flywheel-based hybrid and power boosting systems for off … · 2017-03-08 · combine load...
TRANSCRIPT
Flywheel-based Hybrid and Power Boosting Systems for Off-highway and Industrial Applications
1st March 2017
Dr Andrew Deakin – Chief Engineer
Co
py
rig
ht
To
rotr
ak
2
01
7
Flybrid Company Product OverviewC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 2
MECHANICAL
Flybrid offer a range of tailored solutions for a wide range of
applications
Hydraulic, mechanical and electrically connected options
HYDRAULIC
Storage: 380 - 1,200 kJ
Power: 210 kW
Applications:
Excavators
Loaders
Large FLTs
Port handling
Storage: 380 - 1,200 kJ
Power: 210 kW
Applications:
Mining
Diesel Electric
Excavator slew
Bus and Truck
Storage: 600 – 3,000 kJ
Power: up to 500kW
Applications:
Electric Drilling
Bus and Truck
Automotive
ELECTRIC
Flybrid is part of the Torotrak Group and produces Energy Recovery
Systems, storing the energy in a High Speed Flywheel
Hydraulic ERSC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 3
Flybrid’s Low Cost ERS is Production
Ready
Developed for Off-Highway
o Stores energy for excavators when the
boom is lowered or the excavator slews
o System is going into production next
year, with production hardware on test
later this year
o >300kJ storage per cycle is possible on
a 35T excavator
System is cost effective
o Stores energy on multiple cycles per
minute
o Fuel economy benefit depending on
level integration is 10 – 20%
o Validated by a combination of rig test,
customer tests and simulation
Next step – exploitation of this
production ready system for other
applications
Payback RequirementsC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 4
Payback in <2 years is typically required
o Example Machines run 2000hrs per year
o Burn 15 litres of fuel per hour
o Diesel cost at £0.6/litre
o Fuel cost over 2 years is £36,000
o If actual saving is 15% - sales cost to operator needs to be £5000-6000
o Cost to OEM etc can then be determined which must include ERS module and all
additional hardware including the hydraulic pump.
o Longer term target sales price to the OEM for 380kJ ERM is therefore ~£2000 to
meet operator requirements
o Any machine burning > 15 litres per hour and working >2000 hours per year has
a very strong business case to fit a Flybrid ERS
This business case is convincing for all medium and large off-highway
machines with 15% fuel economy improvement
Co
py
rig
ht
To
rotr
ak
20
17
Pa
ge
5One Product, Many Machine Types
Wheeled loader
Excavator
Forklift
Applications and Available EnergyC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 6
Wheeled Loader
o 25T at 13kph = 160kJ
o 5T bucket at 3m = 150kJ
o 20 – 30 secs per Y cycle
o Multiple events per cycle
Large Forklift
o 30T at 25kph = 720kJ
o 20T load at 4m = 800kJ
Reach Stacker
o 100T at 20kph – 1540kJ
o 20T at 7.5m – 1500kJ
Multiple off-highway applications with
lots of energy to be captured
Reach stacker
Driveline Connect - HydrostatC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 7
Wheeled Loader
o Original concept was to connect the ERM to the axle with a hydraulic motor and
PTO
o Uses the hydraulic motor to brake the vehicle which generates hydraulic flow and
pressure.
o The hydraulic energy is then converted into kinetic energy in the flywheel with the
second hydraulic motor
o Energy can be returned to accelerate the vehicle as required
PTO
Axle connected motor
Flywheel connected motor
FW module
Wheeled loader
Hydrostat Integrated ERSC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 8
Wheeled Loader – Hydrostat Integrated ERS
o Some wheel loaders have hydrostat powertrains – a simplified version is shown
below
o In this case the flywheel hydraulic motor is connected into the existing hydrostat
and can store excess energy under braking and release this under acceleration
o In this case, no additional PTO or second hydraulic motor is required providing a
cost effective solution
Wheeled loader
o Simulation of this set-
up is being
progressed with a
global Tier 1
Diesel Electric DrivelineC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 9
Wheeled Loader – Diesel Electric
o For large diesel electric drivetrains.
o An electrically connected flywheel enables excess energy to be captured under
braking and flywheel charge when the engine power demand is low
o This can improve fuel economy and or improve performance (up to double power)
o More cost effective than a supercap
o Common in underground mining and growth for larger machines
On Highway ApplicationsC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 1
0
On-highway – Bus and Truck
o One potential application is for bus.
o Low floor buses which appear to be the trend in Europe have less space for
packaging a mechanical KERS. Therefore an electric ERS to compliment
conventional powertrain is attractive.
o Can enable start stop using flywheel
energy for hotel loads etc
o More cost effective than supercaps
o LUB fuel saving ~ 15%
Engine Load LevellingC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 1
1
Benefits of load levelling
o Load levelling of the engine allows either a smaller engine to be used or the engine to
be run at lower speeds. It is recognised that for some off-highway applications, peak
power may occasionally be required for prolonged periods
o Running the engine at a lower speed and higher torque can result in significant fuel
saving
o Flybrid ERS could enable cost effective load levelling for off-highway and can also be
applied to power generation
10-15% fuel
saved
15-30%
fuel
saved
If Existing Engine runs
over this range
Engine with load
levelling can run here
Future ObjectiveC
op
yri
gh
t T
oro
tra
k 2
01
7P
ag
e 1
2
Combine Load Levelling and Energy recovery
o Potential to save a real 15% fuel from energy recovery and 15% fuel from load
levelling
Total potential saving of 30% is possible
o Currently exploring ways of producing an energy recovery system which
achieves load levelling combined with energy recovery to achieve 30% fuel
saving with minimal additional ERS cost
Thank you
Co
py
rig
ht
To
rotr
ak
2
01
7
Andrew Deakin+44 (0) 1327 855190