Hybrid Systems for Propulsion = Future Road Transport

Mats Alaküla

Professor, Industrial Electrical Engineering, Lund

University Tech Specialist, AB Volvo

The purpose with this course

To teach Key Technologies that

open the door to a new transport

system

The Course

Fö # Exc # Home Assigment #Calender

Week

Study

WeekDate Location Contents

1 2015-09-01 08:15 - 10:00 E:1406 Introduction to energy supply for transport

2 2015-09-02 08:15 - 10:00 E:1406 Veh dynamics, the ideal vehicle

3 2015-09-03 10:15 - 12:00 M:E Non ideal - The ICE + Mechanical Transmissions

4 # 1 out 2015-09-03 13:15 - 15:00 M:E Simulation and Home Assignment 1 preparation

1 2015-09-10 08:15 - 10:00 M:Em1-2 Simulation, ideal vehicles

2 2015-09-10 10:15 - 12:00 M:Em1-2 Simulation conventional vehicles

3 2015-09-10 15:15 - 17:00 M:Em1-2 Simulation home assignment 1 support

5 # 1 return 2015-09-16 08:15 - 10:00 E:1406 Hybrid System Components : 1 (mainly Energy Storage)

6 2015-09-16 15:15 - 17:00 M:E Hybrid System Components : 2 (mainly Electrical Drives)

7 2015-09-17 10:15 - 12:00 M:E The Parallell Hybrid, Implementations, Modelling and Control

8 # 2 out 2015-09-17 13:15 - 15:00 M:E Energy Storage and Life Time Estimation - Plug In

4 2015-09-24 08:15 - 10:00 M:Em1-2

5 2015-09-24 10:15 - 12:00 M:Em1-2

6 2015-09-24 15:15 - 17:00 M:Em1-2

9 2015-09-29 08:15 - 10:00 M:D The Series and the Complex Hybrid, Implementations, Modelling and Control

10 2015-09-30 08:15 - 10:00 E:1406 Plug In and Slide In - range extention from Hybrid to Full Electric

11 2015-10-01 10:15 - 12:00 M:E Hybridisation of Working vehicles (Construction Equipment)

12 2015-10-01 13:15 - 15:00 M:E Hybridisation of Working vehicles (Construction Equipment)

7 41 6 2015-10-14All day !

(plan for 06:30-

20:00)

*) Field Trip this day (all day event)

Simulations on home assigment 2 the other days

8 2015-10-16 08:15 - 10:00 M:Em1.2 Support to final home assigment

9 2015-10-16 10:15 - 12:00 M:Em1-2 Support to final home assigment

10 # 2 back 2015-10-16 15:15 - 17:00 M:EM1-2 Support to final home assigment

44 exam 2015-10-30 08:00 - 13:00 Vic:3D Written examination

42 7

Simulations on various parallell hybrid vehicles

1

2

3

4

5

36

37

38

39

40

1: CO2 & Energy Supply

• “… - 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 CO2 measured last

week at Hawaii by NOAA • National Oceanic and

Atmospheric Administration

Is CO2 out of control?

Not a Fossil Future …

Source Amount *)

Oil [barrels] 2.00E+12

Oil [kWh] 3.40E+15

Coal [tons] 9.98E+11

Coal [kWh] 7.31E+15

Natural Gas [quads] 6.37E+03

Natural Gas [kWh] 1.87E+15

*) http://en.wikipedia.org/wiki/Reserves-to-production_ratio

Known reserves Predicted Population Growth

Predicted Reserves

Increased average

standard of living

Fossil Fuel will not be a viable

option in a near future !

Known Consumption

35 W/kg (World average)…

129 W/kg (US average)

1 W/kg

Means for CO2 reduction in road transport

...

Conventional, improved … - 40 % CO2 (VERY expensive!)

Conventional, hybridized … - 40 % CO2

Conventional, Bio Fuel … - Is there enough Bio Fuel?

Full electric, renewable electricity …- How to? - Energy from

?

Will there be enough Biofuel?

Ref: EU ENERGY IN FIGURES 2010 CO2 Emissions from Transport by Mode

Volvo Group Trucks Technology

20 % of all global energy use is spent on

land transports

1/3rd of that is spent on ”Volvo type”

vehicles

– Trucks, Buses, Construction Equipment

The more electric we make them ...

... the less energy they need

... BUT the GLOBAL CO2 may increase !

Electro Mobility Perspective150626 Penta, Mats Alaküla

A Global Energy and CO2 Perspective

Volvo Group Trucks Technology

CO2 intensity of electricity generation

Electro Mobility Perspective150626 Penta, Mats Alaküla

0

100

200

300

400

500

600

700

800

900

1000

1985 1990 1995 2000 2005 2010 2015

[g/k

Wh]

CO2 from Electricity Generation

World

EU 27

Sweden

China

North America

India

Africa

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 includedin the calculation.

China has pledged to reduce its CO2

intensity, namely emissions per unit of

GDP, by 40-45% by 2020 compared with

the 2005 level.*1)

India’s CO2 emissions from energy

consumption double, but the country’s

CO2 intensity declines by 28% by 2030.

*1) http://www.world-nuclear-news.org/EE-Chinas-

climate-change-plan-2209144.html

*2) http://www.bp.com/content/dam/bp/pdf/statistical-

review/EnergyOutlook2030/Country-

insights/India_Fact_Sheet.pdf

*3)

*3)

2: Hybridisation

What is a hybrid vehicle?

Electric

machine ICE

Charge sustaining

hybrid ”PlugIn”-

Charging

0 500 1000 1500 2000 0

200

400

600

800

1000

1200

Engine Speed [rpm]

En

gin

e t

orq

ue [

Nm

]

5 5 5 10 10 20

Engine use in a heavy hybrid vehicle

Higher gear

Hig

her

torq

ue

60 kW extra power

to charge battery

• Adaptation of engine operating

point

… but also:

• Regeneration of braking

energy

Potential Fuel Saving Refuse Truck

20 % 5 %

30-40 % 20-50 %

Long Haul Truck

Wheel loader City Bus

Hybrid solutions

- quiet and fuel efficient

35% improved fuel efficiency

It works also for Non

Conventional

Vehicles ...

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

Siemens ECO-RTG Crane Drive System

Example of handling

Example: Excavator

REF: Komatsu Hydraulic Excavators Hybrid PC200LC-8

Battery requirements for electric propulsion

45 000 tons of batteries. The take off weight is 413 tons ! Not possible!

10 kg for 10 km Possible!

40 kg for 10 km Possible!

200 kg for 10 km Possible!

20 tons for 1000 km Not possible!

Comb

Drive!

El Drive

=

Plug In !

Battery operation alone not

possible for Long Haul/Coach …

3: Electric Energy Supply

• 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

Electric Drive is Good!

But Storing Energy is a double problem ...

Time to charge 250 km Battery to store 250 km

5 minutes

7 days

9 hours

4 hours

150 kg diesel-tank

8000 kg battery

8000 kg battery

8000 kg battery

Group Trucks Technology

Rightsizing the Traction Power Requirement

10 15 20 25 30 35 40 45 50 55 60 0

100

200

300

400

500

Vehicle mass [tons]

Ele

ctr

ic P

ow

er

[kW

]

10 15 20 25 30 35 40 45 50 55 60 tons

FL FE FM, FH, ...

Advanced E-Motor Technology 2015

2

axles

3

axles

> 3

axles

Conclusion:

• 1 driven axle should

provide 150...200 kW

• Every additional axle

should provide

another 50...100 kW

• Modularity is

important !

• Is it realistic to let equipment, consuming 50...150 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 !

• Frequent charging is the key!

– Charge e.g. 25 times a day for 0.1 h @ 200 kW.

– 200 kW x 0.1 h = 20 kWh = 400 kg batteries !

– 25x20 kWh = 500 kWh

Full Electric?

10 ton 400 kg

Full Electric Energy Supply

240 km = 140 liter Diesel (90 liter if

Hybrid)

24 charges @ 200 kW for 6 minutes = 0.5 MWh

300…400 kg battery needed

240 km = 0.5 MWh electricity (= 5…10 ton battery)

Continuous charge @ 40 kW for 12 hours

0...100 kg battery needed

Co

nve

nti

on

al

Plu

g In

C

on

tin

uo

us

Ch

arg

ing

Vehicle

Examples

A Car Example

x 3

x 1.8

• 160 km Night Charge • 300 kg batteries

• 80 000 SEK

• 78 % of the annual driving

• 48 km Night Charge • 100 kg batteries

• 27 000 SEK

• 43 % of the annual driving

• 48 km Night Charge + Slide In • 100 kg batteries

• 27 000 SEK

• 100 % of the annual driving

= 14 MSEK/km National

and European road in

Sweden

D = 53 000 SEK

Dx4 million cars =

212 Billion SEK

A City Bus Example

Difference? – 90 % in Battery Weight

Facilitation? - Infrastructure!

MAIN key: opportunity charging at a high

power (100…200 kW)

Electro Mobility

Perspective150626 Penta,

Mats Alaküla

Lund, Sweden 0,13 kW Charging at Every Bus Stop, 160 kW, C=7.2

Charging at End Stop, 100 kW, C=2.5

3,8 tons

400 kg

250kg bat or

400 kg SUPERCAP

A Distribution Truck Example

Difference? - 80 % in battery size!

Facilitation? - Infrastructure!

How to share infrastructure, like Buses can?

• At the Goods Terminal, Loading Dock,

Lunch Stop?

Lower Cost AC Charging connection!

MAIN key: opportunity charging at a high

power (40…100 kW).

Electro Mobility

Perspective150626 Penta,

Mats Alaküla

Charging at Night

Charging at

Every loading dock

40 kW, C=1,4

1,7 tons

300 kg

A Long Haul Truck Example

Difference? – 90 % Battery Size!

Facilitation? - Infrastructure!

Example:

• 15 000 km National and European Road

in Sweden.

D = 50 km = Suitable Battery Range

MAIN keys:

• Electric Road System (ERS).

• Opportunity charging at a high power

(100…200 kW)

Electro Mobility

Perspective150626 Penta,

Mats Alaküla

Slide In + Lunch

Charging,

100 kW, C=1.8

14 tons

1 ton

D

A

B

A

B

Static

and

Dynamic Charging

The Energy Path

Ele

ctro

Mo

bilit

y

Per

spe

ctiv

e15

062

6

Pen

ta,

Mat

s

Ala

küla

Static Connections ...

Size

Po

wer

1 dm 1...2 m

3 kW

44 kW

87 kW

120 kW

200 kW

Something

is missing

HERE !!!

Automatic

Ele

ctro

Mo

bilit

y

Per

spe

ctiv

e15

062

6

Pen

ta,

Mat

s

Ala

küla

This can change

the game!

Tesla’s idea...

VW’s idea ...

Last years LTH students idea ...

ANSALDO

TramWave

Continuous

Charging

TRAM

Motor

Drive

TRAM

Motor

Drive

Truck/BUS

Motor

Drive

Truck/BUS

Motor

Drive

Under Ground Power Supply Line

TRAM

Motor

Drive

CAR

Motor

Drive

Alstom

APS

ALSTOM

APS

OLEV & Primove Bombardier

PRIMOVE

Siemens

eHighway

Truck/Bus

Motor

Drive

Driving Modes with “Slide In”

100

90

40

30

0

SOC (State Of Charge = Battery Charge Level)

time

1 Electric Drive from Battery

2 Hybrid Drive

3 Electric Drive from ERS

Slide In Track Available

[%]

Additional equipment needed

Tank Engine

Transmission Wheel

Battery Electric Drive

Pick Up Electric Power

Conditioner

Power

Supply

Transformer

Conventional vehicle Hybrid Vehicle Plug In Hybrid Vehicle Slide In Hybrid Vehicle

How a charging road can

work ...

• Activated ”step by

step”

• Needs little

precision

• Overtaking on

battery

• 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

• Sparse grid = big batteries

• Dense grid = small batteries

A Slide In World – Battery Size vs Grid Size

A

B

Grid Size

Co

st

• What would be an optimal ERS grid density?

• Europe has 5 million km paved roads and more than 60 000 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 15 000 km roads in SE and 20 000 km in France

ERS Grid Density

50 km = 31 miles

Two Scenarios

50 km + OH ERS

150 km + Night

15 km + End Stop

300 km + High Power

50 km + Road Bound ERS

50 km + Opp

15 km + End Stop

50 km + Road Bound ERS

Over Head ERS Road Bound ERS

Why the difference? 50 km + OH ERS

150 km + Night

15 km + End Stop

300 km + High Power

50 km + Road Bound ERS

50 km + Opp

15 km + End Stop

50 km + Road Bound ERS

Over Head ERS Road Bound ERS

• Road Bound ERS:

• Reduce the need for BIG

batteries significantly

• Eliminates the need for

high power charging

stations for Cars – they

charge on the road

• Opportunity Charging:

• Reduce the need for

batteries significantly i

Distribution Trucks

• Requires Robotic

Connections and Integrated

Chargers (like Renault Chameleon)

Some Conclusions • To accomplish an electric

land transport system for

Cars, Buses, Distribution

Trucks and Long Haul

Trucks we need:

• Road Bound ERS. It has a

DRAMATIC impact on societal

cost for a full electric road

transport system

• Automatic fast charging,

especially for Buses and

Distribution Trucks

5: Actors on the market

• Alstom´s ERS system has long

commersial experience

• In several cities since 2003

• 12 Million km

• Ruggedness proved

• Safety proved

• High generic

efficiency

• Ansaldo’s Tramwave

has problems un-

related to the conductive

principle

• Elways has also proven

the principle

• SIEMENS eHighway i

coming!

Conductive Alternatives

Siemens eHighway Video

A Winter view on Alstom APS

Alstom adapted to trucks

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

Thank You!