennis E400 Installation 11

12 GKN Hybrid Power Building Commercial Success Reliable Operation Real World Results Commercially Viable Initial Focus UK Bus market 30,000 buses in UK 8,000 in London dominates UK market Split between Retro fit and New Build Retro fit programme with Go-Ahead supported by TSB funding OEM Project with ADL supported by APC funding We drive the wheels of hundreds of millions of cars We help thousands of aircraft to fly 12

13 Parallel Hybrid System Cost Increase offset by fuel save Parallel Hybrid Bus Kinetic energy re-used Diesel Engine sized for peak performance Re- Gen Braking Saving Up to 25% depending on route 13

14 Fuel Save What is the Market? Payback map Bus Refuse Trucks Light CV Heavy CV 50, , , ,000 Annual Mileage 14

15 Future Development Series Hybrid Bus System Cost Increase offset by fuel save Parallel Hybrid Bus Kinetic energy re-used Diesel Engine sized for peak performance Small engine and deleted driveline offset on cost Series Hybrid Bus Engine sized for average power use Peak power demands met from flywheel Kinetic energy re-used Greater fuel saving Savings in engine, transmission and driveline costs offset system costs Optimised Engine Fuel Use Saving 28 % Re- Gen Braking + Saving (average) = 20 % Total Saving 42 % 15

16 Fuel Save Series Hybrid Benefit Payback map Bus Refuse Trucks Light CV Heavy CV 50, , , ,000 Annual Mileage 16

17 Future Developments Hybrid Bus Systems Parallel Hybrid Bus Kinetic energy re-used Diesel Engine sized for peak performance Series Hybrid Bus Engine sized for average power use Peak power demands met from flywheel Kinetic energy re-used Greater fuel saving Savings in engine, transmission and driveline costs offset system costs Battery EV Bus Flywheel used to manage energy flow Kinetic energy re-used Higher range Longer battery life 17

18 Delivery Truck Engines Smallest Largest Power kw Torque Nm 650 1,200 Cylinders 4 6 Parallel Hybrid Size l Smallest EVO 140 Combined Series Hybrid Power kw Torque Nm * ,250 * Limited by flywheel capacity so will restrict gradient climbing ability Alternative engine Smaller higher speed diesels (derived from passenger cars) will allow further downsizing 3.5l 190kW 650Nm could improve efficiency further 18

19 Wheel Loader Shovel 19 [DOCUMENT NAME] 19

20 Benefits of edrive Hybrid Technology Current Drivetrain Engine sized to produce maximum workload Ancillary losses Mechani cal losses edrive Series Hybrid Drivetrain Engine sized to produce the average power requirement Power on demand to ancillaries Energy to move, lift, shift Average Power Requirement Energy lost in braking Braking Energy Re-captured Engine Downsize Saving 24 % Re- Gen Energy Saving 25 % + = Total Saving 43 % 20

21 Wheel Loader Shovel Concept Wheel Loader 8L Engine Power 170 kw Torque 1,160 Nm edrive Hybrid Wheel Loader Generator 3l Engine 72 kw GKN EVO AF140 Generator GKN EVO AF 240 Drive motors Power 188 kw (Peak 400 kw) Torque 520 Nm (Peak 1,200Nm) Electric driven hydraulics & cooling Power balance through on-board GKN Hybrid Flywheel energy store Hidden Benefits Design freedom for engine package Eliminate operator error Ease of Control Noise Reduction 21

22 Industrial Energy Storage 22 [DOCUMENT NAME] 22

23 Industrial FESS System (20MJ) Safety Circuit System Application Controller (SAC) Control Control Control Flywheel Energy Storage System (FESS) HV DC Bus FESS Supervisor Controller (FSC) Control Control Power Supply Mk8 Flywheel Module (x6) Flywheel Controller Load Control FW Inverter Control Power Distribution Mk8 Flywheel Flywheel Ancillaries Source: 23