Plug-In-Hybrid Bus Propulsion SystemsSystems
PHEV-Conference-Winnipeg-Nov. 2007
G. Paul Zanetel, P. Eng.Chief Technical Advisor: New Flyer IndustriesChief Technical Advisor: New Flyer [email protected] i R D i E i i U i it f M it bE-i-R , Design Engineering, University of [email protected]
GPZ 1
Presentation Outline
BackgroundBackgroundWhat are the problems?Are Hybrid PHEV Transit Buses possible?F t d l t f t i bl / lFuture developments for sustainable/clean transportation.
Questions?Questions?
GPZ 2
Background Problem # 1Background Problem # 1
Current Status of Fossil Fuels in N.A.:Numbers are estimated years of supply at current
ti t d b t k dconsumption rates and best known ground reserves. New discovery rates are lower than population growth ratesrates. Fossil Fuels Canada N.A. WorldEasy Oil 15 12 40Easy Oil 15 12 40Easy Oil+Tar Sands 150 33 46Natural Gas 9 10 67Natural Gas 9 10 67Canada and USA Transportation is 99% fossil fuel dependent Thus unsustainable
GPZ 3
dependent. Thus, unsustainable.
BackgroundgOil Consumption, CO2 Emissions
30000
35000
mis
sion
s
Annual OilConsumption Mm3Annual CO2Emissions, MMT
20000
25000
m3,
CO
2 em
MT
Oil Reserves,10Mm3
5000
10000
15000
umpt
ion
Mm
MM
5000
0
5000
2000 2010 2020 2030 2040 2050 2060Oil
Con
su
-5000
Time, year
GPZ 4
Background Problem # 2Background Problem # 2Waste heat 2/3
Energy Transformer
Waste heat 2/3Fuel production
Basic Thermodynamic process:Fuel Energy
Energy Transformer Useful work 1/3
Fuel Energy
Oxygen/Air Emissions,CO2,NOx,PMEmissions,CO2,NOx,PM
GPZ 5
BackgroundBackground
Vehicle use engine that transforms chemical energy in the fuel to mechanical energy, through combustion processprocess.Combustion process generates emissions:CO2 green house gas influencing atmospheric dynamicCO2, green house gas influencing atmospheric dynamic behavior, current transportation generates about 30% of NA(Canada , USA) emissions about 2.2 BMT.(Ca ada , US ) e ss o s aboutNOx, NO, NO2,afecting lungs efficiency, irritates bronchial tubes and reduces oxygenation capacity of the yg p yblood. Transportation generates about 50% of NOx.PM10, aggravate respiratory ailments.
GPZ 6
Reduce Vehicle EmissionsReduce Vehicle Emissions
See the Toronto CN Tower?
GPZ 7
Reduce Vehicle EmissionsReduce Vehicle Emissions
Now you don’t, the CN Tower disappears in the smogg
GPZ 8
Reduce Vehicle Emissions
GPZ 9
Problem # 2 Re definedProblem # 2 Re-defined
C d N ti l G l d 50% f CO2 i i bCanada National Goal: reduce 50% of CO2 emissions by 2050.What does it mean?: By 2050 at least 60% of theWhat does it mean?: By 2050 at least 60% of the primary energy must come from renewable sources, carbon neutral, and transportation must at least reduce it d d f il f l b b t 50%its dependency on fossil fuels by about 50%. Increase investment on public transportation.Increase vehicle efficiencies to at least compensate forIncrease vehicle efficiencies to at least compensate for the natural fleet annual growth. NA vehicle fleet may increase by about 40% on 2050.y
GPZ 10
Buses are Cleaner than cars/SUVBuses are Cleaner than cars/SUV
Vehicles CO2 Emissions, g/km-person
45erso
n
2025303540
ns, g
/km
-p
Vehicles
05
101520
2 Em
issi
on
Diesel
BusCNG Bus
iesel
HEV BusSUV, g
asSUV, H
EVpa
ct Car,
gas
act C
ar, di
esel
pact
Car, H
EVCO
2
Die
Comp
Compa
cCom
pa
Vehicles Type
GPZ 11
Toward Solving Problem #1Toward Solving Problem #1
Viable options to change the fuel energy mix forViable options to change the fuel energy mix for transportation, with maximum impact in the shortest possible time: Biofuels, upper limit benefits about 30% , assuming cellulosic bio-fuel and minimum impact on food production.pMaximize introduction of hybrids propulsion systems, benefits about 30%. At least 30 years to achieve. Vehicle change over every 15 yearschange over every 15 years.Introduce electric fuel by tapping into electric grid for some classes of vehicles such as: commuter cars,
h l b l t i t i t ll b F M it bschool buses, electric trains, trolley buses. For Manitoba, benefits can be large in both reduction of CO2 and reduced fossil fuel consumption. Manitoba Hydro can f l 300 000 ith t ddi ti
GPZ 12
fuel up some 300,000 cars without adding generating capacity.
Is PHEV Bus Feasible?Is PHEV Bus Feasible?
City Bus Performance Requirements:City Bus Performance Requirements:GVW:19,000 kgDuty Cycle: 50 cycles per hour, 200,000 cycles per year.Duty Cycle: 50 cycles per hour, 200,000 cycles per year.Top speed: 80kphAverage working speed: 25 kph.Acceleration: 0 to 30 kph in 10 sec.Gradability: 16% at 12 kph.Operating range: 500 kmOperating range: 500 kmAccessories load: 20 kWTypical energy requirements: 3. kWh/kmTypical energy requirements: 3. kWh/kmRegen Power required: 240 kW during 10 sec.Typical diesel fuel economy: 1.3 km/l (3.1 mpg)
GPZ 13
Vehicle Mobility DemandVehicle Mobility Demand
Bus Power Requirements, kW
250
200
W
Mobility PowerEngDrAcc
100
150
Pow
er, k
W
gElectDrAccPWREnDrAccPWRELDrAcc
50
MHDD EngineHHDD Engine
00 50 100 150
Bus Speed, kph
GPZ 14
Vehicle Energy Cycle demandVehicle Energy Cycle demand
50 kph , Bus Cycle Power Profile, kW
250
100150200250
050
100
ower
, kW Cycle Total Power, kW
Accessories Power,kW
-150-100
-50 1 7 13 19 25 31 37 43 49 55Po kW
-200
Cycle Time, sec
GPZ 15
ENERGY FLOW
EngineGEN400VAC
GasolineInverter 1 Generator
M1CGB
GENMOT1 Zebra Battery
and/or
Motor 1400VAC367-667VDC
M2CGB
AUXMOT2
and/orUltraCap
Motor 2
AccessoriesInverter 2 Auxiliary
230VAC
AC/DC
230VAC Braking Resistors
AC M PS AIRACCESSORIES
SIEMENS ELFA SYSTEM
GPZ 16Air Conditioning Motor Power Steering Air Compressor
Vehicle sources of energyVehicle sources of energy
F l Wh/k Wh/L W/k Lif l tFuel: Wh/kg Wh/L W/kg Life-cycle-cost
Lead-Acid 30 75 250 1.5Ni-MH 65 150 200 1.5Ni-Zn 65 130 800Li NanoPH 90 150 300 1 8Li-NanoPH 90 150 300 1.8Zn-Air 250 250 ??Ultra-C 10 1000 1.5FTPHEV 3,333 140 2.0
Diesel 4 100 480 0 65Diesel 4,100 480 0.65Bio-Diesel4,100 480 0.65FCH2 1,100 370 6.0
GPZ 17
Energy Storage SelectionEnergy Storage Selection
F PHEV lik HEV E St C itFor PHEV, like HEV, Energy Store Capacity Selection is Critical:O ti d t i th tOperating range determine the energy storage capacity.A l ti d ti d t i thAcceleration and regeneration determine the power requirements.F hi l th t h ld bFor vehicle the energy storage mass should be below 10% of CVW.B tt l t fBattery mass, largest of range or acceleration/regen and < 0.1 CVW.
GPZ 18
Energy Storage SelectionEnergy Storage Selection
Wh/kgN d d
Li-
Needed
Ni-MH Ni-Zn
Lead-Acid
W/kg
Lead Acid
GPZ 19
ENERGY STORAGE SELECTIONENERGY STORAGE SELECTIONBatteries: REGEN ENERGY available,BATTERY LIFE: Bat. Life ~((1/Temp.),(1/DSOC)). Temperature must be kept below 40 C. Each charge and discharge heat up the battery.C t ti DSOC 0 05 f i l it fCurrent practices: DSOC ~0.05 of nominal capacity, for regen.For HEV good practice battery design charge to belowFor HEV good practice battery design charge to below its nominal capacity, technology dependent.Regen battery capacity: 22 kWhrRegen battery capacity: 22 kWhrFor Ni-MH , mass 340 kgs but for max. regen 1200 kgsLi NanoPh mass 244 kgs but for max regen 800 kgs
GPZ 20
Li-NanoPh, mass 244 kgs but for max. regen 800 kgs
ENERGY STORAGE SELECTIONENERGY STORAGE SELECTION
Energy Storage maximum mass about 10% of CVW. Or 1,500 kgs.F l Wh/k kFuel Wh/kg range, kmNi-MH 65 45/500 Li N Ph 90 60/500Li-NanoPh 90 60/500Zn-Air 250 160/500
3 333 888 3FTPHEV 3,333 888. at 37 kph continuousDiesel 4,100 500 with 450 l of fuel
GPZ 21
Yes PHEV Bus is feasibleYes, PHEV Bus is feasible
PHEV transit bus is possible but will require operationalPHEV transit bus is possible but will require operational compromises and deployment in specific routes, i.e. downtown corridors, University Campus routes, School b tbuses, etc.PHEV transit bus with bio-fuel range extender engine is very feasible and it can be done by building on the y y gcurrent available hybrid buses through down sizing the engine and upsizing the batteries by about a factor of 3X. The estimated benefits can be about 50% CO2 3 e est ated be e ts ca be about 50% COemission reductions and about 40% fossil fuel savings. Yes, some cities in NA are testing PHEV buses.FTPHEV l d i t d iti ith i f t tFTPHEV already exists and cities with infrastructure are cashing in the benefits.
GPZ 22
Yes PHEV bus is feasibleYes, PHEV bus is feasible
Obstacles to overcome:Higher specific energy batteries 500Higher specific energy batteries, 500. Wh/kg.R id h i bl b tt i T tRapid charging capable batteries. To at least 90% in 5 minutes.Development of fast charging induction charger to facilitate opportunity charging atcharger to facilitate opportunity charging at route turn around idle time.
GPZ 23
Future Developments for heavy vehiclesFuture Developments for heavy vehicles
Diesel engines efficiency are scheduled to increase fromDiesel engines efficiency are scheduled to increase from 0.45 to 0.55 by 2012. Reduces emissions and save fuel.Next generation Bio-fuels are being developed, such as: g g p ,bio-butanol, bio-octanol and others. Benefits reduce use of fossil fuel and reduce emissions.Hybrids system are expanding fast from buses intoHybrids system are expanding fast, from buses into heavy trucks. Benefits, 25 % fuel saving, reduce emissions.Work continues in evaluating the use of hydrogen fuelWork continues in evaluating the use of hydrogen fuel cells for niche applications. Reduce use of fossil fuel and emissions.Some cities are evaluating the merits of using PHEV buses, with engine range extender. Reduce use of fossil fuel and emissions
GPZ 24
ReferencesReferences
References:References:BP Statistical Review of World Energy, June 2007.Environment Canada-Canada’s 2005 GHG Inventory.C di El t i it A i ti El t i it d Cli t ChCanadian Electricity Association, Electricity and Climate Change, Feb. 2003.The USA GHG Inventory 2005, EPA, USA.M it b GHG i i 2006Manitoba GHG emissions, 2006.Costs and Emissions Associated with PHEV charging in the Xcel Energy Colorado Territory, NREL Technical Report, May 2007.C St d Eb H b id El t i B d T ll NRELCase Study: Ebus Hybrid Electric Buses and Trolleys, NREL Technical Report, July 2006.Hybrid Electric School Buses, Feasibility Study, Advanced Energy, NC 2005NC, 2005.King County Metro Transit Hybrid Articulated Buses: Final Evaluation Results, NREL Technical Report, December 2006.
GPZ 25
Clean Buses Trolleys early 2000’sClean Buses-Trolleys early 2000 s
GPZ 26
Clean Buses-Trolleys early 2000’sClean Buses Trolleys early 2000 s
40LF Trolley: CVW, 32,000 Lbs comparable to CNG.All electric power system including accessories drive. M i f h d iMain power from overhead wires.Battery aux.. energy source for about 1 km off wires operation Ni Cd batteriesoperation. Ni-Cd batteries.Power supply : 600VTraction Pulse Mod Inverters IGBT: 3PH 250KVATraction Pulse Mod. Inverters, IGBT: 3PH, 250KVATraction Motor: 3PH, 420V, 210 kW , 1287 lbs.All l t i i t i l dAll electric power equipment air cooled.
GPZ 27
C fi tiConfiguration
P����
E����������
ECU
E�����
D���� U���
GPZ 28
New Flyer Diesel-Electric Configuration
GPZ 29
Hybrid System DetailsHybrid System DetailsPropulsionPropulsion
Engine: 213 kWBatteries: 52 kW at 600 VDCTransmission: CVT, 2 Electric Machines in theTransmission: CVT, 2 Electric Machines in the housingGear reduction: 0 4 to 4 25Gear reduction: 0.4 to 4.25Power inverters 3PH, 500 KVA, 800AP t 600 VDC i lPower system 600 VDC nominal
GPZ 30
ISE HYBRIDS ARE DESIGNED TO REDUCE EMISSIONSREDUCE EMISSIONS
Ford V10Gasoline Engine
ElectronicsCooling
• Ford ULEV-rated engineAccessories
• Runs on standard gasoline
• Siemens electric driveEnergy Storage
Accessories
• 40’ New Flyer bus• First bus in service at Omnitrans
Control SystemInverter
Generator Drive Motor
GPZ 31
Hybrid System DetailsHybrid System DetailsPropulsionPropulsion
234 kW (315 hp) peak traction motor powerRated torque 2700 NM (1990 ft-lbs)Motor speed 10,000 RPMMotor speed 10,000 RPMGear reduction 3.5:1Power inverters 500 KVA 800APower inverters 500 KVA, 800APower system 600 VDC nominal
GPZ 32
HYBRID HYDROGEN INTERNAL COMBUSTION ENGINE (HHICE) BUSCOMBUSTION ENGINE (HHICE) BUS
Near Zero Emissions, Engine Production Ready, Reasonable Cost
Control Systemy,
Ford V10 H2 Engine
Energy StorageAccessoriesAccessories
Inverter
GeneratorDrive Motor
GPZ 33
Inverter
New Flyer Productsy
GPZ 34
Hybrid System Detailsy y
Propulsion batteries 6 Modules of 2x3 batteries packs, NiMHNiMH600 VDC nominal, 31 kW-hr, 52 kWRoof mo ntedRoof mountedA/C source air cooled450 kg
GPZ 35
NiMH SystemNiMH System
283m
2175mm(85.6”)
1100mm
m(11.1
”)1100mm(43.3”)
GPZ 36
Clean Buses Trolleys early 1900’sClean Buses-Trolleys early 1900 s
GPZ 37
Clean Buses-Back to the future-T ll l 2000’Trolleys early 2000’s
GPZ 38
Visit New Flyer [email protected] ,
VP Sales and Marketing.VP Sales and [email protected]
Director Sales, Western USAjoel abraman@newflyer [email protected]
Director Sales, Eastern [email protected]
Canadian Sales ManagerCanadian Sales Manager
