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GKN Hybrid Power Flywheel Energy Storage Systems and Applications
2
GKN – A Short Introduction
GKN
ENGINEERING THAT
MOVES THE WORLD…
3
GKN – Engineering that moves the world
Leading first tier supplier to the
global aerospace industry
focusing on aero-structures,
engine systems and products,
and specialty products.
Leading supplier of power
management equipment to the
agriculture, construction and
mining, utility and industrial
markets; with a strong service
capability.
World’s largest manufacturer
of metal powder and sintered
components, predominantly
to the automotive sector.
A global engineering group
Sales of £7.45 billion in 2014
51,500 people in more than 30 countries
Founded in 1759
32 Manufacturing locations
11,700 people
30% of sales
34 Major locations
5,400 people
12% of Sales
34 Manufacturing locations
6,600 people
12% of sales
GKN Land Systems GKN Aerospace GKN Powder Metallurgy
World leading supplier of
automotive driveline systems
and solutions, including all-
wheel drive.
45 Manufacturing locations
24,000 people
46% sales
GKN Driveline
4
GKN Driveline GKN Powder Met GKN Aerospace
eDrive Technology
Technology
Support Technology
Support
eDrive Technology – key development theme
GKN Land Systems
6
Company History - From Williams F1 to GKN HP
“A world-class engineering
company that goes racing”
Founded in 1977
16 FIA Formula One World
Championship titles
Adapting cutting edge F1
innovation and technology for
wider commercial applications
Williams technology improves:
Energy Efficiency
Safety
Performance
2008 2014
Strategic acquisition for GKN
Land Systems
Technology & innovation is at
the heart of GKN
We can industrialize on a
global scale
7
GKN Hybrid Power – History
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 April formation of GKN Hybrid Power
Pre-Production Orders for 500+ Bus systems.
Alexander Dennis Partnership.
Audi R18 e-tron quattro 2.0 raced and won;
DSTL contract.
2015 101 February opening of new Technical engineering center in Abingdon
8
GKN Hybrid Power
We deliver the
power to harvest
crops and move
earth…
And we make
essential
components for
industries that touch
lives across the
globe.
• Victory at Le Mans – again!
• £5m Audi contract for 2015
• 750 Gyrodrive flywheel systems committed over next 2 years
• Production ramp up
• £3m MoD contract
• New facility
9
[IN CONFIDENCE]
Mechanical Battery
Kinetic Energy Storage
10
Flywheels – Principle of Operation
11
The flywheel is an electric motor
Stores energy mechanically
Unique MLC Rotor
12kg Spins at up to 36,000 rpm
Peak Power 120kW
Benefits
Very high power density
Wide operating temperature
range
Very high cycle life with no loss
of performance
Cost effective in volume
The Mechanical Battery
MLC
The inner ring of the flywheel is
made of glass fibre mixed with
magnetic particles. This provides
the magnetic flux for the motor
Magnetic Layered
Composite
Filament Wound Carbon
Fibre Outer Rotor
• 80,000,000 Strands of aero
grade carbon fibre
• Surface Speed: Mach 1.8
• Surface force :250,000g
GKN Hybrid Power Flywheel – Principle of Operation
12
GKN Hybrid Power – Technology Overview
CERAMIC HYBRID
BEARINGS STATOR
MLC
SECTION
CARBON COMPOSITE
ROTOR
CARBON COMPOSITE
END CAP
Mk 4
13
Rotor Stress – The Safety Case
Carbon Rotor
MLC
Rotor Section
Radius 130Radius 145Radius 175
Fa
ilure
Str
ess A
ST
M D
22
90
-08
Str
ess in
Ro
tor
Sample
Testing
• Safety Case based on pressure vessel
design / Nuclear Industry
• Probability of hoop failure < 1x10-9
• Max operational speed controlled by
safety hardware
• All designs fully qualified by test and
analysis
FEA
15
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
16
Gyrodrive Hybrid Bus Principle of operation
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
17
Retro Fit Bus Installation
Laser
scan of
existing
structure.
FESS
Concept
Design
Alexander
Dennis E400
Installation
Design……...……….. Develop…………………. Realise
Drive
train
concept
design.
18
Development and Verification Testing
Vibration
and Shock
Fuel Fire
Test
Ingress Tests
Waterproof ?
19
[DOCUMENT NAME]
Industry and Government in Partnership
Benefit of Collaboration
20
Energy Storage
supplier to OE
10,000PA > 100,000PA
Global markets
− Mass Transit
− HGV
− CV
Integrated system
− Flywheel
− Controls / power supply
− Vac pump
GKN Hybrid Power – Benefit of Collaboration
Retro fit complete
system
1>1000PA
Go-Ahead
− Bus fleet operator
UK Market
Complete System
− Flywheel / Fess
− Driveline
− MGU
− Fitting
Government “Matched” Funding for Low
energy emissions – total grant £7.65m
REDUCED COSTS NEW MARKETS
2014 TRL5 & MRL 4 2016/7 TRL8 & MRL7
Capability Investment
− Carbon Fibre winding
− Magnetization
− Multi-Physics Analysis
− Development and Testing
Cost reduction
− Integration of collaborative
research results
− Design for manufacture
− Process development
− Design for reliability
Service development
− Global Telemetry
Coventry University
− Research and technology
development to support long-term
investment in cost down and
product improvement concepts.
Alexander Dennis ltd
− First Adopter
− Integration of electronic controls
with vehicle CAN
− Chassis and driveline integration
with key supplier such as ZF
S&S Windings
− Develop methodology for ultra low
cost stator
Develop for High volume Original Equipment Fit
21
GKN Hybrid Power – Benefit of Collaboration
Gyrodrive Retro fit development partner - Go-Ahead Group
UK Bus fleet operator
Winning hybrid only routes
Benefitting from fuel save
Well ahead of competition
Gyrodrive Original Equipment development partner – Alexander Dennis Ltd - Bus Manufacturer
Winning additional sales for its new vehicles – Transport for London requirement for hybrids
Forecast that in the near future all its sales could be hybrids
Well ahead of competition
ADL E400 Euro 6 ADL E200 Euro 6
22
Parallel Hybrid Bus • Kinetic energy re-used
• Diesel Engine sized for
peak performance
Next Steps - Series Hybrid System
Fuel Use Current Engine 250g/kWhr
Optimised Engine 180g/kWhr
Saving 28 %
Re- Gen Braking
Saving
20 % + =
Total Saving
43 %
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
Cost Increase of Gyrodrive
offset by 3 year fuel savings
Larger cost of series hybrid
Gyrodrive offset smaller
engine and gearbox deletion.
2 year payback
23
GKN Hybrid Power The Gyrodrive USP
We drive the wheels
of hundreds of
millions of cars…
We help thousands
of aircraft to fly…
Reliable Operation
Real World Results
Commercially Viable
GKN Hybrid Power Storage Systems Applications
25
FESS System – 2016 Deliverable (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
26
Flywheel Pod LRU
Sealed LRU to IP65, Interfaces to FESS 3 Way Backplane
Rapid Prototype model reflects this design
27
Audi Mk6E
R18 e-tron hybrid system with Mk6E Flywheel