GKN Hybrid Power :The use of the Gyrodrive hybrid system in bus, truck

and off highway vehicles

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

8

[DOCUMENT NAME]

Bus & Truck Applications

8

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

19

[DOCUMENT NAME]

Wheel Loader Shovel

19

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

22

[DOCUMENT NAME]

Industrial Energy Storage

22

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