kinetic energy recovery systems
TRANSCRIPT
MT5009 Analyzing Hi-technology Opportunities Group Project
2012-2013, SEM 2
Team Members
Ding Chao A0098500H
Lin Nan A0023807L
Pan Yunru A0105848Y
Xu Mingjie A0082051U
Zhang Mingqi A0028028L
Zhu Jing A0082009M
For information on other new technologies that are becoming economically feasible, see http://www.slideshare.net/Funk98/presentations
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
Kinetic Energy Recovery System - Automotive system for recovering the
kinetic energy from waste heat generated during braking process
Energy stored in reservoir - Flywheel, Battery, etc
Utilized as auxiliary power during the accelerated process
An energy storage device releasing energy to wheels when required
Electrical KERS - use a motor-generator incorporated in the car’s
transmission which converts mechanical energy into electrical energy and
vice verse. Once the energy has been harnessed, it is stored in a battery
and released when required.
Mechanical KERS - capture braking energy and use it to turn a small
flywheel which can spin at up to 80,000 rpm. When extra power is required,
the flywheel is connected to the car’s rear wheels. In contrast to an electrical
KERS, the mechanical energy does not change state and is therefore more
efficient.
Hydraulic KERS - where braking energy is used to accumulate hydraulic
pressure which is then sent to the wheels when required.
Only 88.85 kJ required instead of 278.2,
68% energy saving.
No. Title Assignee priority date Type
EP 0016160 Vehicle braking and kinetic energy recovery system Purification Sciences Inc 20 July, 1978 compressed air
EP 0083557 Device for recovering the kinetic energy of a motor vehicle during braking and
exploiting same during speeding up Ferrero S.p.A 6 January, 1982 electrical
US 4798053 Kinetic energy reclaiming system for vehicle Chang; Jimmy C.K. 10 December, 1986 compressed air
EP 0558662 Mechanical energy storage for vehicle parking brakes Allied-Signal Inc 30 November, 1990 flywheel
EP 0645272 Recovery system for dissipated energy of an engine motor vehicle during its
running conditions Reis, Gianluigi 27 September, 1993 compressed air
US 6460332 Pressure oil energy recover/regeneration apparatus Komatsu Ltd 4 November, 1998 hydraulic
US 7293621 Vehicle drive system with energy recovery system and vehicle mounting
same Charge-O-Matic Energy Recovery
Devices, Llc 10 April, 2002 electrical
EP 1433648 Energy recovery system for a work vehicle CNH Italia S.p.A 23 December, 2002 hydraulic
US 7315088 Fluid device for recovery of the kinetic energy of a vehicle Erriu Fernando 9 July, 2003 hydraulic
EP 1561625 Engine based kinetic energy recovery system for vehicles International Truck Intellectual
Property Company, LLc 3 February, 2004 compressed air
US 7201095 Vehicle system to recapture kinetic energy Pneuvolt Inc 17 February, 2004 hydraulic
US 8290675 Recovery of energy in a hybrid vehicle having a hydraulic or pneumatic
braking system Robert Bosch Gmbh 19 August, 2005 Electrical/hydraulic
EP 1764256 Energy regenerating device for recovering kinetic energy in motor vehicles Ippolito, Massimo 20 September, 2005 electrical
US 8327637 Hydraulic energy recovery system with dual-powered auxiliary hydraulics Parker-Hannifin Corporation 28 March, 2006 hydraulic
EP 2125413 Hybrid vehicle energy management methods and apparatus Mack Trucks, Inc. 22 February, 2007 electrical
US 8111036 System for electrically connecting and disconnecting a vehicle generator from
a vehicle storage unit Stephen George Rosenstock 26 February, 2007 electrical
US 20110320074 Kinetic energy recovery and electric drive for vehicles Erlston Lester J, Miles Michael D 19 December, 2007 electrical
EP 2282907 An energy recovery system for a vehicle driveline Torotrak (Development) Limited 20 May, 2008 flywheel
US 8281587 Supercharged boost-assist engine brake International Engine Intellectual
Property Company, Llc 13 August, 2009 supercapacitor
EP 2492125 Method for recovering kinetic energy of hybrid electric vehicles, and energy
accumulator using compressed air Instituto Alberto Luiz De Coimbra 15 October, 2009 hydraulic
US 20120212042 Hydraulic assembly and brake system for a motor vehicle Robert Bosch Gmbh 2 November, 2009 hydraulic
US 8172022 Energy recovery systems for vehicles and vehicle wheels comprising the
same Toyota Motor Engineering &
Manufacturing North America, Inc 30 November, 2009 flywheel
EP 2397358 Regenerative brake system for a vehicle Paccar Inc 21 June, 2010 electrical/mechanical
US 20120080249 Front wheel energy recovery system Yates Iii William MIngram Benjamin T 4 October, 2010 hydraulic
EP 2450246 Energy recovering device for recovering energy in a vehicle ZanettiStudios S.r.l 3 November, 2010 electrical
US 8344529 Method and system for energy harvesting Energy Intelligence, LLC 18 January, 2011 electrical/mechanical
Comparison of energy storage used in vehicles
Source: Energy Storage Systems Cost Update, Sandia National Laboratories (SAND2011-2730)
April 2011
Electrical Hydraulic Mechanical
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
Technology: Energy Conversion
The vehicle’s electric traction motor is operated as a generator during braking
and its output is supplied to an electrical load.
Examples: Electrical Pancake Generator in cars
Source:
(1) Cibulka, J., “Kinetic energy recovery system by means of flywheel energy storage”, Advanced Engineering
3(2009)1, ISSN 1846-5900
(2) Lester J Erlston, Michael D. Mikes, “ Kinetic energy recovery and electric drive for vehicles”, US Patent
Application Publication, US 2011/03200074, Dec 29,2011
The Development Direction
High energy density: to store energy efficiently
High power density: to release the energy quickly
However, sometimes the development path (indicated by the arrows) is NOT
straight forward to the target.
Source: Electric Power Research Institute, “Electricity Energy Storage Technology
Options: A White Paper Primer on Applications, Costs, and Benefits”, 2010
Lead Acid Battery
Supercapacitor
Compressed Air
Energy Storage
Superconducting Magnetic
Energy Storage
Flow Battery
Application of Supercapacitors in Vehicles
Supercapacitor is one of the six key enabling technologies for electric
vehicles.
Supercapacitor manufacturers are active and many others are tending on
targeting electric vehicle sector.
Source: Dr Peter Harrop, “EV lessons from Energy Harvesting and Supercapacitors event”,
IDTechEx, 15 Nov 2012
Start a car with Supercapacitors
Source: CAP-XX, “Supercapacitors for Automotive & other vehicle application”, March
2012
Case Study -1
Source: CAP-XX, “Supercapacitors for Automotive & other vehicle application”, March
2012
Comparison with Batteries & Conventional Capacitors
Source: P Kurzweil, “Electrochemical Double-Layer Capacitors” Encyclopedia of
Electrochemical Power Sources, Pages 607-633, 2009
Cost Comparison between Battery & Supercapacitor
Cost per energy ($/kWh) of supercapacitor is almost 10 times of battery.
Cost per power ($/kW) of supercapacitor is only ~25% of battery.
Source: Andrew Burke, “Ultracapacitor Technologies and Application in Hybrid and
Electric Vehicles”, International Journal of Energy Research, July 2009
Specific properties of different supercapacitor technologies
Source: P Kurzweil, “Electrochemical Double-Layer Capacitors” Encyclopedia of
Electrochemical Power Sources, Pages 607-633, 2009
Carbonaceous materials for supercapacitors
Source: P Kurzweil, “Electrochemical Double-Layer Capacitors: Carbon Materials”
Encyclopedia of Electrochemical Power Sources, Pages 607-633, 2009
The energy density of supercapacitors are improved through using
different materials as electrode.
Source: Charith Tammineedi, “Modeling Battery-ultracapacitor Hybrid Systems For Solar
And Wind Applications”, A Thesis in Energy and Mineral Engineering , The Pennsylvania
State University, 2011
The lifecycle degradation is improved by using Carbon NanoTubes as
electrodes in superacapacitors.
supercapacitor
with CNT
Other kinds of
supercapacitor
Source: Malachi Noked, Sivan Okashy, Dr. Tomer Zimrin, Prof. Doron Aurbach,
“Composite Carbon Nanotube/Carbon Electrodes for Electrical Double-Layer Super
Capacitors”, Angewandte Chemie, Volume 124, Issue 7, pages 1600–1603, February
13, 2012
Both energy and power density are improved by using Graphene:
Energy density - 25 Wh/Kg (comparable with conventional batteries)
Power density - 10 KW/Kg (suitable for surge power delivery)
Source:
(1) Yan Wang, etc, “Super Capacitor Devices Based on Graphene Materials” , J.
Phys. Chem. C, 2009, 113 (30), pp 13103–13107, ACS, 2009
(2) Hongcai Gao, etc, “High-Performance Asymmetric supercapacitor based on
Graphene Hydrogel and Nanostrucutred MnO2“ ACS, 2012
supercapacitor
with GH//MnO2
Other kinds of
supercapacitors
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
Mechanical KERS, i.e., Flywheel KERS (Flybrid ®)
More efficient & less power loss in energy transfer
Direct translational kinetic energy to rotational kinetic energy transition
Flybrid® grows rapidly in racing cars having potential in commercial cars
Market players like Volvo, Jaguar, Ford have been actively in Flybrid®
Rotational engergy:
where
Another equation – energy density:
Material and size significantly change stored energy
Flywheel now can spin as high as 60,000RPM
400kJ usable energy storage for 60kW power transmission
Carbon fiber (25kg weight, 13L volume, A4 Paper Size)
Constraints: material tensile strength, weight, space
Year Material Weight Ultimate Strength
1940s Steel 1633kg Up to 900Mpa
1950s Titanium alloy ~800kg Up to 1100Mpa
2000s Carbon Fiber 25kg 1600 – 6400Mpa
Future Carbon Nanotube <20kg 11000 – 63000Mpa
Proportion of Kinetic Energy recoverable under braking values in Joules
Douglas. C & Chris. B, Mechanical Hybrid comprising a flywheel and CVT for Motosport & mainstream
Automotive applications, 2008
62.7%
Proportion of stored energy released back to the wheels values in
Joules
Douglas. C & Chris. B, Mechanical Hybrid comprising a flywheel and CVT for Motosport & mainstream
Automotive applications, 2008
83.9%
Carbon-fiber-
reinforced
polymer
Glass-fiber-
reinforced
polymer
Alloy
0
1000
2000
3000
4000
5000
6000
7000
1940 1950 1960 1970 1980 1990 2000 2010
Tensile Strength of Material (MPa)
Steel
Titanium
E-Glass
Laminate
Carbon Fiber
Carbon Fiber
Carbon Fiber
Toray T1000G
S2-Glass
Future:
Carbon Nanotube: 63000
Graphene:130000
0
1
2
3
4
5
6
7
8
9
1940 1950 1960 1970 1980 1990 2000 2010
Material's Density (g/cm3)
Steel
Titanium
E-Glass Laminate
Carbon Fiber
Carbon Fiber
Carbon Fiber
Toray T1000G
S2-Glass
Future:
Carbon Nanotube: 0.37-1.34
Graphene:1.00
0
500
1000
1500
2000
2500
3000
3500
4000
1940 1950 1960 1970 1980 1990 2000 2010
Specific Energy
Specific Energy (kJ/Kg)
Steel
Titanium
E-Glass
S2-Glass
Laminate
Carbon Fiber
Carbon Fiber
Carbon Fiber
Toray T1000G
0
20000
40000
60000
80000
100000
120000
140000
Specific Energy
Specific Energy
Graphene
Carbon Nanotube
Carbon Fiber
Toray T1000G
(kJ/Kg)
Advantages
High Efficiency
Low weight
Long lifespan
Wide working
temperature range
Low impact to
environment
Disadvantages
Space & size constraints
Maintenance
Safety
Materials
Newer materials: carbon nanotube, etc
Process & Design
More efficient in transmission
Gears design
Future
Opportunity of magnetic rotor
Multi-flywheel
Aircraft application
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
Axial Piston Unit + Gearbox (pump)
Hydraulic Pressure Accumulator
Pressure Relief Valve
Valve Control Block HIC
Electronic Controller RC
Initial Status
Braking Accelerating
http://www.grainger.com/Grainger/hydraulic-accumulator/hydraulic-system-
components/hydraulics/ecatalog/N-c7a
12312.5
6512.5
3568.75 2762.5
1850
$1,000
$10,000
$100,000
0 0.05 0.1 0.15 0.2
Do
lla
r p
er
Ga
l
Size (Gal)
Price per unit volumn
Hydraulic Accumulator
Hydraulic Hybrid Vehicles
Conceptual/Passenger car – minor
McLaren Mercedes used it on 1999
City Bus/Delivery Trucks/Garbage Trucks
EATON-UPS HLA project: up to 35% improved fuel economy
and up to 30% CO2 emissions reduction
Bosch Rexroth HRB for garbage trucks in Germany and US, 20-25% fuel save
and 2-3 times brake life extended.
- http://www.gizmag.com/formula-one-kers/11324/
- http://www.marketwatch.com/story/ups-to-add-40-hydraulic-hybrid-vehicles-to-its-fleet-2012-10-03
Advantages
High energy conversion
efficiency
Disadvantages
Size
Weight
Safety
Apply to heavy vehicles
Size & weight reduction
Large Diameter Flat Format (LDFF) hydraulic motors
Development of Piezoelectric Hydraulic Pump
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
KERS is a effective way to improve fuel efficiency by recovering
the kinetic energy from braking energy
Economically save the cost especially the fuel price is rising.
Environmentally, reduced waste exhaust gas that cause pollution
Currently, mostly widely adopted in the Formula 1 racing
Commercial cars launched such as Mercedes S-Series Hybrid.
http://www.youtube.com/watch?v=TgVvzoxGj_g
Battery? Flywheel? Hydraulic?
Future application in Aviation & Sailing
Technology Introduction
Three Main Categories
Electrical KERS
Mechanical KERS
Hydraulic KERS
Entrepreneurial Opportunities
Conclusion
Comparison of three technologies of KERS
KERS, with whatever technology, is still in the stage of explore and
research, such as F1 and Le Mans, where commercialization of KERS still
has a long way to go.
Technologies Scale Material Cost ($/kW)
Electrical -
supercapacitor Larger Graphene 3626-10000
Mechanical - flywheel Smaller (weight &
space constraints)
Steel, Titanium,
carbon fiber,
carbon nanotube
1950-2200
Hydraulic Larger steel, carbon fiber 2500-4300
