GKN Hybrid Power. Hybrid Systems : From Motor-sport to Production. Rick Townend 07/10/14

Transcription

1 GKN Hybrid Power Hybrid Systems : From Motor-sport to Production Rick Townend 07/10/14

2 GKN Hybrid Power - Background EMPLOYEES MILESTONES Automotive Hybrid Power Ltd Incorporated; Contract with WF1 for initial flywheel dev WF1 invests in AHP, renamed WHP Ltd; F1 system rig tested; Porsche GT3R Hybrid developed Porsche GT3R Hybrid raced Audi etron Quattro developed; Productionisation investment (tech, facility) Bus & Tram demonstrator contracts; TSB Gyrodrive grant awarded; Audi etron Quattro wins Le Mans Bus demo trial in London (+20% fuel save); Audi etron Quattro wins Le Mans again GKN acquisition; We drive the wheels of hundreds of millions of cars Prototype Proving Green Bus Certificate achieved; APC grant awarded: 5.3m, 2 year project Development for Production Volume Production onwards 2

3 Hybrid Systems : From Motor-sport to Production 3

4 Hybrid Systems : From Motor-sport to Production 4

5 Example Flywheel Hybrid System 5

6 Flywheel in Le Mans 24 Hr A Simulated Lap Flywheel helped power the AUDI e-tron quattro to win the Le Mans 24 hr race three years running ( ) 6

7 Model Development History Vehicle fuel simulation model of generic SUV Developed in association with JLR Evaluation of fuel savings of a flywheel hybrid vehicle. Straight-line speed & torque simulation ICE Flywheel Gear box Motor Components Differential, Gearbox, Engine, Drive Motor, Flywheel Losses Vehicle level, Mechanical, Electrical 7

8 Model Development History Backward-looking simulation, from drive cycle to fuel burn and electrical energy flow Predicted NEDC fuel consumption of base vehicle correlated Analysis of NEDC and Artemis cycles 8

9 GUI development GUI developed to aid quick changing of simulation parameters, components and drive cycle Parameter files can be saved and loaded. Separate tabs for different components. Complete parameter file can be manually used without GUI 9

10 Strategy Comparisons Different Hybrid Control Strategies were Investigated e.g. Basic, Low Torque, Engine Loading, Flywheel Pre-Spin Yellow Basic Strategy Purple Low Torque Strategy Blue Pre Spun Basic Strategy 10

11 Engine Downsizing Performance Simulation Assess hybrid capability for vehicle acceleration enhancement Non-hybrid Range-Rover acceleration correlated to JLR supplied data 3.0L Diesel non-hybrid vs 2.2L Diesel hybrid 35kW & 70kW motor with a downsized engine & Flywheel kph times Baseline Diesel Non-Hybrid 9.4s Downsized Engine Non- Hybrid Downsized Hybrid (35kW motor) Downsized Hybrid (70kW motor) 12.5s 10.3s 8.7s 11

12 CO2 NEDC HIL Simulation Hardware in the Loop NEDC Simulation Power input provided by Simulation Model Mk III Flywheel run on test dyno Good correlation achieved NEDC Speed Profile Flywheel Speed Real Data Model Data Power Real Data Model Data

13 Bus Simulation Car fuel simulation model adapted for bus. Data logged from CAN on non-hybrid bus. ICE Gear box Analysed to obtain, vehicle specific parameters; gearbox ratios, driveline ratios, ancillary loads and engine fuel map Flywheel MGU Motor Gearbox 13

14 Speed [kph] Bus Correlation Model calibrated against data logged from real vehicle and fuel economy taken from operator s Telematics. Correlation work key to gaining confidence in analysis of hybridisation schemes Predicted fuel saving: 19% Results fed into the design and specification of the Gyrodrive system. Many different hybridisation schemes and electrical strategies tested Not all results were as expected, Underlined importance of simulation first Time[s] Time[s] 14 Putney to Marylebone - heavy traffic Av = 9.1 kph Model predicted fuel savings were key to Go Ahead partnering for development of first prototype hybrid bus.

15 Performance of Gyrodrive System Initial Gyrodrive Correlation: Av = 17.7 kph Hybrid enabled model simulation compared against CAN data from Gyrodrive enabled bus. Engine Torque (top chart), Engine Speed (2 nd chart) Flywheel Speed (middle chart) Fuel Burn (bottom chart). Av = 9.1 kph All show reasonably good correlation 15

16 London Bus Fuel Trials Work is continuing on model correlation. Further analysis of bus data to understand impact of gradients and passenger load. Current state of hybrid model correlation (left), including gradients. 16

17 Multi-Flywheel Control Large applications requiring more than one flywheel gives us scope to control the charge/discharge cycles of each flywheel in unison and/or independently. We simulated different methods of sharing the powers between different groupings of flywheels to see if we could: Lower losses Improved availability of requested power Improved life benefits 17

18 Flywheel Cycling History Matlab script was used to scan the data files and record the cycling history of the flywheel in a 2-d array and produce cycling heat map plots. This cycling history is used in flywheel fatigue life estimations. 18

19 Flywheel Efficiency Maps Simulink model used to produce a 3D map of Flywheel/Inverter efficiency, as a function of flywheel speed and power. Calibrated against test rig data Used to aid understanding of Flywheel behaviour and influence electrical machine development trade-offs 19

20 Mathworks Tool Usage Matlab : General data analysis Simulink : System-level models, Vehicle-level models Future development will use simdriveline, simpowersystems & Stateflow Simulink/Stateflow/Embedded Coder : Gyrodrive Hybrid Controller, Multi-Flywheel System Controller 20

21 GKN Hybrid Power Thank You