GKN Hybrid Power Flywheel Energy Storage Systems and Applications
GKN A Short Introduction GKN ENGINEERING THAT MOVES THE WORLD 2
GKN Engineering that moves the world A global engineering group Sales of 7.45 billion in 2014 51,500 people in more than 30 countries Founded in 1759 GKN Driveline GKN Aerospace GKN Land Systems GKN Powder Metallurgy World leading supplier of automotive driveline systems and solutions, including allwheel drive. Leading first tier supplier to the global aerospace industry focusing on aero-structures, engine systems and products, and specialty products. Leading supplier of power management equipment to the agriculture, construction and mining, utility and industrial markets; with a strong service capability. World s largest manufacturer of metal powder and sintered components, predominantly to the automotive sector. 45 Manufacturing locations 24,000 people 46% sales 32 Manufacturing locations 11,700 people 30% of sales 34 Major locations 5,400 people 12% of Sales 34 Manufacturing locations 6,600 people 12% of sales 3
edrive Technology key development theme GKN Aerospace GKN Driveline GKN Land Systems GKN Powder Met Technology Support Technology Support edrive Technology 4
GKN Hybrid Power 5
Company History - From Williams F1 to GKN HP A world-class engineering company that goes racing Founded in 1977 16 FIA Formula One World Championship titles Adapting cutting edge F1 innovation and technology for wider commercial applications Williams technology improves: Energy Efficiency Safety Performance Strategic acquisition for GKN Land Systems Technology & innovation is at the heart of GKN We can industrialize on a global scale 2008 2014 6
GKN Hybrid Power History Heads 2007 4 F1 system developed 2008 5 F1 system run 2009 10 Porsche GT3R Hybrid developed 2010 15 Porsche Hybrid raced & won Achievements 2011 25 Audi e-tron Quattro developed; WHP s investment in industrialization 2012 35 Bus & Tram demonstrator contracts; Audi R18 e-tron quattro raced & won 2013 46 Bus demonstrator efficacy proved; Significant increase in interest within bus industry; Audi R18 e-tron quattro 2.0 raced and won 2014 98 April formation of GKN Hybrid Power Pre-Production Orders for 500+ Bus systems. Alexander Dennis Partnership. Audi R18 e-tron quattro 2.0 raced and won; DSTL contract. 2015 101 February opening of new Technical engineering center in Abingdon 7
GKN Hybrid Power Victory at Le Mans again! 5m Audi contract for 2015 750 Gyrodrive flywheel systems committed over next 2 years Production ramp up 3m MoD contract New facility We deliver the power to harvest crops and move earth And we make essential components for industries that touch lives across the globe. 8
Kinetic Energy Storage Mechanical Battery 9 [IN CONFIDENCE]
Flywheels Principle of Operation 10
GKN Hybrid Power Flywheel Principle of Operation The Mechanical Battery The flywheel is an electric motor Stores energy mechanically Unique MLC Rotor 12kg Spins at up to 36,000 rpm Peak Power 120kW Filament Wound Carbon Fibre Outer Rotor 80,000,000 Strands of aero grade carbon fibre Surface Speed: Mach 1.8 Surface force :250,000g Benefits Very high power density Wide operating temperature range Very high cycle life with no loss of performance Cost effective in volume MLC The inner ring of the flywheel is made of glass fibre mixed with magnetic particles. This provides the magnetic flux for the motor Magnetic Layered Composite 11
GKN Hybrid Power Technology Overview STATOR CERAMIC HYBRID BEARINGS MLC SECTION Mk 4 CARBON COMPOSITE ROTOR CARBON COMPOSITE END CAP 12
Rotor Stress The Safety Case FEA Failure Stress ASTM D2290-08 Rotor Section Sample Testing Carbon Rotor MLC Radius 130 Radius 145 Radius 175 Stress in Rotor Safety Case based on pressure vessel design / Nuclear Industry Probability of hoop failure < 1x10-9 Max operational speed controlled by safety hardware All designs fully qualified by test and analysis 13
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) 140 120 100 Power & Energy : 400V Power / Energy Electrical Power (kw) Mechanical Energy (kj) 2000 1800 1600 1400 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!! 80 1200 1000 60 800 40 600 400 20 200 0 0 0 5000 10000 15000 20000 25000 30000 35000 40000 RPM 15
Gyrodrive Hybrid Bus Principle of operation 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. 16
Retro Fit Bus Installation Laser scan of existing structure. Drive train concept design. Design..... Develop. Realise FESS Concept Design Alexander Dennis E400 Installation 17
Development and Verification Testing Vibration and Shock Ingress Tests Fuel Fire Test Waterproof? 18
Benefit of Collaboration Industry and Government in Partnership 19 [DOCUMENT NAME]
GKN Hybrid Power Benefit of Collaboration Retro fit complete system 1>1000PA Go-Ahead Bus fleet operator UK Market Complete System Flywheel / Fess Driveline MGU Fitting Government Matched Funding for Low energy emissions total grant 7.65m Develop for High volume Original Equipment Fit Capability Investment Coventry University Carbon Fibre winding Magnetization Multi-Physics Analysis Development and Testing Cost reduction Integration of collaborative research results Design for manufacture Process development Design for reliability Service development Global Telemetry 2014 TRL5 & MRL 4 2016/7 TRL8 & MRL7 REDUCED COSTS NEW MARKETS 20 Research and technology development to support long-term investment in cost down and product improvement concepts. Alexander Dennis ltd First Adopter Integration of electronic controls with vehicle CAN Chassis and driveline integration with key supplier such as ZF S&S Windings Develop methodology for ultra low cost stator Energy Storage supplier to OE 10,000PA > 100,000PA Global markets Mass Transit HGV CV Integrated system Flywheel Controls / power supply Vac pump
GKN Hybrid Power Benefit of Collaboration Gyrodrive Retro fit development partner - Go-Ahead Group UK Bus fleet operator Winning hybrid only routes Benefitting from fuel save Well ahead of competition Gyrodrive Original Equipment development partner Alexander Dennis Ltd - Bus Manufacturer Winning additional sales for its new vehicles Transport for London requirement for hybrids Forecast that in the near future all its sales could be hybrids Well ahead of competition ADL E400 Euro 6 ADL E200 Euro 6 21
Future Development Next Steps - Series Hybrid System Cost Increase of Gyrodrive offset by 3 year fuel savings Parallel Hybrid Bus Kinetic energy re-used Diesel Engine sized for peak performance Larger cost of series hybrid Gyrodrive offset smaller engine and gearbox deletion. 2 year payback 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 Fuel Use Current Engine 250g/kWhr Optimised Engine 180g/kWhr Saving 28 % Re- Gen Braking Saving 20 % + = Total Saving 43 % 22
GKN Hybrid Power The Gyrodrive USP Reliable Operation Real World Results We drive the wheels of hundreds of millions of cars We help thousands of aircraft to fly Commercially Viable 23
GKN Hybrid Power Storage Systems Applications
FESS System 2016 Deliverable (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: 25
Flywheel Pod LRU Sealed LRU to IP65, Interfaces to FESS 3 Way Backplane Rapid Prototype model reflects this design 26
Audi Mk6E R18 e-tron hybrid system with Mk6E Flywheel 27