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;
investment in industrialization
2012
35
Bus & Tram demonstrator contracts; Audi R18 etron 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
WHP’s
2
Flywheel Hybrid System - Principle of Operation
FESS = Flywheel
Energy Storage
System
1-Power Inverter
2-Motor Gearbox
3-HV Bus
4/5-FESS
3
The Mk4 Flywheel – Section View
Mk 4 Flywheel Assembly Section
Phase
Connection
Sensor Harness
Connector
Stator Cooling
Connection
Top
Containment
Bearing Cooling
Connection
Upper Bearing
Stator
Stator Cooling
System
Carbon Rotor
Lower Bearing
MLC
Bearing Housing
Glass Ring
Fixings between
Containments
Rotor End Cap
Lower Containment
Rotor Shaft
Anti Vibration Mount
Flywheel Assy
Mounting Screws
Rotor Nut
Mounting Plate
(Vehicle)
Pressure Burst
Discs
4
The Flywheel Rotor
•
Filament wound carbon T800
•
MLC for rotor magnetics
•
Super precision fits and tolerances
•
Carbon Fibre end cap F1 technology
5
Energy and Power – Why Flywheels?
Maxwell Boostcap
(Super Cap)
GKN HP
MK4 Flywheel
Cont. input 120 kW
Cont. input 120 kW
Cont. input 120 kW
240 kg
370 kg
55 kg
~1,000 cycle life
~1,000,000 cycle
life
>1,000,000 cycle
life
390 kJ/kg
6.3 kJ/kg
30 kJ/kg
93.6 MJ
2.4MJ
1.6MJ
Boost Power up to 120kW
for Bus and ~300kW for
Msport.
Power Delivery / Harvesting
for 2-10 seconds
Electrical Power (kW)
Power & Energy : 400V
Power
/ Energy
Mechanical Energy (kJ)
140
0.35kW/kg
2.2kW/kg
(6 kW/kg Msport)
Think about the Mass
The Flywheel uses ~80% of its stored energy per cycle.
Life costs…. Flywheel 15 years……Battery 4 years
2000
1800
120
1600
Electrical Power (kW)
0.5 kW/kg
100
1400
1200
80
1000
60
800
600
40
400
20
200
0
Disposal cost and environmental impact !!
0
0
5000
10000
15000
20000
RPM
6
25000
30000
35000
40000
Mechanical Energy kJ
A123 Li-ion
(Battery)
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
Rotor Energy 1.2 MJ
1/100 diameter of human hair
4 Hobnobs
7
Bus & Truck Applications
8
[DOCUMENT NAME]
8
Hybrid Bus Programme
GKN HP
Flywheel
GKN Motor &
Gearbox
BRAKING
Power
Electronics
ACCELERATING
Re- Gen Braking
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.
9
The Gyrodrive Cubicles
Cooling
and Oil
Circulation
Mk 4
Flywheel
HV
Power
Power
Inverters
FW /
MGU
Vacuum
System
System
Controller
10
Bus Installation FESS and MGU
Motor
and
Gearbox
Unit
WRIGHTBUS
Installation
Design……...……….. Develop…………………. Realise
FESS
Concept
Design
Alexander
Dennis E400
Installation
11
GKN Hybrid Power – Building Commercial Success
Reliable
Operation
Real World
Results
Commercially
Viable
•
Initial Focus UK Bus market
30,000 buses in UK
8,000 in London – dominates UK market
Split between Retro fit and New Build
We drive the wheels
of hundreds of
millions of cars…
•
Retro –fit programme with Go-Ahead
supported by TSB funding
•
OEM Project with ADL supported by APC
funding
We help thousands
of aircraft to fly…
12
Parallel Hybrid System
Parallel Hybrid Bus
•
•
Cost Increase offset
by fuel save
Re- Gen Braking
Saving
Up to 25%
depending on route
13
Kinetic energy re-used
Diesel Engine sized for
peak performance
What is the Market?
Fuel Save
Payback map
Bus
Refuse
Trucks
Light CV
50,000
100,000
Heavy CV
150,000
14
200,000
Annual Mileage
Series Hybrid Bus System
Parallel Hybrid Bus
•
•
Future
Development
Cost Increase offset
by fuel save
Kinetic energy re-used
Diesel Engine sized for
peak performance
Series Hybrid Bus
•
Small engine and
deleted driveline
offset on cost
Optimised Engine
Fuel Use Saving
28 %
•
•
•
•
Re- Gen Braking
+
Saving (average)
20 %
15
=
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
Total Saving
42 %
Series Hybrid Benefit
Fuel Save
Payback map
Bus
Refuse
Trucks
Light CV
50,000
100,000
Heavy CV
150,000
16
200,000
Annual Mileage
Hybrid Bus Systems
Parallel Hybrid Bus
•
•
Kinetic energy re-used
Diesel Engine sized for
peak performance
Future Developments
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
•
•
•
•
17
Flywheel used to manage
energy flow
Kinetic energy re-used
Higher range
Longer battery life
Delivery Truck
Engines
Parallel Hybrid
Series Hybrid
Smallest
Largest
Power kW
115
220
Torque Nm
650
1,200
Cylinders
4
6
Size l
5.1
7.7
Smallest
EVO 140
Combined
Power
kW
115
94
209*
Torque
Nm
650
600
1,250
* 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
18
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
ancillaries
Mechani
cal
losses
Energy
to move,
lift, shift
Average
Power
Requirement
Braking
Energy
Re-captured
Energy
lost in
braking
Engine Downsize
Saving
24 %
+
Re- Gen Energy
Saving
25 %
20
=
Total Saving
43 %
Wheel Loader Shovel Concept
Wheel Loader
eDrive Hybrid Wheel Loader
8L Engine
Generator
Power 170 kW
− 3l Engine
Torque 1,160 Nm
− 72 kw
− 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
21
Industrial Energy Storage
22
[DOCUMENT NAME]
22
Industrial FESS System (20MJ)
Control
Control
System Application Controller (SAC)
Control
Safety Circuit
Flywheel Energy Storage System (FESS)
HV DC Bus
Control
Control
FESS Supervisor Controller (FSC)
Power Supply
Mk8 Flywheel Module (x6)
Load
Control
Control
Flywheel Controller
FW Inverter
Flywheel
Ancillaries
Mk8 Flywheel
Source:
23
Power
Distribution