2
GKN Hybrid Power – Success and Growth
Growth of the GKN Hybrid Team
This team has developed a leading technology, now moving into production
Heads Achievements
2007 4 F1 system developed
2008 5 F1 system run
2009 10 Porsche GT3R Hybrid developed
2010 15 Porsche Hybrid raced & won
2011 25 Audi e-tron Quattro developed; WHP’s
investment in industrialization
2012 35 Bus & Tram demonstrator contracts; Audi R18 e-
tron quattro raced & won
2013 46 Bus demonstrator efficacy proved; Significant
increase in interest within bus industry; Audi R18
e-tron quattro 2.0 raced and won
2014 98 Pre-Production Orders for 500+ Bus systems.
Alexander Dennis Partnership. Audi R18 e-tron
quattro 2.0 raced and won; DSTL contract and
…..we’re now GKN
3
Flywheel Hybrid System - Principle of Operation
FESS = Flywheel
Energy Storage
System
1-Power Inverter
2-Motor Gearbox
3-HV Bus
4/5-FESS
4
The Mk4 Flywheel – Section View
Sensor Harness
Connector
Top
Containment
Upper Bearing
Stator Cooling
System
Lower Bearing
Bearing Housing
Fixings between
Containments
Lower Containment
Anti Vibration Mount
Flywheel Assy
Mounting Screws
Pressure Burst
Discs
Phase
Connection
Stator Cooling
Connection
Bearing Cooling
Connection
Stator
Carbon Rotor
MLC
Glass Ring
Rotor End Cap
Rotor Shaft
Rotor Nut
Mounting Plate
(Vehicle)
Mk 4 Flywheel Assembly Section
5
The Flywheel Rotor
• Filament wound carbon T800
• MLC for rotor magnetics
• Super precision fits and tolerances
• Carbon Fibre end cap F1 technology
6
Energy and Power – Why Flywheels?
A123 Li-ion
(Battery)
Maxwell Boostcap
(Super Cap)
GKN HP
MK4 Flywheel
Cont. input 120 kW Cont. input 120 kW Cont. input 120 kW
240 kg 370 kg 55 kg
~1,000 cycle life ~1,000,000 cycle
life
>1,000,000 cycle
life
390 kJ/kg 6.3 kJ/kg 30 kJ/kg
93.6 MJ 2.4MJ 1.6MJ
0.5 kW/kg 0.35kW/kg 2.2kW/kg
(6 kW/kg Msport)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0
20
40
60
80
100
120
140
0 5000 10000 15000 20000 25000 30000 35000 40000
Me
chan
ical
En
erg
y kJ
Ele
ctri
cal
Po
we
r (k
W)
RPM
Power & Energy : 400V Electrical Power (kW)
Mechanical Energy (kJ)
Boost Power up to 120kW
for Bus and ~300kW for
Msport.
Power Delivery / Harvesting
for 2-10 seconds
Think about the Mass
The Flywheel uses ~80% of its stored energy per cycle.
Life costs…. Flywheel 15 years……Battery 4 years
Disposal cost and environmental impact !!
Power / Energy
7
Flywheel Key Facts
Centrifugal force –
250,000 x gravity
Mass of 6.5g > 1.6T
80,000,000 Fibres
Population of Germany
Rotor surface speed
600 m/s (Mach 1.8)
Rotor Energy 1.2 MJ
4 Hobnobs
Centre of balance accuracy 2 um
1/100 diameter of human hair
9
Hybrid Bus Programme
Through the motor / generator in the
driveline the Gyrodrive flywheel
captures the kinetic energy during
braking and reuses it to help accelerate the bus.
GKN Motor &
Gearbox
GKN HP
Flywheel
Power
Electronics
BRAKING
ACCELERATING Re- Gen Braking
Saving
Up to 25% depending on route
10
The Gyrodrive Cubicles
Mk 4
Flywheel
Power
Inverters
FW /
MGU
Vacuum
System System
Controller
Cooling
and Oil
Circulation
HV
Power
11
Bus Installation FESS and MGU
Motor
and
Gearbox
Unit
FESS
Concept
Design
WRIGHTBUS
Installation
Alexander
Dennis E400
Installation
Design……...……….. Develop…………………. Realise
12
GKN Hybrid Power – Building Commercial Success
We drive the wheels
of hundreds of
millions of cars…
We help thousands
of aircraft to fly…
Reliable
Operation
Real World
Results
Commercially
Viable
• Initial Focus UK Bus market
30,000 buses in UK
8,000 in London – dominates UK market
Split between Retro fit and New Build
• Retro –fit programme with Go-Ahead
supported by TSB funding
• OEM Project with ADL supported by APC
funding
13
Parallel Hybrid Bus • Kinetic energy re-used
• Diesel Engine sized for
peak performance
Cost Increase offset
by fuel save
Parallel Hybrid System
Re- Gen Braking
Saving
Up to 25% depending on route
14
What is the Market? F
ue
l S
ave
Annual Mileage
50,000 150,000 100,000 200,000
Bus
Refuse
Trucks
Light CV Heavy CV
Payback map
15
Parallel Hybrid Bus • Kinetic energy re-used
• Diesel Engine sized for
peak performance
Series Hybrid Bus System
Optimised Engine
Fuel Use Saving
28 %
Re- Gen Braking
Saving (average)
20 %
+ = Total Saving
42 %
Cost Increase offset
by fuel save
Series Hybrid Bus • Engine sized for average
power use
• Peak power demands met
from flywheel
• Kinetic energy re-used
• Greater fuel saving
• Savings in engine,
transmission and driveline
costs offset system costs
Fu
ture
Deve
lop
me
nt
Small engine and
deleted driveline
offset on cost
16
Series Hybrid Benefit F
ue
l S
ave
Annual Mileage
50,000 150,000 100,000 200,000
Bus
Refuse
Trucks
Light CV Heavy CV
Payback map
17
Parallel Hybrid Bus • Kinetic energy re-used
• Diesel Engine sized for
peak performance
Hybrid Bus Systems
Battery EV Bus • Flywheel used to manage
energy flow
• Kinetic energy re-used
• Higher range
• Longer battery life
Series Hybrid Bus • Engine sized for average
power use
• Peak power demands met
from flywheel
• Kinetic energy re-used
• Greater fuel saving
• Savings in engine,
transmission and driveline
costs offset system costs
Fu
ture
De
ve
lop
me
nts
18
Delivery Truck
Engines
Smallest Largest
Power kW 115 220
Torque Nm 650 1,200
Cylinders 4 6
Size l 5.1 7.7
Smallest EVO 140
Combined
Power
kW
115 94 209*
Torque
Nm
650 600 1,250
* Limited by flywheel capacity so will restrict gradient climbing ability
Alternative engine
Smaller higher speed diesels (derived from
passenger cars) will allow further downsizing
3.5l 190kW 650Nm could improve efficiency further
Parallel Hybrid
Series Hybrid
20
Benefits of eDrive Hybrid Technology
Engine Downsize
Saving
24 %
Re- Gen Energy
Saving
25 % + =
Total Saving
43 %
Energy
to move,
lift, shift
Mechani
cal
losses
Energy
lost in
braking
Ancillary
losses
Engine sized to produce maximum workload Engine sized to produce the average power requirement
Braking
Energy
Re-captured
Power on
demand to
ancillaries
Average
Power
Requirement
Current Drivetrain eDrive Series Hybrid Drivetrain
21
Wheel Loader Shovel Concept
Wheel Loader eDrive Hybrid Wheel Loader
Hidden Benefits
Design freedom for engine package
Eliminate operator error
Ease of Control
Noise Reduction
Generator
− 3l Engine
− 72 kw
− GKN EVO AF140 Generator
GKN EVO AF 240 Drive motors
− Power 188 kW (Peak 400 kW)
− Torque 520 Nm (Peak 1,200Nm)
Electric driven hydraulics & cooling
Power balance through on-board GKN Hybrid
Flywheel energy store
8L Engine
Power 170 kW
Torque 1,160 Nm
23
Industrial FESS System (20MJ)
Source:
Flywheel Controller
Mk8 Flywheel
FW Inverter
Flywheel
Ancillaries
LoadMk8 Flywheel Module (x6)
Flywheel Energy Storage System (FESS)
Co
ntr
ol
Co
ntr
ol
Co
ntr
ol
FESS Supervisor Controller (FSC)
Power Supply
System Application Controller (SAC)
HV DC Bus
Co
ntr
ol
Co
ntr
ol
Power
Distribution
Co
ntr
ol
Safety Circuit
Co
ntr
ol
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