Welcome to the presentation of the Hybrid Trolley-Bus Fitted with an electrical combined storage unit and used for Public Transportation O-Bus Nr. 029, Typ: ÖAF Gräf & Stift NGE 152 M17 hybrid, BBG Eberswalde, 10.08.2010 Ecologically friendly and energy-efficient solution RWS_trolleybus_hybrid_B.doc Seite 1/20
1. Introduction Motivation for the use of the combined storage Use of braking energy Increase the energy efficiency Reduction of current peaks from the catenary Quiet catenary-free operation Approach: Replacment of the emergency dieselgenerator by a combined storage RWS_trolleybus_hybrid_B.doc Seite 2/20
2. Operating diagramm hybrid system RWS_trolleybus_hybrid_B.doc Seite 3/20
3. Electrical equipment of the vehicle 3.1 The diesel engine generator unit was dismantled thus providing free space for the combined storage unit to be installed to. The fixing points remain the same ones. 600 VDC diesel engine generator unit for emergency drive mode Combined storage unit Installation situation Electronic drive/ braking control unit Switch cabinet Display of hybrid control system 600 VDC link on the capacitor plate Vossloh Kiepe RWS_trolleybus_hybrid_B.doc Seite 4/20
3.2. A switch cabinet has been installed for the electronic control of the hybrid system. As a result there will be one seat less than before (out of a total of 46 seats). A seat was removed and mounted at that location, the new switch cabinet. RWS_trolleybus_hybrid_B.doc Seite 5/20
3.3. Display in the driver s cabin Display of the hybrid control system in the driver s cabin LED display : Hybrid control system On Alert smoke detector Fault indication hybrid control system Luminous: power reduction in emergency mode Flashing: switch-off routine still on 0 100% Charging condition of traction battery RWS_trolleybus_hybrid_B.doc Seite 6/20
4. Construction of switch cabinet of the hybrid system Smoke detector MCU 1 und MCU 2 for cell management of BoostCap und Li-Batterie Main Computer AutoBox by the company dspace Signal coupler Control for startup precharge Output contactor, output fuses 24 V power supply, 24 V fuses, on/off control Contactor control Resistors and contactors for 600 V DC startup precharge EMC filter DC/DC Converter for the BoostCap-Battery DC/DC Converter for the Lithium-Battery Room for the Cable inlet RWS_trolleybus_hybrid_B.doc Seite 7/20
5. Construction of electrical combined storage unit 5.1. General view of the electrical combined storage unit ventilator 3 ventilators 1 and 2 Cooling air RWS_trolleybus_hybrid_B.doc Seite 8/20
5.2. Technical data of the Electrical combined storage unit Measures: Width 850, Height 950, Length 1800 [mm] Weight: ca 670 kg Power range of the electrical combined storage unit Li-Batterie UltraCap Number of Cells 120 13 Energy content 17,3 kwh (0,686 kwh) 0,528 kwh Voltage 360 504 V (0-624 V) 300 624 V Charging current I max -80 A -1300 A Discharging current I max +200 A +1300 A Temperature charging 0 bis +40 C -20 bis +65 C Temperature discharging -30 bis +60 C -20 bis +65 C Power Range ±75 kw ±75 kw Useable energy ca. 10 kwh 0,2 bis 0,8 SOC 0,528 kwh Umin = 300V RWS_trolleybus_hybrid_B.doc Seite 9/20
5.3. Batterie Management System (BMS) Li-Battery Li-Battery Battery Monitoring Unit Monitoring Control Unit RWS_trolleybus_hybrid_B.doc Seite 10/20
6. Energy measurement and display with "ControlDesk" 6.1. energy from the catenary energy from the BoostCaps energy into the traction motor State of Charge Li-Battery FhG IVI Acceleration when catenary operation RWS_trolleybus_hybrid_B.doc Seite 11/20
6.2. energyr into the the catenary energy into the BoostCaps energy in the BoostCaps Energy recovery. Braking energy of energy the traction from the motor traction motor State of Charge Li-Battery State of Charge Li-Battery FhG IVI Brakes when catenary operation RWS_trolleybus_hybrid_B.doc Seite 12/20
6.3. energy from the BoostCaps Power reduction to 50 kw is activ energy into the traction motor energy from the Li-Battery FhG IVI Acceleration when emergency operation RWS_trolleybus_hybrid_B.doc Seite 13/20
6.4. energy into the BoostCaps Energy recovery Braking energy from the traction motor energy into the Li-Battery FhG IVI Brakes when emergency operation RWS_trolleybus_hybrid_B.doc Seite 14/20
7. Drive cycle 7.1. move to full throttle and stop (without BoostCap and 6 t payload) Input current Speed Torque RWS_trolleybus_hybrid_B.doc Seite 15/20
7.2. move to full throttle and stop (with BoostCap and 6 t payload) BoostCap Input current Speed Torque RWS_trolleybus_hybrid_B.doc Seite 16/20
7.3 Storage components at catenary operation Catenary operation Emergency operation BoostCap Boostcap Li-Batterie Voltage range 300 to 480 V 300 to 600 V 360 to 490 V Current range +/- 250A +/- 250 A + 160 / -200A Temperature range - 20 to + 65 C - 20 bis + 40 C DC/DC-Converter catenary + 75 kw 75 KW 75 kw Energy content usable 0,247 kwh 0,394 kwh max. 12 kwh RWS_trolleybus_hybrid_B.doc Seite 17/20
8. Evaluation of energy management 8.1. Evaluation of catenary operation - The concentration of trolley busses in the catenary system and the respective time of the day are essential for energy recovery. - Lowering the peak power of 400 A to about 300A - Reducing energy consumption by 7.3 % at 6 t payload by 9,4 % at unloaded operation With a usable storage capacity of 0.247 kwh Average of 3.2 cycles / km (accelerate roll - brake) - This BoostCap memory is too small for a long mountain trip. - Alternatively the Li-battery could be included RWS_trolleybus_hybrid_B.doc Seite 18/20
8.2. Evaluation of emergency operation For emergency operation the power supply is permently reduced to about 40 kw in the Electronic drive/braking control unit (EFB, Vossloh Kiepe). This power supply reduction should be raised. Measuring results: Empty weight Payload of 6 t Operating distance 13,5 km 8,3 km Average speed 22,9 km/h 17,5 km/h Energy consumption 11,8 kwh 9,8 kwh RWS_trolleybus_hybrid_B.doc Seite 19/20
9. Offer of the company RWS The combined storage unit has been developed for the hybrid systems of vehicles used in Public Transportation such as trams, coaches and trolley-busses. It allows the recuperation of braking energy by means of BoostCaps and the traction without catenary on the basis of the energy off a Lithium Battery. Both of the storage batteries have a customized cell management system. Range of services rendered by the RWS Railway Service GmbH: - Preliminary design considering the energy and lay out design - Dimensioning of the energy storage unit and design of the case - Electronic control system and software for the energy management - Display of operating states and fault diagnosis - Cooling system, smoke detector, insulation monitoring - Installation and assembly of the electrical combined storage unit into the vehicle. The company of RWS offers the electrical combined storage unit as a complete package. Static commissioning took place in the test facilities of the Fraunhofer Institute of Transportation and Infrastructure Systems (IVI) in Dresden. The subsequent dynamic commissioning of the electrical combined storage unit has already been successfully completed in the trolley wire system of the Barnim Bus Company in Eberswalde. RWS_trolleybus_hybrid_B.doc Seite 20/20