Hybrid Systems for Propulsion Future Road Transport ht11/Lectures/EHS_L1_2011_intro.pdf · Volvo...

Volvo Powertrain10701 / Mats Alaküla

Hybrid Systems for Propulsion

=Future Road Transport


Vision


Motivation: Reserves to production

Source Amount *)Oil [barrels] 2.00E+12Oil [kWh] 3.40E+15

Coal [tons] 9.98E+11Coal [kWh] 7.31E+15

Natural Gas [quads] 6.37E+03Natural Gas [kWh] 1.87E+15

*) http://en.wikipedia.org/wiki/Reserves-to-production_ratio

Known reserves Predicted Population Growth

Predicted Reserves

Increased averagestandard of living

Fossil Fuel will not be a viableoption in a near future !

Known Consumption

35 W/kg (World average)…129 W/kg (US average)

1 W/kg


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)

http://www.777icons.com/cart.php?add=car--trolley_bus


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!



20 tons for 1000 km Not possible!

CombDrive!

El Drive =

Plug In !

Battery operation alone not possible for Long Haul/Coach …


Energy to different vehicle typesElectric Energy Requirement,

all road vehicles electric[TWh]

0.00

5.00

10.00

15.00

20.00

25.00

30.00

Commercial Vehicles

Non CommercialVehicles

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 !


The Slide In Hybrid Vehicle

Tank EngineTransmission Wheel

Battery Electric Drive

Pick Up Electric PowerConditioner

PowerSupply

Transformer

Conventional vehicleHybrid VehiclePlug In Hybrid VehicleSlide In Hybrid Vehicle


Driving Modes with “Slide In”

10090

4030

0

SOC (State Of Charge = Battery Charge Level)

time

1Electric Drive from Battery

2Hybrid Drive

3Electric Drive from ERS

Slide In Track Available

[%]


• 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

Dense

Sparse

Cos

t Battery ERSSUM


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

http://upload.wikimedia.org/wikipedia/commons/6/60/International_E_Road_Network_green.png


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 5Electric Energy, Battery etc [Euro/10km] 0.54 3.70

# Vehicles [-] 4 427 032 79 312Annual Driving Distance [x10 km] 1 300 50 000Annual Cost Delta [Conventional-EV] [Billion Euro] 3.8 5.2Accumulated Cost Delta 10 years [Billion Euro] 37.9 51.6Length 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 000Annual Cost Delta [Conventional-EV] [Billion Euro] 26.9 52.1Accumulated Cost Delta 10 years [Billion Euro] 268.7 520.7Length 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


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, …


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 !


Who are the Stakeholders ?

• OEM – Cars and Commercial Vehicles

• Road Utility Companies

• Electric Power Generation Companies

• ERS System Manufacturers

• Others …

ERS


How new is the Idea?• Overhead lines (Trolley)

• In use but not realistic for both Cars and Buses/Trucks

• Inductive Power Transfer from the road• Expensive, heavy and bulky• Low efficiency

• Conductive Power Transfer from the road

• Several systems exist, the most modern is INNORAIL.

• Low cost• High efficiency• Very promising if safety and robustness

can be guaranteed. • Safety is adressed in INNORAIL with a

sequential (8 active + 3 isolation [m]) solution that is only feasible with rail bound vehicles. INNORAIL is in use in Bordeaux since 8 years.

• A new solution is developed by XX AB, also applicable to road traffic.

Overhead line voltage: 750 V Battery capacity: 38 kWh Battery autonomy: 12 km

http://www.kaist.ac.kr/english/01_about/06_news_01.php?req_P=bv&req_BIDX=10&req_BNM=ed_news&pt=17&req_VI=2207

Korean solution: “Online Electric Vehicle (OLEV)”$ 21 million / 2009 + $ 83 million / 2010

60 % Efficiency over 12 cm distance

INNORAIL developed for tram by Alstom/Spie, also called APS (Alimentation par Sol),sequential 8+3 meters sections. Used in Bordeaux, France

http://www.youtube.com/watch?v=kSxTniqh_EQ&NR=1

http://www.kaist.ac.kr/english/index.php

http://www.youtube.com/watch?v=66GN7R3brYY&feature=related


Alternative solutions + / -

Inductive ConductiveTop • 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?


Basics on

hybridisation


What is a hybrid vehicle?

Electricmachine

ICECharge sustaining

hybrid”PlugIn”-Charging

http://images.google.se/imgres?imgurl=http://www.hallsberg.se/images/18.23f1bbf9a28618397fff1250/reservdunk.jpg&imgrefurl=http://www.hallsberg.se/4.23f1bbf90c7f52b07fff77.html&h=284&w=330&sz=6&tbnid=LovCx_-JumsJ:&tbnh=98&tbnw=113&start=1&prev=/images?q=reservdunk&hl=sv&lr=&sa=N

http://images.google.se/imgres?imgurl=http://www.merten.se/img/System-Bas/Produktabbildungen/atelier_2fach_sd.jpg&imgrefurl=http://www.merten.se/p_system-bas.html&h=180&w=140&sz=15&tbnid=T2iRzdIXc-0J:&tbnh=95&tbnw=74&start=43&prev=/images?q=v%C3%A4gguttag&start=40&hl=sv&lr=&sa=N


0 500 1000 1500 20000

200

400

600

800

1000

1200

Engine Speed [rpm]

Eng

ine

torq

ue[N

m]

5 5 510 10 1020 20 2025 25 2530 303032.5 32.5

32.5

35

35

35 35

3537

.5

37.5

37.5

37.5

40

40

40

40

40

4141

41

41

4142

42

42

70 kW traction power

50 kW traction

power

(70 km/h)

10 kW traction

power

(30 km/h)

Engine use in a heavy hybrid vehicle

Higher gear

Hig

her

torq

ue

60 kW extra powerto charge battery

• Adaptation of engine operating point

… but also:• Regeneration of braking energy


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!


Potential Fuel Saving

Refuse truck

25 - 30 % 5 - 8 %

20 - 25 % 20 - 50 %City bus

Long haul truck

Wheel loader

20 - 50 %


Engineering

Concepts


The Conventional Drivetrain

Advantage:-High range

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

Diesel Engine AMTgearbox

< 30 % ave 98 %

EnergyStorage

+ -

El.mach

PowerElectronics

95 %

95 %

98 %

90x90 %

Idea to solution:- An electric vehicle


The Electric Vehicle

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

- Packaging

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

EnergyStorage

+ -

El.mach

PowerElectronics

95 %

95 %

98 %

90x90 %

Diesel Engine El.mach

PowerElectronics

>30%

95 %

95 %

EnergyStorage

+ -

El.mach

PowerElectronics

95 %

95 %

98 %

Idea to solution:- ICE range extender -> The Series Hybrid Vehicle


Diesel Engine El.mach

PowerElectronics

>30%

95 %

95 %

EnergyStorage

+ -

El.mach

PowerElectronics

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

EnergyStorage

+ -

El.machDiesel Engine

PowerElectronics

>30 %

95 %

90x90 %

98 %

95 %

Idea to solution:- Connect ICE to wheels mechanically – The Parallell Hybrid


EnergyStorage

+ -

El.machDiesel Engine

PowerElectronics

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


Both Together

Enhanced Performance - Parallell drive

T

rpm

Diesel

Electric Drive

GearboxDiesel Engine

EnergyStorage

+ -

El.mach

PowerElectronics


Example

Honda

Parallell w

ith CVT

One electricdrive

Two electricaldrives

ToyotaComplex


I-SAM

Electric motor70 kW cont, 120 kW peak400 Nm cont, 800 Nm peak

Energy storage 600 VDC

AMT gearbox

Diesel engine

Integrated Starter Alternator Motor


The Complex Hybrid Vehicle

Advantage:- CVT function- Simple mechanical gearbox

Drawbacks:- Two el. drives- Not flexible for alternative ICE’s- Maximum output torque limited by the solar wheel motor

EnergyStorage

+ -

PowerElectronics

El.

mac

hEl

.m

ach

Diesel Engine

PowerElectronics


The Prius Complex Hybrid


The Course


Lectures and ExercisesMIE 100 Course Content distribution Autumn 2010

Fö # Exc # Home Assigment # Calender Week

Study Week Date Contents

1 2011-08-29 M:D Introduction to energy supply for transport2 2011-08-29 M:D Veh dynamics, the ideal vehicle3 2011-08-30 M:IEA Non ideal - The ICE + Mechanical Transmissions4 2011-08-30 M:IEA Different Hybrid Systems

1 2011-09-01 M:Emma1 Simulation, ideal vehicles2 # 1 out 2011-09-01 M:Emma1 Simulation conventional vehicles3 2011-09-02 M:Emma1 Simulation home assignment 1 support

5 2011-09-08 M:IEA Hybrid Systems Control6 2011-09-08 M:IEA The Parallell Hybrid, Implementations, Modelling and Control7 2011-09-09 M:IEA Electrical Drives8 # 1 return 2011-09-09 M:IEA Electrical Energy Storage

4 2011-09-15 M:Ina45 2011-09-15 M:Ina46 2011-09-16 M:Ina4

9 2011-09-22 M:IEA The Series and the Complex Hybrid, Implementations, Modelling and Control10 # 2 out 2011-09-22 M:IEA Auxilliary systems11 2011-09-23 M:IEA Guest lecture12 2011-09-23 E:C Future development expectations

7 2011-09-28 M:Ida8 2011-09-29 M:Ida

2011-09-29 M:Ida9 # 2 a back 2011-09-30 M:Ida10 2011-10-06 M:Ida11 2011-10-06 M:Ida12 2011-10-07 M:Ida13 2011-10-07 M:Ida

13 # 2 b back 2011-10-13 M:Ida Spare14 2011-10-13 M:Ida

42 ex 2011-10-20 Examination

35 1

Test ride this week

Field TripSimulations on home assigment 2

37 3

438

Simulations on various parallell hybrid vehicles

39

6

41 7

36 2

5

40


Matlab needed …


Spare Slides


Subway Train Solution (from the side)

TRACK


Trams and trains (from above)


Cutting asphaltPreparation Digging/Leveling Support frame installation

FRP installation

Ferrite core installation

Cement concreteInverter installationSensors in the track

Surface finishing& lining

The OLEV (On Line Electric Vehicle) of South Korea

111111


INNORAIL, Bordeaux, I


INNORAIL, Bordeaux, II


PRIMOVE


Primove simulation

1 meter

20 000 A in 5 cm diameterand 10 A/mm2 conductor

Magnetizing current

Flux distribution 1 dm above ground

Flux distribution along vertical middle

• Very high magnetizing currents needed• A lot of leakage flux• Low efficiency

Back to overview


Primove data


Historic pictures


The value of the idea• All road transportation can be transferred

from fossil to electric propulsion• without the need for extreme/impossible battery

installations

• Road Transportation will benefit from the higher energy efficiency of electric propulsion, about double.

• As electricity generation is shifted towards renewable, electric transportation follows

• The “Slide In” vehicle:1. Runs first of all on battery only2. Whenever possible, it “slides in” and charges while

driving3. Whenever possible, it is “plugged in” and charges

while parked4. The combustion engine is only started and engaged

when:• The electric motor power is insufficient to drive

the vehicle, e.g. in acceleration or uphill travel.• The battery charge level is approaching

critically low levels and no “slide in” charging is available


European Road Network

• 5 000 000 km paved roads• 61 600 km motorways

• European road vehicles use about 4000 TWh fossil fuels and generates about 4000 TWh el energy

• It could be replaced by about 1200 TWh electric energy or about 30 % of the present European el generation

2000 2010 2020 2030 2040 20502-wheelers 6 6 5 5 5 5Light duty vehicles 220 243 252 248 244 237Small Buses 2 2 3 3 3 3Large Buses 3 3 3 3 3 3Medium Duty Truck 35 41 46 51 54 59Heavy Duty Truck 97 113 128 139 148 157

SUM (Billion Liters Gasoline Equivalent) 363 408 437 449 457 464Gasoline energy density [MJ/litre]Energy Used [TWh] 3 446 3 874 4 153 4 262 4 346 4 410

EUROPE

34.2

http://upload.wikimedia.org/wikipedia/commons/6/60/International_E_Road_Network_green.png

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