natural gas hybridization - energy.gov...natural gas vehicle technology forum 2016 meeting business...

10/31/2016

1

Natural Gas Hybridization

NGVTF

Gas Technology Institute

Ted Barnes

22

GTI Company Overview

> Independent, not-for-profit, established in 1941

> Over 300 employees (~100 in CA)

> 350 active projects

> 1,200 patents; 500 products

10/31/2016

2

33

Reasons for Heavy Duty Hybrids

• Heavy Duty Truck Hybridization – Why?• Critical environmentally sensitive areas looking for “zero

emission” options; natural gas hybrids allow for near-term, at scale, real-world applications

• Increased range, smaller battery pack, ability to keep same duty cycle as diesel

• Fuel economy and low-end torque improvements can be substantial

• Allows for zero tailpipe emissions in critical areas for limited range or through overhead (or rail) power transfer

• NOx emissions already “near-zero” for natural gas but GHG needs constant improvement (diesel-hybrid and biodiesel have significant NOx issues)

44

Current GTI Hybrids Projects

• Energy Commission – Hybrid Trucks• US Hybrid and UC Riverside major technology partners• Two projects with natural gas Class 8 trucks

• US DOE – SCAQMD – ZECT Program• BAE and Kenworth major technology partners• Drayage truck with natural gas “genset”, BAE Hybrid

Drive propulsion, Plug-in, Pantograph for zero-emission operation

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US Hybrid © 1Natural Gas Vehicle Technology Forum 2016 Meeting

Integrated Electric, Fuel Cell and Hybrid Powertrain Components Powering Clean Mobility

Abas Goodarzi, Ph.D., P.E. & Farzad Ahmadkhanlou, Ph.D., P.E. NGVT Forum 2016


US Hybrid HQ: Torrance, CA

Year

Established 1999

Core

Competency

Electric Powertrain for

Electric, Hybrid and Fuel

Cell Heavy Duty Vehicles

Magmotor CorporationWorcester, MA

Year

Established 1876

(Acquired by US Hybrid in 2008)

Core

Competency

Servo Motors and Drives

Automation, Robotic and

Semiconductor Mfg.

US Hybrid Group

www.ushybrid.com

Honolulu, HI

www.magmotor.com

US FuelCellSouth Windsor, CT

Year

Established 2013

Core

Competency

Fuel Cell

Power Plant

Worcester, MA

Torrance, CA

South Windsor, CT

Torrance, CA

www.usfuelcell.com

2


Business Focus is Commercial Vehicles

Class 6 7 8

Category Medium Heavy Heavy

Weight Range

(GVWR)

19,501-26,000

26,001-33,000

>33,000

ExamplesRefuse

Constructions Drayage

Shuttle Bus

Business Focus is Heavy Duty

Commercial Vehicles

Bucket

Municipality Agriculture

Transit BusDelivery

Mining

Monorail

Sao Palo Brazil

KL Malaysia

Mumbai, India


FC BOP

Utility Van

1999 2002 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

EV & FC Scooter

FC BOP to UTC Parallel Hybrid

Parallel Hybrid Series Hybrid Series Hybrid

Series Hybrid PHEV Hybrid

PHEV-Turbine

240kW

Parallel Hybrid

PHEV NG Hybrid

Near Zero Emission Powertrain

Battery ElectricDrayage Truck

Monorail Traction

PHEV Electric

200kW 320kWPM-APU

We have been making and operating Hybrid Heavy Duty Commercial Vehicles for decades

Self Powered Carts

US Hybrid Time Line

http://www.handtrucksystems.com/food service.htm

http://www.handtrucksystems.com/food service.htm

http://www.bauersit.com/transit/

http://www.bauersit.com/transit/

3


Municipality Agriculture

Transit BusDelivery

Mining

Monorail

Sao Palo Brazil

KL Malaysia

Mumbai, India

0

5

10

15

20

25

30

35

40

UDDS 10 mph 20 mph 40 mph 60 mph

Regular Ramp

Ene

rgy

(kW

h)

Drive Cycle

Drag

Acceleration

Rolling

Speed19 mph

GVWR36,300 kg

80,000 lbs.

More than 50% of energy is wasted due to traffic

0

1

2

3

4

5

6

7

8

UCR 5 mph 10 mph 15 mph

Regular Ramp

Ene

rgy

(kW

h)

Drive Cycle

Braking

Drag

Acceleration

Rolling

Speed Ave.

7 mph

GVWR29,545 kg

65,000 lbs.

0

2

4

6

8

10

12

14

Den

ver

Wes

t V

irgi

nia

OC

TA

5 m

ph

10 m

ph

15 m

ph

Ene

rgy

pe

r u

nit

dis

tan

ce (k

Wh

/mile

)

Drive Cycle

Idling lost

Hotel load

Braking (lost)

Drag

Acceleration

Rolling

GVWR20,450 kg

45,000 lbs.

Speed7 mph

Speed9 mph

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

UDDS US06 J45

59% 47% 57%

Ener

gy (

kWh

)

Drive Cycle:

Ave Speed:

Stop/Go (Traffic)Constant

32 kph20 mph

80 kph50 mph

23 kph14 mph

GVWR1,800 kg

Transportation Engineering; Decoupling Traffic


LNG or CNG?

Volumetric Ratio:LNG=1.7 DGE

CNG=3.8 DGE

4


Class-8 Truck Powertrain System Configuration

Fuel Cell Electric Class-8 Truck Powertrain System Configuration

SAE J2601 Standard 25 kg, 350 BAR Fuel Cell, 80kW

Fuel Cell Electric

LNG/CNG Plug-in Hybrid Electric

LNG/CNG Hybrid Electric


LNG/CNG Plug-in Hybrid Electric Powertrain

BMS

Li-Ion Battery

80kWhr

High Voltage Distribution

Electro-Hydraulic Steering

Electro-Air System

DC-DC: 200A, 27.6V

Controller

Cummins ISL-GAuto

Clutch

Electric Motor 300 hp

Transmission

iDriveTelematics

On-board20-kW Charger

EVSE-TTSI interface

Peterbuilt LNG Truck• Model 384 with ISL-G engine• Wheelbase was 189”• Suspension, spring front and air rear. • Stock weight is 13,360lbs.

Enabling Near Zero Goods MovementDouble Power, Torque and Fuel Economy, 80% less NOx

5


Electric Regen Braking Electric only operation during que and traffic Idle control (Engine off operation) Manages low duty engine operation

LNG/CNG Hybrid Electric Powertrains


0 500 1000 1500 2000 2500 3000600

800

1000

1200

1400

1600

1800

Speed (RPM)

To

rqu

e (

N.m

)

0 500 1000 1500 2000 2500 30000

50

100

150

200

250

300

Speed (RPM)

Po

we

r (k

W)

500 1000 1500 20000

200

400

600

800

1000

1200

1400

Speed (RPM)

To

rqu

e (

N.m

)

500 1000 1500 20000

50

100

150

200

250

Speed (RPM)

Po

we

r (k

W)

Specs of Electric Motor and Engine

Electric motor ISL-G 320 Engine (8.9 Liters)

1365 N.m @ 1300 RPM

240 kW

1700 N.m @ 1500 RPM

260 kW350 hp

6


Double Power and Torque


Modeling and Simulation

7


Conventional versus EV and HEV

0 50 100 150 200 2500

20

40

60

80Speed

Time (s)

Sp

ee

d (

mp

h)

Conventional-Loaded

Conventional-Unloaded

EV-Loaded

EV-Unloaded

HEV-Loaded

HEV-Unloaded

0 2 4 6 8 10 12 14 16 18 200

1

2

3

4Acceleration

Time (s)

Acce

lera

tio

n (

m/s

2)

Conventional-Loaded

Conventional-Unloaded

EV-Loaded

EV-Unloaded

HEV-Loaded

HEV-Unloaded


Speed and Acceleration

8


Torque and Power


Drive Cycle 1: Port 710-110

0 1000 2000 3000 4000 5000 6000 7000 80000

20

40

60

80

Time (s)

Sp

ee

d (

mp

h)

Composite of Drayage and Highway

9


Battery Energy and SOC

0 10 20 30 40 50 60 70 80 900

20

40

60

80

100Battery SOC

Distance (mile)

SO

C (

%)

Unloaded

Loaded

0 10 20 30 40 50 60 70 80 900

20

40

60

80Battery Energy Available

Distance (mile)

En

erg

y (

kW

h)

Unloaded

Loaded

Charge Depleting

EV ModeCharge Sustaining

HEV Mode


Simulation Results

ParameterPHEV Conventional

Loaded Unloaded Loaded Unloaded

Torque Tmax (N.m) 2856 1517 1354 1304

Power Pmax (kW) 478 303 239 239

Power Pave (kW) 140 79 144 96

EV Range (miles) 19.5 39.7 0 0

MPG (Diesel Equivalent) 5.0 9.2 4.1 6.8

Fuel Efficiency Increase +22% +35% - -

Considering the idling time, the fuel economy is doubled

10


Drive Cycle 2: Drayage Port-Ware Houses


Battery SOC

0 50 100 150 200 250 3000

20

40

60

80Battery Energy Available

Distance (mile)

En

erg

y (

kW

h)

Unloaded

Loaded

Charge Depleting

EV Mode

Charge Sustaining

HEV Mode

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Simulation Results

ParameterPHEV Conventional

Loaded Unloaded Loaded Unloaded

Torque Tmax (N.m) 3012 3003 1356 1356

Power Pmax (kW) 478 474 239 238

Power Pave (kW) 74 33 78 34

EV Range (miles) 22.7 58.6 0 0

MPG (Diesel Equivalent) 5.8 13.0 4.7 10.3

Fuel Efficiency Increase +23% +26% - -

Considering the idling time, the fuel economy is doubled


Hybrid Electric LNG/CNG Class 8 truck

Li-Ion Battery 28kWhr

Electro-Hydraulic Steering

Electro-Air System

DC-DC: 200A, 27.6V

Controller

Cummins ISL-GElectric Motor

200 hp Automated

Transmission

iDriveTelematics

Peterbuilt LNG Truck• Model 384 with ISL-G engine• Wheelbase was 189”• Suspension, spring front and air rear. • Stock weight is 12,000 lbs.

Commercially viable Near Zero Goods MovementHybrid Electric ISL-G at the same cost as ISX-15G

with double the range/fuel economy

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LNG/CNG Hybrid Electric Powertrains


LNG/CNG Hybrid Electric Vehicle

13


LNG/CNG Hybrid Electric Specification


Fuel Cell Electric Heavy duty Powertrain

Fuel Cell Electric Class-8 Truck Powertrain System Configuration

SAE J2601 Standard 25 kg, 350 BAR Fuel Cell, 80kW

Plug-in

Hybrid

Battery

Electric

Hybrid

Electric

Fuel Cell

Electric

Zero & Near Zero Emission Road map

14


Charge Fueling Time and Convenience

0

1

2

3

4

5

0 60 120 180 240

Mile

s p

er m

inu

te c

har

gin

g/fu

elin

g

Charger Size (kW)

Miles per minute of Charging

Tesla/Leaf/Volts

Transit Bus (18T)

Semi-Truck (37T)

0

5

10

15

20

25

30

35

CNG Gasoline H2 Diesel

Mile

s p

er m

inu

te c

har

gin

g/f

uel

ing

Fueling Type

Miles per minute of Refueling

Semi-Truck

Transit Bus

Limitation of Battery Electric MD/HD Trucks


Conclusions

- Take up more space

- Refueling takes considerably longer

+ Safety advantage in the case of a leak

+ Lower cost to produce and store

+ Double the range (miles) with Hybrid

+ No need to fuel twice a day saves time

Hybrid NG Electric, Commercially feasible, Commercial Delivery: Q2-2017, taking orders now

• Plug-in Hybrid Electric with 30 miles Battery range (dual battery)

• Hybrid Electric with 5 miles, 30 minutes Port queuing battery

operation (single battery)

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Thank you!Abas Goodarzi, Ph.D., P.E.

President

[email protected]

Farzad Ahmadkhanlou, Ph.D., P.E.

[email protected]

www.ushybrid.com

www.usfuelcell.com

mailto:[email protected]

mailto:[email protected]

http://www.ushybrid.com/

http://www.usfuelcell.com/

natural gas hybridization - energy.gov...natural gas vehicle technology forum 2016 meeting business...

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