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Flywheel Energy Storage Systems for Rail

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Flywheel Energy Storage Systems for Rail Imperial College London Department of Mechanical Engineering Flywheel Energy Storage Systems for Rail Matthew Read November 2010 Thesis submitted for the Diploma of the Imperial College (DIC), PhD degree of Imperial College London 1 I declare that the research presented in this Thesis is my own work and that the work of others is properly acknowledged and referenced. Matthew Read 2 Abstract In current non-electrified rail systems there is a significant loss of energy during vehicle braking. The aim of this research has been to investigate the potential benefits of introducing onboard regenerative braking systems to rail vehicles. An overview of energy saving measures proposed within the rail industry is presented along with a review of different energy storage devices and systems developed for both rail and automotive applications. Advanced flywheels have been identified as a candidate energy storage device for rail applications, combining high specific power and energy. In order to assess the potential benefits of energy storage systems in rail vehicles, a computational model of a conventional regional diesel train has been developed. This has been used to define a base level of vehicle performance, and to investigate the effects of energy efficient control strategies focussing on the application of coasting prior to braking. The impact of these measures on both the requirements of an energy storage system and the potential benefits of a hybrid train have been assessed. A detailed study of a range of existing and novel mechanical flywheel transmissions has been performed. The interaction between the flywheel, transmission and vehicle is investigated using a novel application-independent analysis method which has been developed to characterise and compare the performance of different systems. The results of this analysis produce general ‘design tools’ for each flywheel transmission configuration, allowing appropriate system configurations and parameters to be identified for a particular application. More detailed computational models of the best performing systems have been developed and integrated with the conventional regional diesel train model. The performance of proposed flywheel hybrid regional trains has been assessed using realistic component losses and journey profiles, and the fuel saving relative to a conventional train quantified for a range of energy storage capacities and power-train control strategies. 3 Acknowledgments I would like to thank my supervisor, Roderick Smith, for his support and guidance. I am also very grateful to Keith Pullen for his invaluable knowledge, advice and enthusiasm. Many thanks go to my colleague and friend Pablo Martinez. His knowledge and insight has resulted in many thought-provoking conversations and fruitful ideas. I would also like to thank Catherine Griffiths for her advice during the writing-up process and all the members of the Future Railway Research Centre for providing such a stimulating research environment. Finally, I owe an enormous debt of gratitude to my parents. This would not have been possible without their endless support and encouragement. 4 Nomenclature Symbol Unit Meaning E J Energy fc litres/car-km Fuel consumption F N Force G - Speed ratio of gear pair in control gearbox GPE J Gravitational potential energy h m height J kg m2 Moment of inertia K - Speed ratio of gear pair KE J Kinetic energy m kg Mass P W Power R - Characteristic gear ratio of planetary gearset r - Overall transmission speed ratio t s Time T Nm Torque U - Flywheel utilisation factor v m/s Velocity x m Displacement η - Efficiency φ - Variator speed ratio ω rad/s Angular velocity 5 Abbreviations Abreviation Meaning ATOC Association of Train Operating Companies BL Branch-line CGB Control gearbox CVT Continuously variable transmission DDC Dual differential coupled DMU Diesel multiple unit DOD Depth of discharge ESS Energy storage system FC Fluid coupling FDC Final drive coupled FESS Flywheel energy storage system FHRT Flywheel hybrid regional train FMG Flywheel motor generator FWC Flywheel coupled GA Genetic algorithm GHG Greenhouse gas GM General Motors HRDT Hybrid regional diesel train IAM Independent Analysis Method ICE Internal combustion engine IEA International Energy Authority IPCC Intergovernmental Panel on Climate Change IVT Infinitely variable transmission LDV Light duty vehicle Li-ion Lithium ion LPG Liquid petroleum gas ML Main-line NiMH Nickel metal hydride OC Output couped PGS Planetary gearset PST Power-split transmission RSSB Rail Safety and Standards Board RTRI Railway Technical Research Institute SE Specific energy SOC State of charge TC Torque converter ULEV Ultra low emission vehicle UMTA Urban Mass Transportation Administration VRLA Valve regulated lead acid 6 Table of contents Abstract .................................................................................................................................................. 3 Acknowledgments ................................................................................................................................. 4 Nomenclature ........................................................................................................................................ 5 Abbreviations ........................................................................................................................................ 6 List of figures ....................................................................................................................................... 11 List of tables......................................................................................................................................... 18 1. Introduction ................................................................................................................................. 20 1.1. Background to energy consumption in the UK rail network .................................................... 24 1.2. Proposed energy saving options ................................................................................................ 26 1.3. Objectives of the research ......................................................................................................... 28 1.4. Overview of Thesis structure .................................................................................................... 29 2. Literature review ........................................................................................................................ 31 2.1. Hybrid power-train technology ................................................................................................. 31 2.1.1. Overview of hybrid vehicle classification ............................................................................ 32 2.1.2. Energy storage devices.......................................................................................................... 36 2.1.2.1. Energy and power capabilities of storage devices ................................................................ 40 2.1.2.2. Additional considerations ..................................................................................................... 41 2.1.3. Developments in hybrid rail vehicles .................................................................................... 47 2.1.4. Continuously variable transmissions for flywheel energy storage systems .......................... 54 2.1.4.1. Fixed ratio gearbox with slipping clutch ............................................................................... 54 2.1.4.2. Variator technology .............................................................................................................. 55 2.1.4.3. Power-split principles for a simple differential ..................................................................... 58 2.1.4.4. Advanced power split configurations ................................................................................... 61 2.1.5. Mechanical flywheel hybrid vehicles ................................................................................... 62 2.2. Rail vehicle energy modelling .................................................................................................. 67 2.2.1. Optimised control .................................................................................................................. 68 7 2.2.2. Hybrid rail vehicle analysis................................................................................................... 69 2.2.3. Rail vehicle modelling .......................................................................................................... 71 2.3. Summary ................................................................................................................................... 74 3. Effects of driving strategy on conventional and hybrid diesel regional trains ...................... 75 3.1. Approach to vehicle modelling ................................................................................................. 75 3.1.1. Vehicle dynamics module ..................................................................................................... 76 3.1.2. Power-train module ............................................................................................................... 77 3.1.3. Vehicle control module ......................................................................................................... 79 3.1.4. Description of route data ......................................................................................................
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