FutureProofingTTI Vanguard -- Advanced Technology Conference

Tokyo, JapanJune 19, 2012

Innovation of Complex Systems

(in Two Short Years):

OLEV and MH

Nam P. Suh

KAIST

Thank you for the invitation to speak!

Gordon Bell

Hal Levin

Why?

1. Why does it take so long to develop engineered systems?

2. Why do major corporations miss the delivery dates of their newly

developed systems?

3. Why does the cost of development often exceed the original estimated

cost?

Plausible causes?

Is it the excessive reliance on experience?

or

too much reliance on detailed analyses of sub-systems while ignoring the

system-level theoretic design issues?

Examples of Innovative Engineering Systems: Two Disruptive Technologies Created at KAIST

•On-Line Electric Vehicle (OLEV)

•Mobile Harbor (MH)

Video of OLEVVideo of OLEV(On-Line Electric Vehicle)(On-Line Electric Vehicle)

Mobile Harbor (video)

Selected as the second most promising technology by an

Australian organization

Universities do not teach

“design of complex large systems”. Why?

Special Programs @ KAIST

Renaissance Ph.D. Program

Freshman Design Course

What is the most difficult first step in technology innovation?

Money?

Clever people?

Invention?

My answer:

Discovery or identification of the problem (need) that requires

solutions!!

What is the most difficult step in creating the innovative system, after

the problem (need) is identified?

Rational design of the system

that satisfies the highest-level FRs and constraints at all times!

Rational design = No Functional Coupling throughout the entire

system!

How do we create an engineering system?

1. Satisfy certain specific societal needs.

2. FRs at the highest level must be satisfied at the same time within a set of constraints.

3. FRs must be decomposed to create lower-level FRs, a top-down approach.

4. We design and create DPs to satisfy all the FRs at all levels, layer-by-layer.

5. When design is completed, FRs at a given level must be independent of other FRs.

Why OLEV?•Energy, Environment, Water, Sustainability (EEWS)

•CO2 problem -- 50% reduction by 2050

•Elimination of IC engines from automobiles•Lithium Battery -- expensive, heavy, big, safety

•OLEV -- Funding history•Opposition -- why?

•Remarkable achievement -- two years from concept to realization

Mobile Harbor (MH)

•Singapore harbor

•Larger and larger container ships•$2~3 billion to build a large harbor with deep water

(>15 m)•Environmental problems -- 9 km of shore land

•Two years from concept to demonstration on open sea (2009 to 2011)

Secret behind the fast realization of the technology, i.e., two years

Axiomatic Design Theory

Clearly Define the Goal

1. Do you want to go to Korea?

2. Do you want to Boston, U.S.A.?

Many different ways of achieving the goal

• Once you defined the goal (FRs), there are many different ways of achieving the goal.

• Choose the most promising method.

(robust design)

What should we do,when there are more than one goal?

• Water faucet problem

• Two goals:– Control the flow rate of water

– Control the temperature of water.

When we choose DPs, FRs must remain independent.

Or

Maintain the independence of FRs.

When we choose DPs, FRs must remain independent.

Or

Maintain the independence of FRs.

Water Faucet Design

Water Faucet Design

I used AD to innovate many things.

• Axiomatic design

– Independence Axiom

– Information Axiom • Many examples other than OLEV and MH:

– Mixalloy (TiB2/Cu dispersion strengthened alloy)

– Microcellular plastic (MuCell)– Charge decay NDE– USM foam molding technology– Lamination process

Functional Domain

Customer Environment

Physical Domain

ProcessDomain

Customer Needs

Functional Requirements

Design Parameters

Process Variables

Axiomatic design: Mapping, hierarchies, and zigzagging

What? How ?

What? How ?

◈◈ Proving of original technology by implementing the research achievements in the field.Proving of original technology by implementing the research achievements in the field.◈◈ Verification on safety and reliability of OLEV technology at the public place.Verification on safety and reliability of OLEV technology at the public place.◈◈ OLEV test bed system needed to commercialize technology.OLEV test bed system needed to commercialize technology.

OLEV tram starts COMMERCIAL OPERATION at Seoul Grand ParkOLEV tram starts COMMERCIAL OPERATION at Seoul Grand Park

• FR1 = Propel the vehicle with electric power

• FR2 = Transfer electricity from underground electric cable to the vehicle

• FR3 = Steer the vehicle

• FR4 = Brake the vehicle

• FR5 = Reverse the direction of motion

• FR6 = Change the vehicle speed

• FR7 = Provide the electric power when there is no external electric power supply

• FR8 = Supply electric power to the underground cable

FRs of the On-Line Electric Vehicle (OLEV)

Constraints (Cs)

• C1 = Safety regulations governing electric systems

• C2 = Price of OLEV (should be competitive with cars with IC engines)

• C3 = No emission of greenhouse gases

• C4 = Long-term durability and reliability of the system

• C5 = Vehicle regulations for space clearance between the road and the bottom of the vehicle

DPs of OLEV

• DP1 = Electric motor

• DP2 = Wireless power transfer system

• DP3 = Conventional steering system

• DP4 = Conventional braking system

• DP5 = Electric polarity

• DP6 = Motor drive

• DP7 = Re-chargeable battery

• DP8 = Electric power supply system

Design Matrix

{FRs} = [DM] {DPs}

[DM] must be either

Diagonal -- > Uncoupled Design

Or

Triangular --> Decoupled Design

Decomposition of FR2 and DP2

FR2 = Transfer electricity from underground electric cable to the vehicle

DP2 = Power transfer system

Decomposition of FR2

FR21 = Generate an alternating magnetic field

FR22 = Control the power level of the magnetic field

FR23 = Shape the magnetic field to control the height of the field, H

FR24 = Control the radiation (EMF)

FR25 = On/Off the magnetic field

FR26 = Maximize the pick-up of the power in the alternating magnetic field created under the ground for use in the vehicle

Decomposition of DP2

DP21 = Underground power lines with AC field surrounding the magnetic core (ferrite)

DP22 = Electric power level, i.e., current (I) times voltage (V), at a given frequency

DP23 = Width of the magnetic poles established by the magnetic core in the ground

DP24 = Active or passive shields for EMF

DP25 = Switches that turn on/off the underground power

DP26 = Pick-up unit mounted on the car that resonates the frequency of the alternating magnetic field

Decomposition involves only the diagonal elements, but …

Decomposition involves only the diagonal element, but the off-diagonal element must be checked for possible

coupling.

Ferrite

Pick-up system

Shaped Magnetic Field in Resonance

Power supply system

SMFIR (Shaped Magnetic Field in Resonance)

• On-Line Electric Vehicle (OLEV)

Examples of Large Complex Systems

구 간 길 이

1 구간 122.5m[24mx5+2.5m]

2 구간 122.5m[24mx5+2.5m]

3 구간 122.5m[24mx5+2.5m]

4 구간 5m[2.5m+2.5m]

급전구간 : 372.5m급전구간 : 372.5m

1144

33

22

급전∙수전인프라급전∙수전인프라

: 인버터 위치 : 맨홀의 위치 : 케이블 트랙길이 : 배전선 : 공동구내 배선

서울대공원 OLEV 시스템 개요

Batteries: Major Roadblock for Mass Adoption of Electric Vehicles

• EV Battery Problem– Weight– Cost– Limited driving range– Long recharge time– Plug-in charging, manual user experience

• KAIST Online Electric Vehicle (OLEV) technology solves EV battery problem– 80% smaller battery size with less cost and weight– Stationary or “in-motion” charging with no need to pull out of service for

recharge– Automated charging with no manual efforts

© 2011 OLEV Technologies, Inc. All Rights Reserved. 36

The OLEV Technology – Key Differentiators

Challenges Breakthrough Innovations

“In-Motion” Charging

Real-time, dynamic charging with variable length segment control to provide safe, peak power and no down-time operation

High Power Capacity Over 100kW to power heavy-duty (HD) vehicles

High Efficiency Over 83% end-to-end power transfer efficiency

High Ground Clearance

Over 8” to meet bus operating requirements

Safety Electromagnetic field (EMF) well below international standards on human safety

© 2011 OLEV Technologies, Inc. All Rights Reserved. 37

The OLEV Technology – EMF, EMI Safety

• International Standards for Electromagnetic Field (EMF) Safety

• Electromagnetic Interference (EMI) – No interference with radio devices

© 2011 OLEV Technologies, Inc. All Rights Reserved. 38

Public Exposure Limits mG (milli Gauss)

Country/Organization OLEV Equipped Vehicle Meets Specified Requirements

62.5 mG Korea 200 mG ICNIRP 2000 mG IEEE

Case Study - Energy Cost Savings*

© 2011 OLEV Technologies, Inc. All Rights Reserved. 39

Bus Type Annual Fuel Cost ($) Unit $/Fuel

Unit $/Mile

Diesel (40 ft) $ 52,000 gallon $ 4.00 $ 1.30

Diesel Hybrid BRT (60 ft) $ 43,000 gallon $ 4.00 $ 1.08

CNG (40 ft) $ 32,000 MBTU $ 20.96 $ 0.80

OLEV (60 ft) $ 18,000 kWh $ 0.10 $ 0.46

*Estimates based on 40,000 annual miles, $4.00 per diesel gallon and $0.10 per kWh. These numbers are illustrative comparison purposes only.

Case Study - CO2 Emission Reduction*

© 2011 OLEV Technologies, Inc. All Rights Reserved. 40

Bus Type Annual CO2 Emission (tons) Unit

CO2/Unit(lbs)

Unit/Year

Diesel (40 ft) 132 gallon 22.377 12,983

Diesel Hybrid BRT (60 ft) 110 gallon 22.377 10,819

CNG (40 ft) 93 MBTU 133.47 1,529

OLEV (60 ft) 0 kWh 0 182,212

OLEV (60 ft) - grid* 69 kWh 0.83428 182,212

*Estimates based on 40,000 annual miles, $4.00 per diesel gallon and $0.10 per kWh. These numbers are illustrative comparison purposes only.

Mobile Harbor (MH)

Rate Limiting Process in Ocean Transportation Systems

“Why should ships come into harbor?”

Why couldn’t a harbor go to the ship?

The Concept of a Mobile Harbor

Creativity of KAIST - MH(July 31, 2008 file)

• “Why should large container ships come into harbor?”

• “Why shouldn’t harbor go out to the ship?”

• “Why should large container ships come into harbor?”

• “Why shouldn’t harbor go out to the ship?”

• Execute high speed loading and unloading in the wavy open sea

• Deploy original, advanced technologies

Large Containership

Draft 15m Shallow or Congested port

Large Containership

Draft 15m Shallow or Congested port

Large Containership

Draft 15m Shallow or Congested port

Mobile Harbor (MH)

Examples of Large Complex Systems

•Mobile Harbor (MH) : “Why should large container ships come into harbor?” “Why shouldn’t harbor go out to the ship?”

21/24

EUROPE ASIA

S. AMERICA

OCEANIA

AFRICA

N. AMERICA

• 항만 증설이 어려운 지역

• 수심이 낮은 연안

• 항구 인프라 미비지역

• 물동량 적체 지역

• 파나마 운하지역

• 항만 증설이 어려운 지역

Possible Regions for Use of MH

Three Laws of Innovation(N. P. Suh, 2010)

•The 1st Law: – Innovation continuum

•The 2nd Law: – Nucleation of innovation hub

•The 3rd Law: – The rate of nucleation versus the rate of diffusion

Thank you.