Hybrid Systems for Propulsion = Future Road Transport. Volvo Powertrain / Mats Alaküla

Transcription

1 Hybrid Systems for Propulsion = Future Road Transport

2 Vision

3 Motivation: Reserves to production Known reserves Known Consumption Predicted Population Growth Source Amount *) Oil [barrels] 2.00E+12 Oil [kwh] 3.40E W/kg (World average) 129 W/kg (US average) Coal [tons] Coal [kwh] Natural Gas [quads] Natural Gas [kwh] 9.98E E E E+15 1 W/kg Predicted Reserves Increased average standard of living Fossil Fuel will not be a viable option in a near future! *)

4 Opportunities to solution Short term: Increase transport efficiency by Reduced transportation? Increased load per vehicle! Reduced fuel consumption! Long term: Transfer to renewable energy Biofuels not enough (max %) Electricity via batteries not enough (max 20 25%, due to battery limitations) Continuous electric energy supply the best option Not with catenary from above Excludes light traffic From underneath Inductively Conductively Continuous Electric Energy Supply referred to either as: Slide In Technology, or Electric Road System (ERS)

5 Battery requirements for electric propulsion El Drive 10 kg for 10 km Possible! = 40 kg for 10 km Possible! Plug In! 200 kg for 10 km Possible! Comb Drive! 20 tons for 1000 km Not possible! Battery operation alone not possible for Long Haul/Coach tons of batteries. The take off weight is 413 tons! Not possible!

6 Energy to different vehicle types Sweden as an example: If all road vehicles were electric, 27 TWh el would be enough: 10 TWh for Heavy Duty 17 TWh for Light Duty Plug In Electric Energy Requirement, all road vehicles electric [TWh] Commercial Vehicles Non Commercial Vehicles Technology Selection should apply to all road traffic! Slide In 5.00 Plug In 0.00

7 The Slide In Hybrid Vehicle Plug Slide Conventional Hybrid In Hybrid Vehicle vehicle Vehicle Power Supply Tank Engine Transmission Wheel Transformer Battery Electric Drive Pick Up Electric Power Conditioner

8 Driving Modes with Slide In [%] SOC (State Of Charge = Battery Charge Level) Slide In Track Available time 1 Electric Drive from Battery 2 Hybrid Drive 3 Electric Drive from ERS

9 A Slide In World Battery Size vs Grid Size Assume: All vehicles has a battery capacity for a certain range Some roads have ERS equipment A trip from A to B will then be all electric if the battery covers the non-ers parts of the trip The total societal cost for such a system is the cost for batteries and the cost for ERS systems Cost Battery Sparse SUM Grid Size B ERS Dense Sparse grid = big batteries Dense grid = small batteries A

10 ERS Grid Density What would be an optimal ERS grid density? Europe has 5 million km paved roads and more than km motorways is this density enough? If Sweden and France, as example, was square the National and European Roads would in both countries correspond to a 50 km grid This is a high but realistic battery capacity for both EV Cars and EV Trucks/Buses This corresponds to km roads in SE and km in France

11 A Slide In World Example of opportunity With realistic expectations on Fossil fuel, Electric energy, Battery Cost & Lifetime development in 2030 Compare Costs for Fossil Drive vs. Electric drive, for 2030: Unit Cars Trucks Fossil Fuel [Euro/10km] Electric Energy, Battery etc [Euro/10km] SWEDEN # Vehicles [-] Annual Driving Distance [x10 km] Annual Cost Delta [Conventional-EV] [Billion Euro] Accumulated Cost Delta 10 years [Billion Euro] Length National & European Road/Highway [km] Accumulated Cost Delta 10 years / km [Million Euro/km] France # Vehicles [-] Annual Cost Delta [Conventional-EV] [Billion Euro] Accumulated Cost Delta 10 years [Billion Euro] Length National & European Road/Highway [km] Accumulated Cost Delta 10 years / km [Million Euro/km] Compare to Public Domain Million Euro/km

12 Conclusions, so far ERS is the most promising alternative to fossil fuel in the future Many national initiatives started, conferences arranged etc Possible alternatives that need to be observed are: Large scale bio-fuel production in balance with food production Cold Fusion? and more The economic potential in ERS seems big enough to make it interesting for all primary stake holders A competition will take place in the near future Trolley, Inductive and Conductive ERS will be developed to compete on system cost, ruggedness, efficiency,

13 Time Dev & Demo Standardisation Sparse Grid Denser Grid Full Grid What will be the time frame? Driven by market, like GSM? time Driven by diminishing fossil fuel resources? We may have years!

14 Who are the Stakeholders? OEM Cars and Commercial Vehicles Road Utility Companies Electric Power Generation Companies ERS System Manufacturers ERS Others

15 How new is the Idea? Overhead lines (Trolley) In use but not realistic for both Cars and Buses/Trucks Inductive Power Transfer from the road Expensive, heavy and bulky Low efficiency Conductive Power Transfer from the road Several systems exist, the most modern is INNORAIL. Low cost High efficiency Very promising if safety and robustness can be guaranteed. Safety is adressed in INNORAIL with a sequential (8 active + 3 isolation [m]) solution that is only feasible with rail bound vehicles. INNORAIL is in use in Bordeaux since 8 years. A new solution is developed by XX AB, also applicable to road traffic. Overhead line voltage: 750 V Battery capacity: 38 kwh Battery autonomy: 12 km Korean solution: Online Electric Vehicle (OLEV) $ 21 million / $ 83 million / % Efficiency over 12 cm distance INNORAIL developed for tram by Alstom/Spie, also called APS (Alimentation par Sol),sequential 8+3 meters sections. Used in Bordeaux, France

16 Alternative solutions + / - Top Inductive Unrealistic due to size and weight Low efficiency Visual impression Conductive Already in use Low cost Does not work for cars Visual impression Side Under Works for all road vehicles Unsafe for objects on roadside Low efficiency Heavy, bulky and expensive Only one lane possible Rugged and Safe Expensive Low efficiency EMC Works for all road vehicles Low cost Unsafe for objects on roadside Only one lane possible Works for all road vehicles Low cost High efficiency Safe and rugged?

17 Basics on hybridisation

18 What is a hybrid vehicle? PlugIn - Charging Electric machine Charge sustaining hybrid ICE

19 Engine use in a heavy hybrid vehicle kw traction power (70 km/h) Engine torque [Nm] kw traction power Higher torque kw tractionpower (30 km/h) 25 0 Adaptation of engine operating point 60 kw extra power to charge battery but also: Regeneration of braking energy Higher gear Engine Speed [rpm]

20 Benefits? Reduction of fuel consumption % depending on type, driving habits etc Reduction of emissions Depends more on the fuel used and the catalyst Increased electric power Increased subsystem efficiency and functionality, e.g. the Air Conditioner. Enough power for an electrically heated villa!

21 Potential Fuel Saving % 5-8 % Refuse truck % Long haul truck City bus % % Wheel loader

22 Engineering Concepts

23 The Conventional Drivetrain < 30 % ave Diesel Engine 95 % 98 % 98 % El. AMT gearbox mach 95 % Advantage: -High range Drawbacks: - Low average efficiency, % - No regenerative braking + - Energy Storage 90x90 % Power Electronics Idea to solution: - An electric vehicle

24 The Electric Vehicle >30% 95 % 95 % 98 % Diesel Engine El. mach El. mach Advantage: - High average efficiency - Regenerative Traction motor power - Packaging Drawbacks: - Low range - High cost / kw tractive power 95 % Power Electronics Idea to solution: - ICE range extender -> The Series Hybrid Vehicle + - Energy Storage 90x90 % 95 % Power Electronics

25 The Series Hybrid Vehicle >30% Diesel Engine 95 % >30 % El. mach Diesel Engine El. mach 95 % 98 % 98 % El. mach Gearbox 95 % 95 % 95 % 95 % Advantage: - High range Power Electronics Power Electronics + - Drawbacks: Energy - Low ICE drive efficiency Storage - High drive system cost / kw - All installed power NOT available on the wheels Power Electronics + - Energy Storage 90x90 % Idea to solution: - Connect ICE to wheels mechanically The Parallell Hybrid

26 The Parallell Hybrid Vehicle Diesel Engine El. mach Gearbox Advantage: - High range - High ICE drive efficiency due to hybrid control - ICE downsizing - Low system cost / kw tractive power - High commonality with non-hybrid drive train - Redundancy if electric drive malfunction Power Electronics + - Energy Storage Drawbacks: - Lower max regenerative braking due to lower EM rating than series

27 Enhanced Performance - Parallell drive Both Together Diesel Engine El. mach Gearbox T Diesel Power Electronics + - Energy Storage Electric Drive rpm

28 Example Honda Parallell with CVT Two electrical drives Toyota Complex One electric drive

29 I-SAM Integrated Starter Alternator Motor Diesel engine Electric motor 70 kw cont, 120 kw peak 400 Nm cont, 800 Nm peak AMT gearbox Energy storage 600 VDC

30 The Complex Hybrid Vehicle Power Electronics El. mach + - Energy Storage Diesel Engine Advantage: - CVT function - Simple mechanical gearbox Power Electronics El. mach Drawbacks: - Two el. drives - Not flexible for alternative ICE s - Maximum output torque limited by the solar wheel motor

31 The Prius Complex Hybrid

32 The Course

33 Lectures and Exercises MIE 100 Course Content distribution Autumn 2010 Fö # Exc # Home Assigment # Calender Study Week Week Date Contents M:D Introduction to energy supply for transport M:D Veh dynamics, the ideal vehicle M:IEA Non ideal - The ICE + Mechanical Transmissions M:IEA Different Hybrid Systems M:Emma1 Simulation, ideal vehicles 2 # 1 out M:Emma1 Simulation conventional vehicles M:Emma1 Simulation home assignment 1 support M:IEA Hybrid Systems Control M:IEA The Parallell Hybrid, Implementations, Modelling and Control M:IEA Electrical Drives 8 # 1 return M:IEA Electrical Energy Storage M:Ina M:Ina4 Simulations on various parallell hybrid vehicles M:Ina M:IEA The Series and the Complex Hybrid, Implementations, Modelling and Control 10 # 2 out M:IEA Auxilliary systems M:IEA Guest lecture E:C Future development expectations M:Ida Field Trip M:Ida Simulations on home assigment M:Ida 9 # 2 a back M:Ida M:Ida M:Ida M:Ida Test ride this week M:Ida 13 # 2 b back M:Ida Spare M:Ida 42 ex Examination

34 Matlab needed

35

36 Spare Slides

37 Subway Train Solution (from the side) TRACK

38 Trams and trains (from above)

39 The OLEV (On Line Electric Vehicle) of South Korea Preparation Cutting asphalt Digging/Leveling Support frame installation FRP installation Surface finishing & lining Sensors in the track Inverter installation Cement concrete Ferrite core installation 11

40 INNORAIL, Bordeaux, I

41 INNORAIL, Bordeaux, II

42 PRIMOVE

43 Primove simulation Flux distribution 1 dm above ground Very high magnetizing currents needed A lot of leakage flux Low efficiency 1 meter Flux distribution along vertical middle A in 5 cm diameter and 10 A/mm 2 conductor Magnetizing current Back to overview

44 Primove data

45 Historic pictures

46 The value of the idea All road transportation can be transferred from fossil to electric propulsion without the need for extreme/impossible battery installations Road Transportation will benefit from the higher energy efficiency of electric propulsion, about double. As electricity generation is shifted towards renewable, electric transportation follows The Slide In vehicle: 1. Runs first of all on battery only 2. Whenever possible, it slides in and charges while driving 3. Whenever possible, it is plugged in and charges while parked 4. The combustion engine is only started and engaged when: The electric motor power is insufficient to drive the vehicle, e.g. in acceleration or uphill travel. The battery charge level is approaching critically low levels and no slide in charging is available

47

48 European Road Network km paved roads km motorways European road vehicles use about 4000 TWh fossil fuels and generates about 4000 TWh el energy It could be replaced by about 1200 TWh electric energy or about 30 % of the present European el generation EUROPE wheelers Light duty vehicles Small Buses Large Buses Medium Duty Truck Heavy Duty Truck SUM (Billion Liters Gasoline Equivalent) Gasoline energy density [MJ/litre] 34.2 Energy Used [TWh]