GKN Hybrid Power :The use of the Gyrodrive hybrid system in bus, 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. 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 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

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

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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

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C C Power Distribution FW Inverter

Flywheel Ancillaries Mk8 Flywheel

Source:

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