Post on 04-Jun-2018
1
Volvo Powertrain
10701 / Mats Alaküla
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)
2
Volvo Powertrain
10701 / Mats Alaküla
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!
3
Volvo Powertrain
10701 / Mats Alaküla
Continuous Charging Illustrated
240 km = 140 liter Diesel (90 liter if Hybrid)
24 charges @ 100 kW for 12 minutes = 0.5 MWh
300…400 kg battery needed
240 km = 0.5 MWh electricity (= 5…10 ton battery)
Continuous charge @ 40 kW for 12 hours
0...100 kg battery needed
Co
nv
en
tio
nal
Plu
g I
n
Slid
e I
n
Volvo Powertrain
10701 / Mats Alaküla
Battery requirements for electric propulsion
45 000 tons of batteries. The take off weight is 413 tons ! Not possible!
10 kg for 10 km Possible!
40 kg for 10 km Possible!
200 kg for 10 km Possible!
20 tons for 1000 km Not possible!
Comb
Drive!
El Drive
=
Plug In !
Battery operation alone not
possible for Long Haul/Coach …
4
Volvo Powertrain
10701 / Mats Alaküla
Why we need to include light traffic
Electric Energy Requirement,
all road vehicles electric
[TWh]
0.00
5.00
10.00
15.00
20.00
25.00
30.00
Commercial Vehicles
Non Commercial
Vehicles
Plug In
Plug In
Slide In
• 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
• Technology Selection
should apply to all road
traffic !
BUS
Motor
Drive
BUS
Motor
Drive CAR
Motor
Drive
Volvo Powertrain
10701 / Mats Alaküla
The Slide In Hybrid Vehicle
Tank Engine
Transmission Wheel
Battery Electric Drive
Pick Up Electric Power
Conditioner
Power
Supply
Transformer
Conventional vehicle Hybrid Vehicle Plug In Hybrid Vehicle Slide In Hybrid Vehicle
5
Volvo Powertrain
10701 / Mats Alaküla
Alternative solutions + / -
Inductive Conductive
Top
• Unrealistic due to size and
weight
• Low efficiency
• Visual impression
• Already in use
• Low cost
• Does not work for cars
• Visual impression
Side • 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
Under • Rugged and Safe
• Expensive
• Low efficiency
• EMC
• Works for all road vehicles
• Low cost
• High efficiency
• Safe and rugged?
Volvo Powertrain
10701 / Mats Alaküla
Electric
Roads
TRAM
Motor
Drive
TRAM
Motor
Drive
Truck/BUS
Motor
Drive
PRIMOVE ALSTOM
APS
Truck/BUS
Motor
Drive
Power Supply Line
ANSALDO
TramWave
OLEV & Primove
TRAM
Motor
Drive
CAR
Motor
Drive
Alstom
APS
Siemens
eHighway
Truck/Bus
Motor
Drive
6
Volvo Powertrain
10701 / Mats Alaküla
Driving Modes with “Slide In”
100
90
40
30
0
SOC (State Of Charge = Battery Charge Level)
time
1 Electric Drive from Battery
2 Hybrid Drive
3 Electric Drive from ERS
Slide In Track Available
[%]
Volvo Powertrain
10701 / Mats Alaküla
• Assume:
• All vehicles has a battery capacity for a
certain range
• Some roads have ERS equipment
• 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
• Sparse grid = big batteries
• Dense grid = small batteries
A
B
A Slide In World – Battery Size vs Grid Size
Grid Size
Co
st
7
Volvo Powertrain
10701 / Mats Alaküla
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:
Compare to Public Domain Estimates @ 0.6 – 2.4 Million Euro/km
Unit Cars TrucksFossil Fuel [Euro/10km] 1.2 5
Electric Energy, Battery etc [Euro/10km] 0.54 3.70
# Vehicles [-] 4 427 032 79 312
Annual Driving Distance [x10 km] 1 300 50 000
Annual Cost Delta [Conventional-EV] [Billion Euro] 3.8 5.2
Accumulated Cost Delta 10 years [Billion Euro] 37.9 51.6
Length National & European Road/Highway [km]
Accumulated Cost Delta 10 years / km [Million Euro/km] 2.5 3.4 5.8
# 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]
Accumulated Cost Delta 10 years / km [Million Euro/km] 12.9 25.0 37.9
20 807
SWEDEN
15 329
France
8
Volvo Powertrain
10701 / Mats Alaküla
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
time
Dev
&
Demo
Standar-
disation Sparse Grid Denser Grid Full Grid
• What will be the time
frame?
• Driven by market, like GSM?
• Driven by diminishing fossil
fuel resources? We may have 20…30 years !
9
Volvo Powertrain
10701 / Mats Alaküla
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
10
Volvo Powertrain
10701 / Mats Alaküla
What is a hybrid vehicle?
Electric
machine ICE
Charge sustaining
hybrid ”PlugIn”-
Charging
Volvo Powertrain
10701 / Mats Alaküla
0 500 1000 1500 2000 0
200
400
600
800
1000
1200
Engine Speed [rpm]
En
gin
e to
rqu
e [N
m]
5 5 5 10 10 20
Engine use in a heavy hybrid vehicle
Higher gear
Hig
her
torq
ue
60 kW extra power
to charge battery
• Adaptation of engine operating
point
… but also:
• Regeneration of braking energy
11
Volvo Powertrain
10701 / Mats Alaküla
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
Refuse truck
25 - 30 % 5 - 8 %
20 - 25 % 20 - 50 % City bus
Long haul truck
Wheel loader
20 - 50 %
12
Volvo Powertrain
10701 / Mats Alaküla
Engineering
Concepts
Volvo Powertrain
10701 / Mats Alaküla
The Conventional Drivetrain
Advantage:
-High range
Drawbacks:
- Low average efficiency, 10..20 %
- No regenerative braking
Diesel Engine AMT
gearbox D
< 30 % ave 98 %
D
Energy
Storage
+ -
El.
mach
Power
Electronics
95 %
95 %
98 %
90x90 %
Idea to solution:
- An electric vehicle
13
Volvo Powertrain
10701 / Mats Alaküla
The Electric Vehicle
Advantage:
- High average efficiency
- Regenerative braking
@ Traction motor power
- Packaging
Drawbacks:
- Low range
- High cost / kW tractive power
D
Energy
Storage
+ -
El.
mach
Power
Electronics
95 %
95 %
98 %
90x90 %
Diesel Engine El.
mach
Power
Electronics
>30%
95 %
95 %
D
Energy
Storage
+ -
El.
mach
Power
Electronics
95 %
95 %
98 %
Idea to solution:
- ICE range extender -> The Series Hybrid Vehicle
Volvo Powertrain
10701 / Mats Alaküla
Diesel Engine El.
mach
Power
Electronics
>30%
95 %
95 %
D
Energy
Storage
+ -
El.
mach
Power
Electronics
95 %
95 %
98 %
The Series Hybrid Vehicle
Advantage:
- High range
Drawbacks:
- Low ICE drive efficiency
- High drive system cost / kW
- All installed power NOT available on the wheels
Gearbox D
Energy
Storage
+ -
El.
mach Diesel Engine
Power
Electronics
>30 %
95 %
90x90 %
98 %
95 %
Idea to solution:
- Connect ICE to wheels mechanically – The Parallell Hybrid
14
Volvo Powertrain
10701 / Mats Alaküla
D
Energy
Storage
+ -
El.
mach Diesel Engine
Power
Electronics
Gearbox
The Parallell Hybrid Vehicle
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
Drawbacks:
- Lower max regenerative braking due to lower EM rating than series
Volvo Powertrain
10701 / Mats Alaküla
The Course
15
Volvo Powertrain
10701 / Mats Alaküla
Lectures and Exercises
MIE 100 Course Content distribution, Autumn 2012
Fö # Exc # Home Assigment #Calender
Week
Study
WeekDate Location Contents
1 2011-09-06 M:D Introduction to energy supply for transport
2 2011-09-07 M:D Veh dynamics, the ideal vehicle
3 # 1 out 2011-09-07 M:D Non ideal - The ICE + Mechanical Transmissions
1 2011-09-12 M:Em1-2 Simulation, ideal vehicles
2 2011-09-13 M:Em1-2 Simulation conventional vehicles
3 2011-09-14 M:Em1-2 Simulation home assignment 1 support
4 # 1 return 2011-09-18 M:D Hybrid System Components : 1 (mainly Energy Storage)
5 2011-09-19 M:D Hybrid System Components : 2 (mainly Electrical Drives)
6 2011-09-20 M:D The Parallell Hybrid, Implementations, Modelling and Control
7 # 2 out 2011-09-21 M:D Energy Storage and Life Time Estimation - Plug In
4 2011-09-26 M:Em1-2
5 2011-09-27 M:Em1-2
6 2011-09-28 M:Em1-2
8 2011-10-03 M:D The Series and the Complex Hybrid, Implementations, Modelling and Control
9 2011-10-04 M:D Plug In and Slide In - range extention from Hybrid to Full Electric
7 2011-10-09 M:Em1-2 *)
8 2011-10-10 M:Em1-2 *)
9 2011-10-11 M:Em1-2 *)
10 2011-10-12 M:Em1-2 *)
10 # 2 back 2011-10-18 M:E Auxilliary Systems
11 2011-10-19 M:D Spare
43 exam 2011-10-23 Gasquesalen Examination
42
*) Field Trip one of these days
Simulations on home assigment 2 the other days
Simulations on various parallell hybrid vehicles
1
2
3
4
5
6
7
36
37
38
39
40
41
Volvo Powertrain
10701 / Mats Alaküla