GKN Hybrid Power :The use of the Gyrodrive hybrid system in bus, truck and off highway vehicles GKN Hybrid Power – Success and Growth
Growth of the GKN Hybrid Team
This team has developed a leading technology, now moving into production
Heads Achievements 2007 4 F1 system developed 2008 5 F1 system run 2009 10 Porsche GT3R Hybrid developed 2010 15 Porsche Hybrid raced & won 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 Pre-Production Orders for 500+ Bus systems. Alexander Dennis Partnership. Audi R18 e-tron quattro 2.0 raced and won; DSTL contract and …..we’re now GKN
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Flywheel Hybrid System - Principle of Operation
FESS = Flywheel Energy Storage System
1-Power Inverter 2-Motor Gearbox 3-HV Bus 4/5-FESS
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The Mk4 Flywheel – Section View
Mk 4 Flywheel Assembly Section
Phase Sensor Harness Connection Connector
Stator Cooling Top Connection Containment
Bearing Cooling Upper Bearing Connection
Stator Cooling Stator System
Carbon Rotor Lower Bearing
MLC Bearing Housing
Fixings between Glass Ring Containments
Rotor End Cap Lower Containment
Rotor Shaft Anti Vibration Mount
Flywheel Assy Rotor Nut Mounting Screws
Mounting Plate Pressure Burst (Vehicle) Discs
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The Flywheel Rotor
• Filament wound carbon T800 • MLC for rotor magnetics • Super precision fits and tolerances • Carbon Fibre end cap F1 technology
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Energy and Power – Why Flywheels?
A123 Li-ion Maxwell Boostcap GKN HP Boost Power up to 120kW (Battery) (Super Cap) MK4 Flywheel for Bus and ~300kW for Msport. Cont. input 120 kW Cont. input 120 kW Cont. input 120 kW
240 kg 370 kg 55 kg Power Delivery / Harvesting for 2-10 seconds ~1,000 cycle life ~1,000,000 cycle >1,000,000 cycle life life 390 kJ/kg 6.3 kJ/kg 30 kJ/kg
93.6 MJ 2.4MJ 1.6MJ Power & Energy : 400V Electrical Power (kW) Power / Energy Mechanical Energy (kJ) 140 2000 0.5 kW/kg 0.35kW/kg 2.2kW/kg 1800 120 (6 kW/kg Msport) 1600 100 1400
1200 80 1000 Think about the Mass 60
800 Mechanical Mechanical Energy kJ The Flywheel uses ~80% of its stored energy per cycle. Electrical Power (kW) 40 600 400 20 Life costs…. Flywheel 15 years……Battery 4 years 200 0 0 Disposal cost and environmental impact !! 0 5000 10000 15000 20000 25000 30000 35000 40000 RPM
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Flywheel Key Facts
Centrifugal force – 80,000,000 Fibres 250,000 x gravity Population of Germany Mass of 6.5g > 1.6T
Rotor surface speed 600 m/s (Mach 1.8)
Centre of balance accuracy 2 um 1/100 diameter of human hair Rotor Energy 1.2 MJ 4 Hobnobs
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Bus & Truck Applications
8 [DOCUMENT NAME] 8 Hybrid Bus Programme
GKN HP GKN Motor & Flywheel Gearbox BRAKING
Power Electronics Re- Gen Braking ACCELERATING Saving Up to 25% depending on route
Through the motor / generator in the driveline the Gyrodrive flywheel captures the kinetic energy during braking and reuses it to help accelerate the bus.
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The Gyrodrive Cubicles
Cooling Mk 4 and Oil Flywheel Circulation
HV Power Power Inverters FW / MGU Vacuum System System Controller
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Bus Installation FESS and MGU
Motor WRIGHTBUS and Installation Gearbox Unit
Design……...……….. Develop…………………. Realise
FESS Alexander Concept Dennis E400 Design Installation
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GKN Hybrid Power – Building Commercial Success
Reliable • Initial Focus UK Bus market Operation Real World 30,000 buses in UK Results
Commercially Viable 8,000 in London – dominates UK market
Split between Retro fit and New Build
• Retro –fit programme with Go-Ahead supported by TSB funding
• OEM Project with ADL supported by APC funding
We drive the wheels We help thousands of hundreds of of aircraft to fly… millions of cars…
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Parallel Hybrid System
Parallel Hybrid Bus • Kinetic energy re-used • Diesel Engine sized for peak performance Cost Increase offset by fuel save
Re- Gen Braking Saving Up to 25% depending on route
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What is the Market?
Payback map
Bus Fuel Save Fuel
Refuse Trucks
Light CV Heavy CV
50,000 100,000 150,000 200,000 Annual Mileage
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Series Hybrid Bus System
Parallel Hybrid Bus • Kinetic energy re-used • Diesel Engine sized for peak performance Cost Increase offset
by fuel save
Series Hybrid Bus • Engine sized for average Future power use Small engine and • Peak power demands met deleted driveline from flywheel • Kinetic energy re-used Development offset on cost • Greater fuel saving • Savings in engine, transmission and driveline costs offset system costs
Optimised Engine Re- Gen Braking Total Saving Fuel Use Saving + Saving (average) = 42 % 28 % 20 %
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Series Hybrid Benefit
Payback map
Bus FuelSave Refuse Trucks
Light CV Heavy CV
50,000 100,000 150,000 200,000 Annual Mileage
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Hybrid Bus Systems
Parallel Hybrid Bus • Kinetic energy re-used • Diesel Engine sized for peak performance
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
Battery EV Bus Future DevelopmentsFuture • Flywheel used to manage energy flow • Kinetic energy re-used • Higher range • Longer battery life
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Delivery Truck
Engines Smallest Largest
Power kW 115 220
Torque Nm 650 1,200
Cylinders 4 6
Size l 5.1 7.7 Parallel Hybrid
Smallest EVO 140 Combined
Power 115 94 209* kW Torque 650 600 1,250 Nm Series Hybrid * Limited by flywheel capacity so will restrict gradient climbing ability
Alternative engine Smaller higher speed diesels (derived from passenger cars) will allow further downsizing 3.5l 190kW 650Nm could improve efficiency further
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Wheel Loader Shovel
19 [DOCUMENT NAME] 19 Benefits of eDrive Hybrid Technology
Current Drivetrain eDrive Series Hybrid Drivetrain Engine sized to produce maximum workload Engine sized to produce the average power requirement Ancillary losses Power on demand to Mechani ancillaries cal losses
Energy to move, Average lift, shift Power Requirement
Energy Braking lost in Energy braking Re-captured
Engine Downsize Re- Gen Energy Total Saving Saving + Saving 24 % 25 % = 43 %
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Wheel Loader Shovel Concept
Wheel Loader eDrive Hybrid Wheel Loader 8L Engine Generator Power 170 kW − 3l Engine − 72 kw Torque 1,160 Nm − GKN EVO AF140 Generator GKN EVO AF 240 Drive motors − Power 188 kW (Peak 400 kW) − Torque 520 Nm (Peak 1,200Nm) Electric driven hydraulics & cooling Power balance through on-board GKN Hybrid Flywheel energy store
Hidden Benefits
Design freedom for engine package Eliminate operator error Ease of Control Noise Reduction
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Industrial Energy Storage
22 [DOCUMENT NAME] 22 Industrial FESS System (20MJ)
Safety Circuit System Application Controller (SAC)
l l l
o o o
r r r
t t t
n n n
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C C C
Flywheel Energy Storage System (FESS) HV DC Bus
FESS Supervisor Controller (FSC) l l Power Supply o o r r t t n n o o C C
Mk8 Flywheel Module (x6) Load
Flywheel Controller
l l
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r r
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C C Power Distribution FW Inverter
Flywheel Ancillaries Mk8 Flywheel
Source:
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