Hybrid Systems for Propulsion = Future Road Transport

Transcription

1 Hybrid Systems for Propulsion = Future Road Transport Mats Alaküla Professor, Industrial Electrical Engineering, Lund University Tech Specialist, AB Volvo

2 The purpose with this course To teach Key Technologies that open the door to a new transport system

3 The Course MIE 100 Course Content Distribution, Autumn 2014 Fö # Exc # Home Assigment # Calender Study Week Week Date Location Contents :15-10:00 E:1406 Introduction to energy supply for transport :15-10:00 E:1406 Veh dynamics, the ideal vehicle :15-12:00 M:E Non ideal - The ICE + Mechanical Transmissions 4 # 1 out :15-15:00 M:E Simulation and Home Assignment 1 preparation :15-10:00 M:Em1-2 Simulation, ideal vehicles :15-12:00 M:Em1-2 Simulation conventional vehicles :15-17:00 M:Em1-2 Simulation home assignment 1 support 5 # 1 return :15-10:00 E:1406 Hybrid System Components : 1 (mainly Energy Storage) :15-17:00 M:E Hybrid System Components : 2 (mainly Electrical Drives) :15-12:00 M:E The Parallell Hybrid, Implementations, Modelling and Control 8 # 2 out :15-15:00 M:E Energy Storage and Life Time Estimation - Plug In :15-10:00 M:Em :15-12:00 M:Em1-2 Simulations on various parallell hybrid vehicles :15-17:00 M:Em :15-10:00 E:1406 The Series and the Complex Hybrid, Implementations, Modelling and Control :15-10:00 E:1406 Plug In and Slide In - range extention from Hybrid to Full Electric :15-12:00 M:E Hybridisation of Working vehicles (Construction Equipment) :15-15:00 M:E Hybridisation of Working vehicles (Construction Equipment) All day! (plan for 06:30-20:00) :15-10:00 M:Em1.2 Support to final home assigment :15-12:00 M:Em1-2 Support to final home assigment 10 # 2 back :15-17:00 M:EM1-2 Support to final home assigment 44 exam :00-13:00 ED:026 Written examination *) Field Trip this day (all day event) Simulations on home assigment 2 the other days

4 1: CO 2 & Energy Supply

5 Is CO 2 out of control? - it's as if no-one is listening to the scientific community! - We need a radical plan! Corinne Le Quere, director of the Tyndall Centre for Climate Change Research UN Climate Conf in DOHA 400 ppm CO 2 measured last week at Hawaii by NOAA National Oceanic and Atmospheric Administration

6 Not a Fossil Future 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! *)

7 Means for CO 2 reduction in road transport... Conventional, improved - 40 % CO 2 (VERY expensive!) Conventional, hybridized - 40 % CO 2 Conventional, Bio Fuel - Is there enough Bio Fuel? Full electric, renewable electricity - How to? - Energy from?

8 Will there be enough Biofuel? Ref: EU ENERGY IN FIGURES 2010 CO2 Emissions from Transport by Mode

9 TWh World Energy Use for Road Transport - The value of electricity! Million Ton CO2 Primary Energy Use for Road Transport CO2 Emissions from Road Transport Cars Fuel Cars Electricity HDT Fuel HDT Electricity MDT Fuel MDT Electricity Bus Fuel Bus Electricity Constr Eq Fuel Constr Eq Electricity 2-Wheeler Fuel 2-Wheeler Electricity Cars World Cars EU27 Cars SE HDT World HDT EU27 HDT SE MDT World MDT EU27 MDT SE Bus World Bus EU27 Bus SE Constr Eq World Constr Eq EU27 Constr Eq SE 2-Wheeler World 2-Wheeler EU27 2-Wheeler SE

10 [g/kwh] CO2 intensity of electricity generation CO2 from Electricity Generation 1000 India China 700 Africa North America World EU 27 CO2 emissions from fossil fuels consumed for electricity generation, in both electricity-only and combined heat and power plants, divided by output of electricity generated from all fossil and non-fossil sources. Both main activity producers and autoproducers have been included in the calculation. Sweden

11 2: Hybridisation

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

13 Engine torque [Nm] Higher torque Engine use in a heavy hybrid vehicle Adaptation of engine operating point but also: Higher gear 60 kw extra power to charge battery Regeneration of braking energy Engine Speed [rpm]

14 Potential Fuel Saving Refuse Truck Long Haul Truck 20 % 5 % City Bus Wheel loader % %

15 Hybrid solutions - quiet and fuel efficient 35% improved fuel efficiency

16 It works also for Non Conventional Vehicles...

17 Different types of Cranes used REF: Energy Management Strategy for a Hybrid Container Crane Master of Science Thesis For the degree of Master of Science in Systems and Control at Delft University of Technology Steven Mulder

18 Siemens ECO-RTG Crane Drive System

19 Example of handling

20 Example: Excavator REF: Komatsu Hydraulic Excavators Hybrid PC200LC-8

21 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!

22 3: Electric Energy Supply

23 Electric Drive is Good! Electric Traction Motors Are at least twice as energy efficiency as combustion engines Need almost no service, no sparkplugs, no oil changes.. Are quiet Let out no exhaust Are much smaller than a combustion engine for the same rating Can recover energy when slowing down or going downhill

24 But Storing Energy is a double problem... Time to charge 250 km Battery to store 250 km 5 minutes 150 kg diesel-tank 7 days 8000 kg battery 9 hours 8000 kg battery 4 hours 8000 kg battery

25 Electric Power [kw] Electric Power Requirements - as a function of weight FL FE FM, FH, tons Vehicle mass [tons]

26 Full Electric? Is it realistic to let equipment, consuming kw average power, be pure electric and run on batteries? - No, not if the charging occasions are to few! 50 kw x 10 h = 500 kwh = 10 tons of batteries! 10 ton 400 kg Frequent charging is the key! Charge e.g. 25 times a day for kw. 200 kw x 0.1 h = 20 kwh = 400 kg batteries! 25x20 kwh = 500 kwh

27 Continuous Charging Plug In Conventional Full Electric Energy Supply 240 km = 140 liter Diesel (90 liter if Hybrid) 240 km = 0.5 MWh electricity (= 5 10 ton battery) kw for 6 minutes = 0.5 MWh kg battery needed Continuous 40 kw for 12 hours kg battery needed

28 Vehicle Examples

29 A Car Example 160 km Night Charge 300 kg batteries SEK 78 % of the annual driving 48 km Night Charge 100 kg batteries SEK 43 % of the annual driving 48 km Night Charge + Slide In 100 kg batteries SEK 100 % of the annual driving D = SEK Dx4 million cars = 212 Billion SEK = 14 MSEK/km National and European road in Sweden x 1.8 x 3

30 A Distribution Truck Exampel A Night Time Charge Only 3,3 tons battery 1,2 MSEK (Drive System+Battery) Every Loading Dock Charging 700 kg battery 290 ksek (Drive System + Battery) - How to share infrastructure, like Buses can? At the Goods Terminal At every Loading Dock At the Lunch Stop? Requires Low Cost for High Density!

31 A City Bus Example Night Time Charging 6 tons battery 2,1 MSEK (Drive System+Battery) End Stop Charging < 1,0 tons battery 400 ksek (Drive System + Battery) Lund, Sweden Every Bus Stop Charging 400 kg battery 170 ksek (Drive System + Battery) Cost reduction via Charging Infrastructure Sharing!

32 Malmö, Sweden

33 Battery Energy Content [kwh] More Charging... Less Batteries Distribution truck with optional loading dock charging Charging at Night DisCharging at Day 1,7 tons Charging at Every loading dock 40 kw, C=1,4 300 kg City Bus with optional end station or bus stop charging 3,8 tons 250kg bat or 400 kg SUPERCAP 0,13 kw Charging at End Stop, 100 kw, C= kg Charging at Every Bus Stop, 160 kw, C=7.2 Long Haul Truck with optional 87 % Slide In 14 tons Slide In + Lunch Charging, 100 kw, C=1.8 Time of day [hours] 1 ton

34 Some Conclusions 1 Frequent Recharging, ideally continuous el energy supply, is key. 2 Two lines of development needed: Static Charging Systems, that need to be: High Power, kw, depending on application Automatic, not only for Buses but for Trucks and Constr. Eq. Low cost, since there must be many of them, to serve e.g. Distributions Trucks Visually Appealing! Dynamic / Slide In / Continuous Charging systems: For Long Haul, BRT, City Buses, Construction Eq.

35 Static and Dynamic Charging

36 The Energy Path

37 Manual Power Static Connections kw Good Looking Something is missing HERE!!! Automatic 120 kw 87 kw 44 kw 3 kw 1 dm m Size

38 Continuous Siemens ehighway Charging Bombardier PRIMOVE ALSTOM APS ANSALDO TramWave OLEV & Primove Truck/Bus TRAM TRAM TRAM Alstom APS Truck/BUS Truck/BUS Motor Drive Motor Drive Motor Drive CAR Motor Drive Motor Drive Motor Drive Under Ground Power Supply Line

39 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

40 Additional equipment needed Slide Plug Conventional Hybrid In Hybrid Vehicle vehicle Vehicle Power Supply Tank Engine Transmission Wheel Transformer Battery Electric Drive Pick Up Electric Power Conditioner

41 How a charging road can work... Activated step by step Needs little precision Overtaking on battery

42 i.e. maybe % of annual range is electric Why we need Electric Road Systems (ERS) Sweden as an example: If all road vehicles were to be electric, 27 TWh el would be enough: Plug In Electric Energy Requirement, all road vehicles electric [TWh] up to 50 km... Commercial Vehicles Non Commercial Vehicles 10 TWh for Heavy Duty 17 TWh for Light Duty Conclusions: ERS Plug In More realistic EL range, with a real family car... 1.ERS are

43 Proportions If ALL 4 million Swedish cars were Nissan Leaf: 300 kg batteries, 24 kwh, 160 km, SEK Would cover 75 % of all car driving IF the batteries of these were reduced to 100 kg batteries, 8 kwh energy, 50 km range, SEK Difference? 4 million x ( ) = 212 billion SEK ABOUT times as much as the cost for Electric Road Systems on ALL National and European roads in Sweden. And then 100 % of all road traffic could be all electric

44 Cost 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 Grid Size B The total societal cost for such a system is the cost for batteries and the cost for ERS systems Sparse grid = big batteries Dense grid = small batteries A

45 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 realistic battery capacity for both EV Cars and EV Trucks/Buses This corresponds to km roads in SE and km in France 50 km = 31 miles

46 5: Actors on the market

47 Conductive Alternatives Alstom s ERS system has long commersial experience In several cities since Million km Ruggedness proved Safety proved High generic efficiency Ansaldo s Tramwave has problems unrelated to the conductive principle Elways has also proven the principle SIEMENS ehighway i coming!

48 Siemens ehighway Video

49 A Winter view on Alstom APS

50 Alstom adapted to trucks

51 Elways AB 0:55 Dry asphalt 5:45 Plowing snow out of the track 6:14 Running in new plowed track 6:47 Running in snowy track

52 ABB TOSA / Flash Charge DC Charging at 400 kw, 500 V Charging Station charges SuperCaps while waiting for a bus, at <50 kw. Claimed for 15 seconds = 1.6 kwh = 1 km of driving Requires that the bus batteries can take 400 kw charging power

53 Siemens 15 minute charge at each end stop for km range Power? Siemens pantograpth connector Night time slow charge

54 Volvo BUS - BusBaar Up to 100+ kw for 6 minutes = 10 kwh = about 8 km of range

55 Landskrona Trolley line used for Slide In. Drive about 1/3 rd of the range within the Trolley Line, 2/3 rds in battery mode. Comment from a senior bus driver: Oh, if we only had more of these then we would run all city buses full electric...

56 The PVI Watt System Uses Supercaps and fast charging Automatic!

57 Inductive Alternatives Bombardiers PRIMOVE has several vehicles and demonstration tracks OLEV Technologies has several vehicles and demonstration tracks Qualcomm/Halo...

58 Bombardier s Primove 200 kw TÜV approved (incl magnetic field) 2012 Today used in several cities Braunschweig, 12 km route, 2 buses (12m/18m) Mannheim Lommel (Flanders Drive) Augsburg

59 More on Primove 200 kw stationary 150 kw dynamic Experimentally verified

60 OLEV Technologies khz resonance frequency kw/section % efficiency

61 Video from Kaist Campus :20 Facts about Track length 0:50 20 % covered 1:00 Instrument view Example: Mean power 30 kw Charge power 150 kw 20 % of the time

62 6: Societal Value

63 A Slide In World Example of opportunity With realistic expectations on Fossil fuel (2x), Electric energy (1.5x), Battery Cost (0.5x) & Lifetime (2x) development by 2030 Compare Costs for Fossil Drive vs. Electric drive, for 2030: Unit Cars L Trucks H Trucks Fossil Fuel [Euro/10km] 1, ,55 6,82 Electric Energy, Battery etc [Euro/10km] 0,30 0,61 1,84 SWEDEN # Vehicles [-] Annual Driving Distance [x10 km] Annual Cost Delta [Conventional-EV] [Billion Euro] 5,4 2,2 2,0 Accumulated Cost Delta 10 years [Billion Euro] 54,4 21,7 20,2 Length National & European Road/Highway [km] Accumulated Cost Delta 10 years / km [Million Euro/km] 3,5 1,4 1,3 6,3 France # Vehicles [-] Annual Cost Delta [Conventional-EV] [Billion Euro] 38,6 15,4 14,3 Accumulated Cost Delta 10 years [Billion Euro] 385,7 153,9 143,4 Length National & European Road/Highway [km] Accumulated Cost Delta 10 years / km [Million Euro/km] 18,5 7,4 6,9 32,8

64 Los Angeles as example of continuous energy supply: - I 710 as (extreme?) example

65 Used model Traffic intensity cars/h, kg trucks/h, kg trucks/h, kg 60/40 ratio North /South Lanes, 2 * 7 lanes 9 km road 25 meter road sections, feed-in points every 50 m Voltage to road, 400 V three phase Slope 3 km -1%, 2 km 0%, 500 m 6%,500 m -6%, 2 km 0.25%, 1km 2.5 %

66 A 9 km section as example 9 km One transformer every 150 meters SE US kw/km kw/9km kw/18mile kw/km

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69 Costs Estimate SUMMARY Electrical system from incoming 230 kv to low voltage connection points: In total 15 MEUR for 18 km 800'000 EUR/km From low voltage connection points to each lane and section The cost of these cables becomes EUR/km Altogether < 1 MEuro/km And this 7-lane road is an extreme example. Most roads should en up at a fraction of this level. Add the ERS (7x0.4=2.8 Meuro/km) equipment, and the total is still < 4 MEuro/km FOR THIS 14-lane road! The Societal Value is in the range >>> MEuro/km!

70 Plenty of room for the Stakeholders! OEM Cars and Commercial Vehicles Road Utility Companies Electric Power Generation Companies ERS System Manufacturers Vehicle Customer Others ERS and not least: The Environment!

71 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 We may have years! fuel resources?

72 Summary Both Static and Continuous Charging is essential for Electro Mobility to become a game changer in road transportation Some form of continuous energy supply is crucial! Automatic Static charging is also crutial! There are several mature or almost mature solutions available from different suppliers. A strong industrial and societal interest in getting to know these technologies An ERS grid density around 50 km seems economically feasible and does not impose any extreme battery requirements on any vehicle A / Mats new Alaküla business opportunity is

73 Thank You!