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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