Hybrid Systems for Propulsion = Future Road Transport

Hybrid Systems for Propulsion = Future Road Transport Volvo Powertrain 10701 / Mats Alaküla Opportunities to solution • • Short term: Increase tra...
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Hybrid Systems for Propulsion = Future Road Transport

Volvo Powertrain 10701 / Mats Alaküla

Opportunities to solution •



Short term: Increase transport efficiency by • • •

Reduced transportation ? Increased load per vehicle ! Reduced fuel consumption !

Long term: Transfer to renewable energy • • •

Biofuels not enough (max 20…25 %) Electricity via batteries not enough (max 20…25%, due to battery limitations) Continuous electric energy supply the best option • Not with catenary “from above” – Excludes light traffic

• From underneath



– Inductively – Conductively

Continuous Electric Energy Supply referred to either as: • •

Slide In Technology, or Electric Road System (ERS)

Volvo Powertrain 10701 / Mats Alaküla

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External Electric Power Supply

Volvo Powertrain 10701 / Mats Alaküla

Full Electric? •

Is it realistic to let equipment, consuming 30...100 kW average power, be pure electric and run on batteries?



- No, not if the charging occasions are to few! • 100 kW x 10 h = 1000 kWh = 20 tons of batteries !



Frequent charging is the key!

Volvo Powertrain 10701 / Mats Alaküla

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Conventional

Continuous Charging Illustrated

240 km = 140 liter Diesel (90 liter if Hybrid)

Plug In

240 km = 0.5 MWh electricity (= 5…10 ton battery)

Slide In

24 charges @ 100 kW for 12 minutes = 0.5 MWh 300…400 kg battery needed

Continuous charge @ 40 kW for 12 hours 0...100 kg battery needed

Volvo Powertrain 10701 / Mats Alaküla

Battery requirements for electric propulsion 10 kg for 10 km Possible!

El Drive = 40 kg for 10 km Possible! Plug In200!kg for 10 km Possible! 20 tons for 1000 km Not possible!

Comb45 000 tons Battery of batteries. operation alone not The take off weight is 413 Drive!tons ! Notpossible possible! for Long Haul/Coach … Volvo Powertrain 10701 / Mats Alaküla

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Why we need to include light traffic • Sweden as an example: • If all road vehicles were electric, 27 TWh el would be enough: • 10 TWh for Heavy Duty • 17 TWh for Light Duty

Electric Energy Requirement, all road vehicles electric [TWh] 30.00

25.00

Commercial Vehicles

Plug In

Non Commercial Vehicles

20.00

Slide In

• Technology Selection should apply to all road traffic !

BUS

BUS

15.00

10.00

5.00

Plug In

CAR Motor Drive

Motor Drive

Motor Drive

0.00

Volvo Powertrain 10701 / Mats Alaküla

The Slide In Hybrid Vehicle Slide Plug Hybrid In In Hybrid Hybrid Vehicle Vehicle Vehicle Conventional vehicle Power Supply

Tank

Transformer Battery

Pick Up

Engine Transmission

Wheel

Electric Drive

Electric Power Conditioner

Volvo Powertrain 10701 / Mats Alaküla

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+/-

Alternative solutions

Inductive •

Top

Side

Under

Conductive

• •

Unrealistic due to size and weight Low efficiency Visual impression

• • • •

Already in use Low cost Does not work for cars Visual impression

• • • • •

Works for all road vehicles Unsafe for objects on roadside Low efficiency Heavy, bulky and expensive Only one lane possible

• • • •

Works for all road vehicles Low cost Unsafe for objects on roadside Only one lane possible

• • • •

Rugged and Safe Expensive Low efficiency EMC

• • • •

Works for all road vehicles Low cost High efficiency Safe and rugged?

Volvo Powertrain 10701 / Mats Alaküla

Siemens Electric eHighway Roads

PRIMOVE

ALSTOM APS

ANSALDO TramWave

OLEV & Primove

Alstom APS TRAM Truck/Bus

TRAM

TRAM

Motor Drive

Motor Drive

Motor Drive

Truck/BUS

CAR Motor Drive

Truck/BUS

Motor Drive

Motor Drive

Power Supply Line

Volvo Powertrain 10701 / Mats Alaküla

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Driving Modes with “Slide In” [%] SOC (State Of Charge = Battery Charge Level) 100 90

40 30

Slide In Track Available

0

time

1

2

3

Electric Drive from Battery

Hybrid Drive

Electric Drive from ERS

Volvo Powertrain 10701 / Mats Alaküla

A Slide In World – Battery Size vs Grid Size Assume: • All vehicles has a battery capacity for a certain range • Some roads have ERS equipment

• •

Cost



A trip from A to B will then be all electric if the battery covers the non-ERS parts of the trip The total societal cost for such a system is the cost for batteries and the cost for ERS systems

Grid Size

B

• Sparse grid = big batteries • Dense grid = small batteries

A

Volvo Powertrain 10701 / Mats Alaküla

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ERS Grid Density •

What would be an optimal ERS grid density? • Europe has 5 million km paved roads and more than 60 000 km motorways … is this density enough?



If Sweden and France, as example, was square the National and European Roads would in both countries correspond to a 50 km grid • This is a high but realistic battery capacity for both EV Cars and EV Trucks/Buses • This corresponds to 15 000 km roads in SE and 20 000 km in France

Volvo Powertrain 10701 / Mats Alaküla

A Slide In World – Example of opportunity •

With realistic expectations on … •



Fossil fuel, Electric energy, Battery Cost & Lifetime development in 2030 …

Compare Costs for Fossil Drive vs. Electric drive, for 2030: Fossil Fuel Electric Energy, Battery etc

Unit [Euro/10km] [Euro/10km]

SWEDEN # Vehicles [-] Annual Driving Distance [x10 km] Annual Cost Delta [Conventional-EV] [Billion Euro] Accumulated Cost Delta 10 years [Billion Euro] Length National & European Road/Highway [km] Accumulated Cost Delta 10 years / km [Million Euro/km]

Cars 1.2 0.54

Trucks 5 3.70

4 427 032 79 312 1 300 50 000 3.8 5.2 37.9 51.6 15 329 2.5 3.4

5.8

France # Vehicles [-] 31 394 000 800 000 Annual Cost Delta [Conventional-EV] [Billion Euro] 26.9 52.1 Accumulated Cost Delta 10 years [Billion Euro] 268.7 520.7 Length National & European Road/Highway [km] 20 807 Accumulated Cost Delta 10 years / km [Million Euro/km] 12.9 25.0

37.9

Compare to Public Domain Estimates @ 0.6 – 2.4 Million Euro/km

Volvo Powertrain 10701 / Mats Alaküla

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Conclusions, so far … •

ERS is the most promising alternative to fossil fuel in the future • Many national initiatives started, conferences arranged etc …



Possible alternatives that need to be observed are: • Large scale bio-fuel production in balance with food production • Cold Fusion ? and more …

• •

The economic potential in ERS seems big enough to make it interesting for all primary stake holders A competition will take place in the near future • Trolley, Inductive and Conductive ERS will be developed to compete on system cost, ruggedness, efficiency, …

Volvo Powertrain 10701 / Mats Alaküla

Time Dev & Demo



Standardisation

Sparse Grid

Denser Grid

Full Grid

time What will be the time frame? • Driven by market, like GSM? • Driven by diminishing fossil fuel resources?

We may have 20…30 years !

Volvo Powertrain 10701 / Mats Alaküla

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Who are the Stakeholders ? •

OEM – Cars and Commercial Vehicles



Road Utility Companies



Electric Power Generation Companies



ERS System Manufacturers



Others …

ERS

Volvo Powertrain 10701 / Mats Alaküla

Basics on hybridisation

Volvo Powertrain 10701 / Mats Alaküla

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What is a hybrid vehicle?

Electric machine

ICE Charge sustaining hybrid

”PlugIn”Charging

Volvo Powertrain 10701 / Mats Alaküla

Engine use in a heavy hybrid vehicle



Adaptation of engine operating 60 kW extra power point to charge battery … but also: • Regeneration of braking energy

1000 800 600

Higher torque

Engine torque [Nm]

1200

400

Higher gear

200 0

20 510

0

500

5

1000 1500 Engine Speed [rpm]

510

2000

Volvo Powertrain 10701 / Mats Alaküla

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Benefits?

• Reduction of fuel consumption • 0...50 % depending on type, driving habits etc

• Reduction of emissions • Depends more on the fuel used and the catalyst

• Increased electric power • Increased subsystem efficiency and functionality, e.g. the Air Conditioner. • Enough power for an electrically heated villa!

Volvo Powertrain 10701 / Mats Alaküla

Potential Fuel Saving 25 - 30 %

Refuse truck

City bus

5-8%

Long haul truck

20 - 50 %

20 - 25 %

20 - 50 %

Wheel loader

Volvo Powertrain 10701 / Mats Alaküla

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Engineering Concepts

Volvo Powertrain 10701 / Mats Alaküla

The Conventional Drivetrain 95 %98 % 98 %

< 30 % ave

El.AMT mach gearbox

Diesel Engine

D

95 %

Advantage: -High range

Power Electronics +

Drawbacks: - Low average efficiency, 10..20 % - No regenerative braking

-

Energy Storage 90x90 %

Idea to solution: - An electric vehicle Volvo Powertrain 10701 / Mats Alaküla

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The Electric Vehicle 95 %

95 %

98 %

>30% El. mach

Diesel Engine

95 %

Advantage: - High average efficiency - Regenerative braking @ Traction motor power - Packaging

D

El. mach

95 %

Power Electronics

Power Electronics +

-

Energy Storage

Drawbacks: - Low range - High cost / kW tractive power

90x90 %

Idea to solution: - ICE range extender -> The Series Hybrid Vehicle Volvo Powertrain 10701 / Mats Alaküla

The Series Hybrid Vehicle >30%

95 % >30 %

95 % 98 % 98 %

El. Diesel Engine Diesel Engine mach

El. mach

95 %

95 %

Advantage: - High range

Power Electronics

El. Gearbox mach

D

95 %95 %

Power Power Electronics Electronics +

Energy Drawbacks: Storage - Low ICE drive efficiency - High drive system cost / kW - All installed power NOT available on the wheels

-

+

-

Energy Storage 90x90 %

Idea to solution: - Connect ICE to wheels mechanically – The Parallell Hybrid Volvo Powertrain 10701 / Mats Alaküla

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The Parallell Hybrid Vehicle

Diesel Engine

Advantage: - High range - High ICE drive efficiency due to hybrid control - ICE downsizing - Low system cost / kW tractive power - High commonality with non-hybrid drive train - Redundancy if electric drive malfunction

El. mach

Gearbox

D

Power Electronics +

-

Energy Storage

Drawbacks: - Lower max regenerative braking due to lower EM rating than series Volvo Powertrain 10701 / Mats Alaküla

The Course

Volvo Powertrain 10701 / Mats Alaküla

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Lectures and Exercises MIE 100 Course Content distribution, Autumn 2012 Fö # Exc # Home Assigment # 1 2 3

Study Week

36

1

37

2

38

3

39

4

# 1 out 1 2 3

4 5 6 7

# 1 return

# 2 out 4 5 6

8 9 7 8 9 10 10 11

Calender Week

# 2 back

40

5

41

6

42

7

43

exam

Date 2011-09-06 2011-09-07 2011-09-07 2011-09-12 2011-09-13 2011-09-14 2011-09-18 2011-09-19 2011-09-20 2011-09-21 2011-09-26 2011-09-27 2011-09-28 2011-10-03 2011-10-04 2011-10-09 2011-10-10 2011-10-11 2011-10-12 2011-10-18 2011-10-19 2011-10-23

Location M:D M:D M:D M:Em1-2 M:Em1-2 M:Em1-2 M:D M:D M:D M:D M:Em1-2 M:Em1-2 M:Em1-2 M:D M:D M:Em1-2 *) M:Em1-2 *) M:Em1-2 *) M:Em1-2 *) M:E M:D Gasquesalen

Contents Introduction to energy supply for transport Veh dynamics, the ideal vehicle Non ideal - The ICE + Mechanical Transmissions Simulation, ideal vehicles Simulation conventional vehicles Simulation home assignment 1 support Hybrid System Components : 1 (mainly Energy Storage) Hybrid System Components : 2 (mainly Electrical Drives) The Parallell Hybrid, Implementations, Modelling and Control Energy Storage and Life Time Estimation - Plug In Simulations on various parallell hybrid vehicles The Series and the Complex Hybrid, Implementations, Modelling and Control Plug In and Slide In - range extention from Hybrid to Full Electric *) Field Trip one of these days Simulations on home assigment 2 the other days

Auxilliary Systems Spare Examination

Volvo Powertrain 10701 / Mats Alaküla

Volvo Powertrain 10701 / Mats Alaküla

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Spare Slides

Volvo Powertrain 10701 / Mats Alaküla

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