Kinetic Energy Recovery System_report Data

7/26/2019 Kinetic Energy Recovery System_report Data

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PLEASE NOTE: THE MATTER

PRODUCED BELOW IS

REFERENCE MATERIAL ONLY

FOR PREPARING THE PROJECT

REPORT. IT IS NOT THE

COMPLETE PROJECT REPORT.

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A PROJECT REPORT ON

KERS

Submitted in partial fulfillment of the requirements

For the award of the degree

AC!E"OR OF EN#$NEER$N#

$N

%%%%%%%%%%%%%%%%%%%%%%%%%%%%%% EN#$NEER$N#

S&'$TTE( )

(EPART'ENT OF %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

%%%%%%%% CO""E#E OF EN#$NEER$N#

AFF$"$ATE( TO %%%%%%%%%%%%%% &N$*ERS$T)

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CERTIFICATE

This is to +ertif, that the dissertation wor- entitled KERS

is the wor- done b, %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

%%%%%%%%%%%%%% submitted in partial fulfillment for the award of .AC!E"OR

OF EN#$NEER$N# /0E12 in %%%%%%%%%%%%%%%%%%%%%%%%% Engineering from

%%%%%%%% College of Engineering affiliated to %%%%%%%%%%%%&ni3ersit,4

!,derabad0

The results obtained in this pro5e+t ha3e not submitted to an, other &ni3ersit, or

$nstitution for the award of an, degree or diploma0

______________________ _______________(Head of the department, M.E.) (Assistant Professor)

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ACK!"#E$%EMET

The satisfa+tion and euphoria that a++ompan, the su++essful +ompletion of

an, tas- would be in+omplete without the mentioning of the people whose +onstant

guidan+e and en+ouragement made it possible0 6e ta-e pleasure in presenting

before ,ou4 our pro5e+t4 whi+h is result of studied blend of both resear+h and

-nowledge0

6e e7press our earnest gratitude to our internal guide4 Assistant Professor

%%%%%%%%%%%%%%4 (epartment of 'E4 our pro5e+t guide4 for his +onstant support4en+ouragement and guidan+e0 6e are grateful for his +ooperation and his 3aluable

suggestions0

Finall,4 we e7press our gratitude to all other members who are in3ol3ed

either dire+tl, or indire+tl, for the +ompletion of this pro5e+t0

4


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$EC#ARATI!

6e4 the undersigned4 de+lare that the pro5e+t entitled .KERS24 being submitted in

partial fulfillment for the award of a+helor of Engineering (egree in

%%%%%%%%%%%%%%%%%%%%% Engineering4 affiliated to %%%%%%%%&ni3ersit,4 is the

wor- +arried out b, us0

The results embodied in this thesis ha3e not been submitted to an, other &ni3ersit,

or $nstitute for the award of an, diploma or degree0

%%%%%%%%%%%% %%%%%%%%%%%% %%%%%%%%%%%

%%%%%%%%%%%% %%%%%%%%%%%% %%%%%%%%%%%

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Kineti& Ener' Re&oer Sstem

80 $NTRO(&CT$ON

9ERS means 9ineti+ Energ, Re+o3er, S,stem and it refers to the me+hanisms that

re+o3er the energ, that would normall, be lost when redu+ing speed0 The energ, is stored in a

me+hani+al form and retransmitted to the wheel in order to help the a++eleration0 Ele+tri+

3ehi+les and h,brid ha3e a similar s,stem +alled Regenerati3e ra-e whi+h restores the energ,

in the batteries0The de3i+e re+o3ers the -ineti+ energ, that is present in the waste heat +reated b,

the +ar2s bra-ing pro+ess0 $t stores that energ, and +on3erts it into power that +an be +alled upon

to boost a++eleration0

There are prin+ipall, two t,pes of s,stem : batter, /ele+tri+al1 and fl,wheel /me+hani+al10

Ele+tri+al s,stems use a motor: generator in+orporated in the +ar2s transmission whi+h +on3erts

me+hani+al energ, into ele+tri+al energ, and 3i+e 3ersa0 On+e the energ, has been harnessed4 it

is stored in a batter, and released when required0

'e+hani+al s,stems +apture bra-ing energ, and use it to turn a small fl,wheel whi+h +an spin at

up to ;


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batteries under bra-ing and releasing the power on a++eleration0 This s,stem +onsists of three

important parts?

80 An ele+tri+ motor /'#&? 'otor #enerator &nit1 situated between the fuel tan- and the

engine4 lin-ed dire+tl, to the +ran-shaft of the *; to deli3er additional power0=0 Some latest generation ion:lithium batteries /!*? !igh *oltage atter, Pa+-1 +apable

of storing and deli3ering energ, rapidl,0

@0 A +ontrol bo7 /9C&? 9ERS Control &nit14 whi+h manages the beha3ior of the '#&

when +harging and releasing energ,0 $t is lin-ed to the +ar2s standard ele+troni+ +ontrol

unit0

$n essen+e a 9ERS s,stems is simple4 ,ou need a +omponent for generating the power4 one for

storing it and another to +ontrol it all0 Thus 9ERS s,stems ha3e three main +omponents? The'#&4 the PC& and the batteries0 The, are simpl, laid out as in the diagram below?

Fig 80< S+hemati+ Assembl, Of 9ERS in a F8 +ar

=08 '#& /'otor #enerator unit1

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'ounted to the front of the engine4 this is dri3en off a gear at the front of the +ran-shaft0

6or-ing in two modes4 the '#& both +reates the power for the batteries when the +ar is

bra-ing4 then return the power from the batteries to add power dire+tl, to the engine4 when the

9ERS button is deplo,ed0 Running high RP' and generating a signifi+ant (+ +urrent the unit

run 3er, hot4 so teams t,pi+all, oil or water +ool the '#&0

Fig 808'arelli '#& as used b, Ferrari Fig 80= 'arelli protot,pe PC&

=0= atteries

(uring the =


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=0@PC& /Power Control &nit1

T,pi+all, mounted in the sidepod this bla+- bo7 of ele+troni+s ser3ed two purposes4 firstl, to

in3ert +ontrol the swit+hing of +urrent from the batteries to the '#& and se+ondl, to monitor

the status of the indi3idual +ells with the batter,0 'anaging the batter, is +riti+al as the effi+ien+,

of a pa+- of "i:ion +ells will drop if one +ell starts to fail0 A failing +ell +an o3erheat rapidl, and

+ause safet, issues0 As with all 9ERS +omponents the PC& needs +ooling0

@09ERS $N FOR'&"A 8

The F$A /Federation $nternationale"DAutomobile1 ha3e authoried h,brid dri3etrains in Formula

8 ra+ing for the =


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A total s,stem weight of =G -g

A total pa+-aging 3olume of 8@ litres

The la,out of the de3i+e was tailored e7a+tl, to meet the +ustomerHs requirement resulting in a

trul, bespo-e solution that fitted within the tight pa+-aging +onstraints of a F8 +ar0

The me+hani+al 9ERS s,stem utilises fl,wheel te+hnolog, de3eloped b, Fl,brid S,stems to

re+o3er and store a mo3ing 3ehi+le2s -ineti+ energ, whi+h is otherwise wasted when the 3ehi+le

is de+elerated0

6ith a fo+us on safet,4 the F$A ha3e spe+ified a limit on both the power rating of the h,brid

s,stem at


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Fig =080Fl,brid 9ineti+ Energ, Re+o3er, S,stem Fig =0=0A 9ERS fl,wheel

@080 An+illaries

Aside from these main +omponents the 9ERS s,stem also integrates with the F$A Se+urit, in

order to +ontrol and monitor the PC&0 9ERS has to be dri3er a+ti3ated> this is a+hie3ed from a

steering wheel button0 Although the dri3e has to initiate the 9ERS boost4 the teams set the

s,stem up su+h that the dri3er -nows to engage the s,stem out of spe+ifi+ +orners4 the s,stem

then deli3ers the predetermined amount of boost spe+ifi+ to the demands of that se+tion of tra+-0

$n pra+ti+e the 9ERS s,stems is being +harged and dis+harged to this preset map of a+ti3ations4

whi+h smoothens the balan+e between +harging and dis+harging4 so the s,stem does not

o3er+harge abo3e the regulator, limit0 Again the SEC& ensures no more than the +apped amount

of energ, is deli3ered ea+h lap0

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Fig @0 9ERS S+hemati+

Sensors*boost button4 bra-e sensor

A&t+ators* ele+tri+ motorKgenerator unit4 +ontinuousl, 3ariable transmission4 fl,wheel4

ele+tro:h,drauli+ s,stem4 +lut+h0

$ata Comm+ni&ations* CAN us0

Man+fa&t+rers* os+h 'otorsport4 Fl,brid S,stems4 'agneti'arelli4 6illiams !,brid

Power4 L,te- #roup0

13
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B0 T)PES OF 9ERS

Ad3an+ed transmissions that in+orporate hi:te+h fl,wheels are now being used as regenerati3e

s,stems in su+h things as formula:8 +ars4 where the,Hre t,pi+all, referred to as -ineti+ energ,

re+o3er, s,stems /9ERS10

The t,pes of 9ERS that ha3e been de3eloped are?

B080 'e+hani+al 9ERS

B0=0 Ele+tro:me+hani+al 9ERS

B0@0 !,drauli+ 9ERS

B0B0 Ele+troni+ 9ERS

Of the three t,pes of 9ERS units M me+hani+al4 ele+tri+al and h,drauli+ M Formula 8

teams ha3e de+ided to go for the me+hani+ one0 The reasons behind this +hoi+e are quite

logi+al? less weight4 better weight distribution4 in+reased power boost and impro3ed fuel

e+onom,0

B080 'e+hani+al 9ERS

The me+hani+al 9ERS s,stem has a fl,wheel as the energ, storage de3i+e but it does awa, with

'#&s b, repla+ing them with a transmission to +ontrol and transfer the energ, to and from the

dri3eline0 The -ineti+ energ, of the 3ehi+le end up as -ineti+ energ, of a rotating fl,wheel

through the use of shafts and gears0 &nli-e ele+troni+ 9ERS4 this method of storage pre3ents the

need to transform energ, from one t,pe to another0 Ea+h energ, +on3ersion in ele+troni+ 9ERS

brings its own losses and the o3erall effi+ien+, is poor +ompared to me+hani+al storage0 To +ope

with the +ontinuous +hange in speed ratio between the fl,wheel and road:wheels4 a +ontinuousl,

3ariable transmission /C*T1 is used4 whi+h is managed b, an ele+tro:h,drauli+ +ontrol s,stem0 A

+lut+h allows disengagement of the de3i+e when not in use0

As "i:ion batteries are still an e7pensi3e emerging te+hnolog,4 plus the, ha3e asso+iated ris-s4

re+,+ling and transport problems0 The attra+tion of fl,wheel 9ERS is ob3ious4 howe3er no team

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ha3e ra+ed su+h a s,stem in F80 Fl,wheels +an effe+ti3el, repla+e the "i:ion batteries with in a

t,pi+al 9ERS s,stem4 the fl,wheel being mated to a se+ond '#& to +on3ert the power

generated b, the primar, '#& on the engine into the -ineti+ to be stored in the fl,wheel0

6illiams are belie3ed to ha3e 5ust su+h a s,stem0 !owe3er the simper fl,wheel solution is

+onne+t the fl,wheel s,stem 3ia a +lut+hed and geared me+hanism0

B0=0 Ele+tro:me+hani+al 9ERS

$n ele+tro:me+hani+al 9ERS energ, is not stored in batteries or super:+apa+itors4 instead it spins

a fl,wheel to store the energ, -ineti+all,0 This s,stem is effe+ti3el, an ele+tro:me+hani+al

batter,0 There is limited spa+e in a ra+e+ar so the unit is small and light0 Therefore4 the fl,wheel

spins 3er, fast to speeds of G


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see a short term appli+ation0 Separate to the +ars other h,drauli+ s,stems4 a h,drauli+ 9ERS

would use a pump in pla+e of the '#& and an a++umulator in pla+e of the batteries0 Simple

3al3ing would route the fluid into the a++umulator or to the pump to either generate or reappl,

the stored power0 !,drauli+ a++umulators are alread, used in hea3, industr, to pro3ide ba+- up

in the e3ent of failure to +on3entional pumped s,stems0

&sing filament wound +arbon fibre +asing4 an a++umulator of suffi+ient +apa+it, +ould be made

light enough to fit into the +ar0 The, might be +apped in terms of pra+ti+al storage with in the

+onfines of an F8 sied s,stem4 but '+"aren had prepared 5ust su+h an energ, re+o3er, s,stem

ba+- on the late


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motors0 Another is the weight of in+ompressible fluids0 And a third is the amount of spa+e

needed for the h,drauli+ a++umulators4 and their aw-ward form fa+tor0 None of this matters too

mu+h in4 sa,4 hea3, +ommer+ial 3ehi+les but it ma-es this option unsuitable for road and ra+ing

+ars0

Fig B080Carbon Fibre !,drauli+ A++umulator Fig B0=0 !"A /!,drauli+ "aun+h Assist1

B0B0 Ele+troni+ 9ERS

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$n ele+troni+ 9ERS4 bra-ing rotational for+e is +aptured b, an ele+tri+ motor K generator unit

/'#&1 mounted to the engines +ran-shaft0 This '#& ta-es the ele+tri+al energ, that it +on3erts

from -ineti+ energ, and stores it in batteries0 The boost button then summons the ele+tri+al

energ, in the batteries to power the '#&0 The most diffi+ult part in designing ele+troni+ 9ERS

is how to store the ele+tri+al energ,0 'ost ra+ing s,stems use a lithium batter,4 whi+h is

essentiall, a large mobile phone batter,0 atteries be+ome hot when +harging them so man, of

the 9ERS +ars ha3e more +ooling du+ts sin+e +harging will o++ur multiple times throughout a

ra+e0 Super:+apa+itors +an also be used to store ele+tri+al energ, instead of batteries4 the, run

+ooler and are debatabl, more effi+ient0

G0 9ERS RE#ENERAT$*E RA9$N#

Sin+e -ineti+ energ, is the energ, of motion4 ,ou +ould probabl, guess that +ars +reate lots of it0

Capturing some of that -ineti+ energ, for the sa-e of fuel effi+ien+, in a h,brid +ar is a little

tri+-,4 but regenerati3e bra-ing is one +ommon method emplo,ed b, man, automa-ers0

On a non:h,brid +ar during a routine stop4 me+hani+al bra-ing slows and then stops the 3ehi+le0

For instan+e4 if ,our 3ehi+le has dis+ bra-es4 thebra-e pads+lamp down on a rotorto stop the

+ar0 $f ,our +ar has drum bra-es4the bra-e shoe pushes the bra-e lining material outward toward

the bra-e drum surfa+e to slow or stop the +ar0 $n both +ases4 most of the -ineti+ energ, in the

spinning wheels is absorbed b, the pads or the drums4 whi+h +reates heat0

On a h,brid +ar that uses regenerati3e bra-ing4 the ele+tri+ motor is used to slow the +ar0 6hen

the motor is operating in this mode4 it a+ts as a generator to re+o3er the rotational -ineti+ energ,

at the wheels4 +on3ert it into energ, and store it in the +arHs batteries0 6hen the dri3er of the

h,brid +ar ta-es his or her foot off of the a++elerator pedal4 the resistan+e pro3ided b, the

generator slows the +ar first and then the me+hani+al bra-e pads +an be applied to finish the 5ob0

Of +ourse4 the me+hani+al bra-e pads +an also be engaged immediatel, in an emergen+, bra-ing

s+enario0

The +ar uses the energ, stored in the batter, to power the ele+tri+ motor whi+h dri3es the +ar at

low speeds0 (epending on the t,pe of h,brid4 the ele+tri+ motor +an either wor- alone to mo3e

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the +ar or it +an wor- in +on+ert with the +arHs gasoline:powered engine0 So regenerati3e bra-ing4

+oupled with e+o:friendl, dri3ing te+hniques li-e slow starts and slower o3erall 3ehi+le speeds4

is an important feature on some of some of the most fuel:effi+ient 3ehi+les on the road toda,0

Regenerati3e bra-es ma, seem 3er, hi:te+h4 but the idea of ha3ing Denerg,:sa3ing reser3oirsD in

ma+hines is nothing new0 Engines ha3e been using energ,:storing de3i+es +alled fl,wheels

3irtuall, sin+e the, were in3ented0

The basi+ idea is that the rotating part of the engine in+orporates a wheel with a 3er, hea3, metal

rim4 and this dri3es whate3er ma+hine or de3i+e the engine is +onne+ted to0 $t ta-es mu+h more

time to get a fl,wheel:engine turning but4 on+e itHs up to speed4 the fl,wheel stores a huge

amount of rotational energ,0 A hea3, spinning fl,wheel is a bit li-e a tru+- going at speed? it has

huge momentum so it ta-es a great deal of stopping and +hanging its speed ta-es a lot of effort0

That ma, sound li-e a drawba+-4 but itHs a+tuall, 3er, useful0 $f an engine /ma,be a steam

enginepowered b, +,linders1 supplies power errati+all,4 the fl,wheel +ompensates4 absorbing

e7tra power and ma-ing up for temporar, lulls4 so the ma+hine or equipment itHs +onne+ted to is

dri3en more smoothl,0

The hea3, metal fl,wheel atta+hed to this engine helps to -eep it running at a stead, speed0 Note

that most of the hea3, metal mass of the fl,wheel is +on+entrated around its rim0 That gi3es itwhatHs +alled a high moment of inertia? it ta-es a lot of energ, both to ma-e it spin fast and slow

down0 $tHs eas, to see how a fl,wheel +ould be used for regenerati3e bra-ing0 $n something li-e a

bus or a tru+-4 ,ou +ould ha3e a hea3, fl,wheel that +ould be engaged or disengaged from the

transmission at different times0 )ou +ould engage the fl,wheel e3er, time ,ou want to bra-e so it

soa-ed up some of ,our -ineti+ energ, and brought ,ou to a halt0 Ne7t time ,ou started off4 ,ouHd

use the fl,wheel to return the energ, and get ,ou mo3ing again4 before disengaging it during

normal dri3ing0 The main drawba+- of using fl,wheels in mo3ing 3ehi+les is4 of +ourse4 their

e7tra weight0 The, sa3e ,ou energ, b, storing power ,ouHd otherwise squander in bra-es4 but

the, also +ost ,ou energ, be+ause ,ou ha3e to +arr, them around all the time0

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Ad3an+ed transmissions that in+orporate hi:te+h fl,wheels are now being used as regenerati3e

s,stems in su+h things as formula:8 +ars4 where the,Hre t,pi+all, referred to as -ineti+ energ,

re+o3er, s,stems /9ERS10

G080 9ERS dissimilar from Regenerati3e ra-ing

Traditional h,brids a+quire ele+tri+al energ, from bra-ing in a similar wa, that ele+tri+al 9ERS

equipped 3ehi+les do but the differen+e lies in how the energ, is reused0 6hile 9ERS qui+-l, re:

in5e+ts the energ, ba+- into the powertrain to pro3ide additional power boost in +on5un+tion with

the engine4 the traditional h,brid sa3es the energ, to power the ele+tri+ power train0 9ERS is

different from traditional h,brids in that the stop start fun+tionalit, is not a prime goal of the

s,stem0 9ERS wor- 3er, well in +on5un+tion with engine mounted StopKStart s,stems4 or it +an

be engine mounted and used for stop start fun+tionalit,0 The 9ERS h,brid s,stem +annot be

D+hargedD b, the engine dire+tl,4 whi+h is the requirement that has lead to its name4 D9ERSD0

0 CAR'A9ERS M APP"$CAT$ON OF 9ERS TEC!NO"O#)

080 Pors+he

At =


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Fig G080 Pors+he 8;RSR Con+ept Car Fig G0=0 Ferrari *ettura "aboratorio !):9ERS

0=0 Ferrari

The !):9ERS 3ettura laboratorio /e7perimental 3ehi+le1 is an e7ample of how Ferrari is

approa+hing the de3elopment of h,brid te+hnolog, without losing sight of the performan+e traits

and dri3ing in3ol3ement that ha3e alwa,s e7emplified its +ars0

6eighing about B< -g4 the +ompa+t4 tri:phase4 high:3oltage ele+tri+ motor of the !):9ERS is

+oupled to the rear of the dual:+lut+h :speed F8 transmission0 $t operates through one of the

transmission2s two +lut+hes and engages one of the two gearbo7 primar, shafts0 Thus power is

+oupled seamlessl, and instantaneousl, between the ele+tri+ motor and the *8=0 The ele+tri+

motor produ+es more than 8


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ele+troni+s module whi+h was de3eloped appl,ing e7perien+e gained in F8 and4 as well as

managing the power suppl, and re+harging the batteries4 the module also powers the engine2s

an+illaries /power steering4 power:assisted bra-es4 air +onditioning4 on:board s,stems1 3ia a

generator mounted on the *8= engine when running 8


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+arma-er e7pe+ts +ars with fl,wheel te+hnolog, to rea+h the showrooms within a few ,ears if

the tests and te+hni+al de3elopment go as planned0

Fig G0@0 *ol3o Fl,wheel 9ERS S,stem "a,out

0B0 Jaguar

A +onsortium led b, a Jaguar "and Ro3er is de3eloping a fl,wheel:h,brid s,stem that it sa,s

boosts performan+e b, < -ilowatts /about ;< horsepower1 while impro3ing fuel effi+ien+, =

Kinetic Energy Recovery System_report Data

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Transcript of Kinetic Energy Recovery System_report Data