GKN Hybrid Power Flywheel Energy Storage Systems and Applications

2

GKN – A Short Introduction

GKN

ENGINEERING THAT

MOVES THE WORLD…

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GKN – Engineering that moves the world

Leading first tier supplier to the

global aerospace industry

focusing on aero-structures,

engine systems and products,

and specialty products.

Leading supplier of power

management equipment to the

agriculture, construction and

mining, utility and industrial

markets; with a strong service

capability.

World’s largest manufacturer

of metal powder and sintered

components, predominantly

to the automotive sector.

A global engineering group

Sales of £7.45 billion in 2014

51,500 people in more than 30 countries

Founded in 1759

32 Manufacturing locations

11,700 people

30% of sales

34 Major locations

5,400 people

12% of Sales

34 Manufacturing locations

6,600 people

12% of sales

GKN Land Systems GKN Aerospace GKN Powder Metallurgy

World leading supplier of

automotive driveline systems

and solutions, including all-

wheel drive.

45 Manufacturing locations

24,000 people

46% sales

GKN Driveline

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GKN Driveline GKN Powder Met GKN Aerospace

eDrive Technology

Technology

Support Technology

Support

eDrive Technology – key development theme

GKN Land Systems

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GKN Hybrid Power

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Company History - From Williams F1 to GKN HP

“A world-class engineering

company that goes racing”

Founded in 1977

16 FIA Formula One World

Championship titles

Adapting cutting edge F1

innovation and technology for

wider commercial applications

Williams technology improves:

Energy Efficiency

Safety

Performance

2008 2014

Strategic acquisition for GKN

Land Systems

Technology & innovation is at

the heart of GKN

We can industrialize on a

global scale

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GKN Hybrid Power – History

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;

WHP’s investment in industrialization

2012 35 Bus & Tram demonstrator contracts;

Audi R18 e-tron 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 April formation of GKN Hybrid Power

Pre-Production Orders for 500+ Bus systems.

Alexander Dennis Partnership.

Audi R18 e-tron quattro 2.0 raced and won;

DSTL contract.

2015 101 February opening of new Technical engineering center in Abingdon

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GKN Hybrid Power

We deliver the

power to harvest

crops and move

earth…

And we make

essential

components for

industries that touch

lives across the

globe.

• Victory at Le Mans – again!

• £5m Audi contract for 2015

• 750 Gyrodrive flywheel systems committed over next 2 years

• Production ramp up

• £3m MoD contract

• New facility

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[IN CONFIDENCE]

Mechanical Battery

Kinetic Energy Storage

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Flywheels – Principle of Operation

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The flywheel is an electric motor

Stores energy mechanically

Unique MLC Rotor

12kg Spins at up to 36,000 rpm

Peak Power 120kW

Benefits

Very high power density

Wide operating temperature

range

Very high cycle life with no loss

of performance

Cost effective in volume

The Mechanical Battery

MLC

The inner ring of the flywheel is

made of glass fibre mixed with

magnetic particles. This provides

the magnetic flux for the motor

Magnetic Layered

Composite

Filament Wound Carbon

Fibre Outer Rotor

• 80,000,000 Strands of aero

grade carbon fibre

• Surface Speed: Mach 1.8

• Surface force :250,000g

GKN Hybrid Power Flywheel – Principle of Operation

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GKN Hybrid Power – Technology Overview

CERAMIC HYBRID

BEARINGS STATOR

MLC

SECTION

CARBON COMPOSITE

ROTOR

CARBON COMPOSITE

END CAP

Mk 4

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Rotor Stress – The Safety Case

Carbon Rotor

MLC

Rotor Section

Radius 130Radius 145Radius 175

Fa

ilure

Str

ess A

ST

M D

22

90

-08

Str

ess in

Ro

tor

Sample

Testing

• Safety Case based on pressure vessel

design / Nuclear Industry

• Probability of hoop failure < 1x10-9

• Max operational speed controlled by

safety hardware

• All designs fully qualified by test and

analysis

FEA

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Energy and Power – Why Flywheels?

A123 Li-ion

(Battery)

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

0.5 kW/kg 0.35kW/kg 2.2kW/kg

(6 kW/kg Msport)

0

200

400

600

800

1000

1200

1400

1600

1800

2000

0

20

40

60

80

100

120

140

0 5000 10000 15000 20000 25000 30000 35000 40000

Me

chan

ical

En

erg

y kJ

Ele

ctri

cal

Po

we

r (k

W)

RPM

Power & Energy : 400V Electrical Power (kW)

Mechanical Energy (kJ)

Boost Power up to 120kW

for Bus and ~300kW for

Msport.

Power Delivery / Harvesting

for 2-10 seconds

Think about the Mass

The Flywheel uses ~80% of its stored energy per cycle.

Life costs…. Flywheel 15 years……Battery 4 years

Disposal cost and environmental impact !!

Power / Energy

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Gyrodrive Hybrid Bus Principle of operation

Through the motor / generator in the

driveline the Gyrodrive flywheel

captures the kinetic energy during

braking and reuses it to help accelerate the bus.

GKN Motor &

Gearbox

GKN HP

Flywheel

Power

Electronics

BRAKING

ACCELERATING

Re- Gen Braking

Saving

Up to 25% Depending on route

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Retro Fit Bus Installation

Laser

scan of

existing

structure.

FESS

Concept

Design

Alexander

Dennis E400

Installation

Design……...……….. Develop…………………. Realise

Drive

train

concept

design.

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Development and Verification Testing

Vibration

and Shock

Fuel Fire

Test

Ingress Tests

Waterproof ?

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[DOCUMENT NAME]

Industry and Government in Partnership

Benefit of Collaboration

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Energy Storage

supplier to OE

10,000PA > 100,000PA

Global markets

− Mass Transit

− HGV

− CV

Integrated system

− Flywheel

− Controls / power supply

− Vac pump

GKN Hybrid Power – Benefit of Collaboration

Retro fit complete

system

1>1000PA

Go-Ahead

− Bus fleet operator

UK Market

Complete System

− Flywheel / Fess

− Driveline

− MGU

− Fitting

Government “Matched” Funding for Low

energy emissions – total grant £7.65m

REDUCED COSTS NEW MARKETS

2014 TRL5 & MRL 4 2016/7 TRL8 & MRL7

Capability Investment

− Carbon Fibre winding

− Magnetization

− Multi-Physics Analysis

− Development and Testing

Cost reduction

− Integration of collaborative

research results

− Design for manufacture

− Process development

− Design for reliability

Service development

− Global Telemetry

Coventry University

− Research and technology

development to support long-term

investment in cost down and

product improvement concepts.

Alexander Dennis ltd

− First Adopter

− Integration of electronic controls

with vehicle CAN

− Chassis and driveline integration

with key supplier such as ZF

S&S Windings

− Develop methodology for ultra low

cost stator

Develop for High volume Original Equipment Fit

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GKN Hybrid Power – Benefit of Collaboration

Gyrodrive Retro fit development partner - Go-Ahead Group

UK Bus fleet operator

Winning hybrid only routes

Benefitting from fuel save

Well ahead of competition

Gyrodrive Original Equipment development partner – Alexander Dennis Ltd - Bus Manufacturer

Winning additional sales for its new vehicles – Transport for London requirement for hybrids

Forecast that in the near future all its sales could be hybrids

Well ahead of competition

ADL E400 Euro 6 ADL E200 Euro 6

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Parallel Hybrid Bus • Kinetic energy re-used

• Diesel Engine sized for

peak performance

Next Steps - Series Hybrid System

Fuel Use Current Engine 250g/kWhr

Optimised Engine 180g/kWhr

Saving 28 %

Re- Gen Braking

Saving

20 % + =

Total Saving

43 %

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

Fu

ture

Deve

lop

me

nt

Cost Increase of Gyrodrive

offset by 3 year fuel savings

Larger cost of series hybrid

Gyrodrive offset smaller

engine and gearbox deletion.

2 year payback

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GKN Hybrid Power The Gyrodrive USP

We drive the wheels

of hundreds of

millions of cars…

We help thousands

of aircraft to fly…

Reliable Operation

Real World Results

Commercially Viable

GKN Hybrid Power Storage Systems Applications

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FESS System – 2016 Deliverable (20MJ)

Source:

Flywheel Controller

Mk8 Flywheel

FW Inverter

Flywheel

Ancillaries

LoadMk8 Flywheel Module (x6)

Flywheel Energy Storage System (FESS)

Co

ntr

ol

Co

ntr

ol

Co

ntr

ol

FESS Supervisor Controller (FSC)

Power Supply

System Application Controller (SAC)

HV DC Bus

Co

ntr

ol

Co

ntr

ol

Power

Distribution

Co

ntr

ol

Safety Circuit

Co

ntr

ol

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Flywheel Pod LRU

Sealed LRU to IP65, Interfaces to FESS 3 Way Backplane

Rapid Prototype model reflects this design

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Audi Mk6E

R18 e-tron hybrid system with Mk6E Flywheel