Platform Solutions in New York
• Johnson City, NY
– Serves multiple markets, products
and customers
– 625,000 square feet
– 1,400 employees
– 800 engineers
• Hybrid development & production
– Product design
– Development and qualification
– Manufacturing facility
– 10 dynamometer stands
– 9 engine stands
– Two vehicle modification garages
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Product design center for global business
HybriDrive® Propulsion System
• Fleet
– In production >10 years
– Serving bus manufacturers worldwide
– Shipped 3,000th propulsion system in June 2010
– World’s largest hybrid bus fleet (1,675) in New York City
– Other hybrid bus fleets: Houston, London, Ottawa,
San Francisco, Seattle, Toronto, and others
• Fleet usage
– Surpassed 200 million fleet miles in July 2010
– 1 million passengers trips daily
– 1 billion passenger trips cumulative
• Public benefits
– 10 million gallons saved cumulative
– 100,000 tons of CO2 prevented cumulative
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Leading emerging global market for hybrid buses
Evolving & Adapting Power & Energy Capabilities
Highly reliable and safety
certified vehicle management
and engine control systems
Hybrid electric propulsion/
electric accessories, leading
edge control and power
management solutions
Power management and storage
solutions for industrial, utility and
renewable energy applications
Migrated applications of
power management and
control on high performance
military aircraft
Transitioning
capabilities into
stationary energy
and power markets
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Applying power & energy experience to new markets
BAE Systems stationary energy initiative
• Primary Power – HybriGen™
– Remote Stand-alone or micro-grid connected power
• Facility Scale Integrated Energy Manager
– Commercial /Industrial power/energy management
• Large Scale Integrated Energy Manager
– Utility or large facility power/energy management
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We believe vehicle energy storage technologies can be adapted & used
Are the duty cycles compatible?
• Passenger Car-
– 5-7 days/week
– 1-4 hours/day
• Transit/Commercial Vehicle
– 5-7 days/week
– 12-20 hours/day
• Stationary Energy Application
– 365 days/year
– 24 hours/day
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Duty Cycle cont’d - Electrical
• HEV
– kW / kW-hr ratio is high
– Many “micro” cycles
– Small SOC excursions
• PHEV / EV
– kW / kW-hr ratio is moderate
– Slightly fewer “micro” cycles
– Larger SOC excursions
• Stationary
– kW-hr / kW ratio is moderate to high
– ? SOC excursions moderate to large ?
– Wide application variations
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Note
Reversal
-100
0
100
Power
0
50
100
SOC
-100
0
100
Power
0
50
100
SOC
• Simulations exist
• Some pilot data exists
• Field data will likely provide
significant corrections
Opportunities
• Research $$$$ in automotive market should elevate all technologies
– New Anode/Cathode materials
– Electrolyte chemistries
– Separator and packaging improvements
• New Large Manufacturing Facilities
– Manufacturing scale & innovations should reduce costs
– Stationary may require application specific types
• Performance & Life data on a massive scale
– PHEV’s & EV’s need to make it in the marketplace
– Hopefully some data becomes public
• Ton’s of Cheap, Used Batteries coming for stationary markets?
– HoHoHo or Bah-Humbug?
– “80% of initial capacity” model has potential issues
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Challenges
• Energy : Power ratios are reversed between vehicle & stationary
– Larger problem with HEV batteries (currently most widely available)
– Less of an issue for EV applications
• Incompatible packaging requirements
– Vehicles: Unique shapes, tight form factors, harsh environments
– Stationary: Need easy access and serviceability, controlled environment
• Huge scaling problem
– 100’s to 1000’s of equivalent vehicle packs required for many envisioned
stationary applications
– Insulation, Creapage & Clearance on vehicle modules/packs may be
inadequate for stacking to high-voltages required for some stationary
applications
• PHEV’s & EV’s still need to become mainstream
– Wide spread, low cost availability of batteries will probably lag behind for
several more years
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Summary
• Introduction and acceptance of more electric vehicle technologies will
clearly help the stationary/industrial energy storage marketplace
?and maybe the reverse?
• Storage technology & manufacturing improvements from vehicle
research will provide largest boost to stationary systems
• Vehicle battery systems are not likely to be a drop-in fit for most
stationary applications
• There is much work ahead to understand how stationary duty cycles
will affect vehicle battery systems
• Visions of limitless supply of inexpensive, used batteries from vehicle
marketplace are probably overly optimistic
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