Flanders Make Strategic Research Centre for the Manufacturing Industry Energy Efficiency in Mechatronics: why, what and how? Walter Driesen, Program Manager Flanders Make Mission It is our mission to strengthen the long-term international competitivenessof the Flemish manufacturing industry by performing excellent, industry-driven, pre-competitive research in the following domains: mechatronics product development methods advanced manufacturing technologies 2 1
Actual Industrial Members 3 Flanders Make manufacturing innovation network APPLICATION AREAS TECHNOLOGY DOMAINS 4 2
The Scope of industry-driven research 8 RESEARCH PRIORITIES (= PROGRAMS) 3 APPLICATION AREAS Industrial needs Research programs Projects RP1 RP8 Machines Projects Vehicles Projects Factories RP1: Clean energy-efficient motion systems 5 Energy Efficiency in Mechatronics Market drivers Global warming Energy prices 50 years Energy & emission regulation Energy & emission regulation 6 3
Market drivers Energy & emission regulation Long term objectives: improve energy efficiency, reduce gas emissions w.r.t. 1990 2020: 20% (Europe s 20-20-20 targets) 2030: 50% (ERTRAC) 2050: 80-95% (Roadmap 2050) Legislation Passenger vehicle emissions Electric motor efficiency labels FLEET 7 What to focus on? MARKET DRIVERS for machines & vehicles -energy prices -energy & emission regulation - social awareness INDUSTRIAL NEED energy-efficient drivetrains for vehicles and machines Electromechanical drivetrain electric supply power electronics electromagnetic actuator/generator mechanical transmissions torque position 8 4
What are the KPIs?? Total cost of ownership (TCO) total cost of acquisition operating costs + TCO Installation cost - ±0% ±0% + 5 years Target region Drivers - Legislation - Energy prices - Social awareness - Market - Energy consumption 1 year 9 How to improve these KPIs? How to build energy efficiency electromechanical drivetrains at optimal TCO? What do you need? 1. Use more efficient components 2. Store energy flowing back to reuse it when you need it 3. Integrate all components optimally into 1 system Flanders Make develops the technology the industry needs to make these three steps 10 5
How to apply? Evolution Retro fitting for energy efficiency Redesigning for energy efficiency Early stage energyefficient design? Ignore energy efficiency Virtual prototyping Energy flow mapping Concept evaluation Component sizing Controller design 11 Case: hydrostatic drivetrain Hydrostatic drivetrain Combustion engine to pump to hydraulic motors to 1 or more loads Variable stroke volumes continuously variable transmission ratio Power flowing back is lost! Experimental setup with electromotors 12 6
Case: hydrostatic drivetrain Model Concepts Super capacitors Component sizing Fitted on experiments Hydraulic accumulator TCO Optimization Controller design Energy flow mapping Concept evaluation Component sizing Controller design 13 Case: hydrostatic drivetrain Outcome: Hydraulic hybrid more efficient!?! Though hydraulic storage components are less efficient Electrical hybrid Far from load DC/AC Total cost DC/DC Hydraulic hybrid Close to load 14 7
Understeer effect Case: torque vectoring Understeer characteristic: cornering at constant radius and radius and increasing speed Steering-wheel Angle Linear Region Effect of Torque-Vectoring Asymptote ~ 0.5 g 0.9-1.1 g Yaw torque Lateral Acceleration In collaboration with Dr. Aldo Sorniotti 15 Case: torque vectoring Torque vectoring Besides improved stability also potential for reducing energy losses 30 25 Power losses in electrical drivetrain P LOSS,Α Large losses due to lateral slip during cornering PLOSSkW 20 15 10 P LOSS,TR P LOSS,M P LOSS,ROLL P LOSS,Σ 5 0 0 2 4 6 8 10 a yms 2 Lateral Acceleration In collaboration with Dr. Aldo Sorniotti 16 8
Case: torque vectoring Model Controller design Validated with experiments dyndeg 80 experiments exponential approximation 60 40 20 0 0 2 4 6 8 10 ayms 2 Energy flow mapping Concept evaluation Component sizing Controller design In collaboration with Dr. Aldo Sorniotti De Novellis, L., Sorniotti, A., Gruber, P., SAE Int. J. Passenger Cars - Mech.Syst, 6 (1), pp. 128-136, 2013 De Novellis, L., Sorniotti, A., Gruber, P., IEEE Trans. on Vehicular Technology, vol.63 (4), pp. 1593-1602, 2013 17 Case: torque vectoring Simulation results Dynamic steering angle Relative improvement of energy consumption Lateral Acceleration Improved understeering characterisitic is acheived Lateral Acceleration Up to 6% of improved energy consumption In collaboration with Dr. Aldo Sorniotti 18 9
Case: torque vectoring Experimental results 4 WD at R = 60 m 100 80 Total energy consumption sport mode baseline Tests at the Lommel Proving Ground P in [kw] 60 40 20 In collaboration with Dr. Aldo Sorniotti 0 0 1 2 3 4 5 6 7 8 9 10 a y [m/s 2 ] Lateral Acceleration Up to 5-10kW of lower energy consumption! 19 Energy efficiency in mechatronics Conclusions Why Energy prices, legislation, social awareness What Electromechanical drivetrain Energy efficiency andtco How Energy-efficiency from early design stage Virtual prototyping approach 20 10
Thank you for your attention QUESTIONS? Walter Driesen walter.driesen@flandersmake.be +32 498 91 94 38 11