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Assessment of Needs and Research Roadmaps for Rechargeable Energy Storage System Onboard Electric Drive Buses

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Assessment of Needs and Research Roadmaps for Rechargeable Energy Storage System Onboard Electric Drive Buses ASSESSMENT OF NEEDS AND RESEARCH ROADMAPS FOR RECHARGEABLE ENERGY STORAGE SYSTEM ONBOARD ELECTRIC DRIVE BUSES Report No. FTA-TRI-MA-26-7125-2011.1 Background, Research Needs, Stakeholder and Expert Input, Research Recommendations, and Research and Technology (R&T) Roadmaps DECEMBER 2010 http://www.fta.dot.gov/research Form Approved REPORT DOCUMENTATION PAGE OMB No. 0704-0188 1. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED December 2010 4. TITLE AND SUBTITLE 5. FUNDING/GRANT NUMBER Assessment of Needs and Research Roadmaps for Rechargeable Energy Storage System (RESS) Onboard Electric Drive Buses MA-26-7125 6. AUTHOR(S) Dr. Aviva Brecher, National Technical Expert, Energy Technology Division 7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 8. PERFORMING ORGANIZATION REPORT DOT/RITA Volpe National Transportation Systems Center NUMBER 55 Broadway DOT-VNTSC-FTA-11-01 Cambridge, MA 021542 Website: www.volpe.dot.gov 9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSORING/MONITORING AGENCY Federal Transit Administration REPORT NUMBER U.S. Department of Transportation Website: http://www.fta.dot.gov/research FTA-TRI-MA-26-7125-2011.1 1200 New Jersey Avenue, SE Washington, DC 20590 11. SUPPLEMNTARY NOTES. Available Online [http://www.fta.dot.gov/research] 12a. DISTRIBUTION/AVAILABILITY STATEMENT 12b. DISTRIBUTION CODE Available from the National Technical Information Service (NTIS), 5285 Port Royal Road, Springfield, VA 22161. Phone 1-800-553-6847 or (703) 605- 6000 Fax 703- 605-6900; TDD (703) 487-4639 Email [[email protected]] 13. ABSTRACT (Maximum 200 words) - In support of the Federal Transit Administration (FTA) Electric Drive Strategic Plan (EDSP), this report assesses state-of-art advances in lithium-ion batteries, ultracapacitors, and related power management and control technologies for the rechargeable energy storage systems (RESS) on-board existing and emerging electric drive buses. RD&T roadmaps for near-, mid-, and long-term are developed for FTA and potential partners developing next generation electric drive buses, based on a review of technical literature, and inputs from experts and transit stakeholders regarding lessons learned, knowledge gaps, and priority RD&T needs. Illustrative projects up to 2020 are proposed based on the identified priority needs in these roadmaps. They promise to advance RESS technologies from research, development, demonstration, test and evaluation to full integration in more fuel efficient, environmentally sustainable, and cost-effective commercial electric drive transit buses. 14. SUBJECT TERMS 15. NUMBER OF PAGES Fuel cell bus (FCB), hybrid-electric bus (HEB), electric bus (EB), Technology Readiness 134 Level (TRL), Research, Development and Technology (RD&T) Roadmap, Rechargeable 16. PRICE CODE Energy Storage System (RESS), battery, ultracapacitor, flywheel, electric drive, fuel cell, Ragone Plot, Battery Management System (BMS), Thermal Management System (TMS), power electronics, system integration, Hardware in the Loop (HIL) performance testing, safety and electrical standards, charging infrastructure, lithium-ion batteries (LIB), Nickel Metal Hydride (NiMH) battery, lead acid battery, regenerated braking energy, Subject Matter Experts (SMEs). 17. SECURITY CLASSIFICATION 18. SECURITY CLASSIFICATION 19. SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACT OF REPORT OF THIS PAGE OF ABSTRACT Unclassified Unclassified Unclassified ASSESSMENT OF NEEDS AND RESEARCH ROADMAPS FOR RECHARGEABLE ENERGY STORAGE SYSTEM ONBOARD ELECTRIC DRIVE BUSES DECEMBER 2010 Prepared by: Dr. Aviva Brecher National Technical Expert DOT/RITA Volpe Center Cambridge, MA 02142 Prepared for: Federal Transit Administration Office of Research, Demonstration and Innovation U.S. Department of Transportation 1200 New Jersey Avenue, SE Washington, DC 20590 http://www.fta.dot.gov/research Report No. FTA-TRI-MA-26-7125-2011.1 Available Online http://www.fta.dot.gov/research FOREWORD This report assesses state-of-art advances in lithium-ion batteries, ultracapacitors, and related power management and control technologies for the rechargeable energy storage systems (RESS) on-board existing and emerging electric drive buses, in support of the Federal Transit Administration (FTA) Electric Drive Strategic Plan (EDSP). There is a need to develop Research, Development and Technology (RD&T) roadmaps for the near-, mid-, and long-term, to guide FTA, its partners, and stakeholders in developing the next generation of electric drive buses. To this end this report summarizes findings from a review of technical literature, and inputs from leading technical experts and transit stakeholders regarding lessons learned, knowledge gaps, and priority RD&T needs. Illustrative projects up to 2020 are proposed based on the identified priority needs in these roadmaps. They promise to advance RESS technologies from research, development, demonstration, test and evaluation to full integration in more fuel efficient, environmentally sustainable, and cost-effective commercial electric drive transit buses The proposed Roadmap priorities will remain valid for the next decade, since they are designed to capture and exploit the rapid advances in battery and energy storage technologies for vehicle electrification, and complement ongoing efforts to develop advanced urban buses less dependent on fossil fuels. The principal author of this report is Dr. Aviva Brecher, National Technical Expert in Energy Technology, Energy and Environmental Systems at the U.S. DOT Volpe Center. Contributions from Volpe Center colleagues Stephen Costa, Scott Lian, Karen Shilo, and Michael Kay are gratefully acknowledged. The FTA sponsors of this project are thanked for valuable guidance and review comments: Mr. Walter Kulyk, Director of the FTA Office of Mobility Innovation, and his staff: Ms. Christina Gikakis, Mr. Sean Ricketson, and Mr. Gregory Rymarz. DISCLAIMER NOTICE This document is disseminated under the sponsorship of the United States Department of Transportation in the interest of information exchange. The United States Government assumes no liability for its contents or use thereof. The United States Government does not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the objective of this report. Table of Contents List of Abbreviations .......................................................................................................... v Summary .......................................................................................................................... viii 1. Introduction ................................................................................................................. 1 2. Rechargeable Energy Storage Systems (RESS) for Hybrid Electric and Fuel Cell Buses ................................................................................................................................... 5 2.1. RESS Components and System Integration ............................................................ 5 2.2. Hybrid Electric Bus Architectures .......................................................................... 8 2.3. RESS Characteristics for Hybrid Electric Buses .................................................. 11 2.3.1. RESS for Series Hybrid Electric Buses ............................................................ 13 2.3.1.1. ISE Corporation’s ThunderVolt Drive.............................................................. 13 2.3.1.2. The BAE Systems HybriDrive.......................................................................... 16 2.3.1.3. Other Series Hybrid Electric Drive-trains ......................................................... 18 2.3.2. RESS for Parallel Hybrid Buses ....................................................................... 18 2.3.2.1. The GM Allison EP Two-mode Electric Drives ............................................... 18 2.3.2.2. The Azure Dynamics (AZD) Balance ™ Drive-train ....................................... 19 2.3.3. RESS for Other Complex Hybrid Electric Drive Systems ............................... 20 2.3.3.1. The Enova Systems HybridPower with Fuel Cell APUs .................................. 20 2.3.3.2. The Proterra Buses with TerraVolt RESS ........................................................ 22 2.3.3.3. The Capstone Microturbine RESS in the DesignLine ECOSaver IV Bus........ 24 2.3.3.4. RESS in Hybrid Electric Buses with Fuel Cell APUs ...................................... 26 2.4. International Advanced Hybrid Electric Buses ..................................................... 26 2.4.1. The European CUTE Fuel Cell Bus Partnership .............................................. 26 2.4.1.1. The Van Hool (Belgium) Diesel Electric and Fuel Cell Hybrid Buses ........... 27 2.4.1.2. The Mercedes Benz Citaro Bus ........................................................................ 27 2.4.1.3. Volvo Hybrid Bus ............................................................................................. 28 2.4.1.4. The Optare (UK) Hybrid Buses ........................................................................ 28 2.4.1.5. The Dutch e-Traction Bus ................................................................................. 28 2.4.1.6. The German MAN Lion’s City Hybrid Bus ..................................................... 28 2.4.1.7. The Irisbus Iveco hybrids.................................................................................. 29
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