DRIVING EFFICIENT TRANSPORT

GKN Hybrid Power
GYRODRIVE BY GKN HYBRID POWER
DRIVING EFFICIENT TRANSPORT
GKN Hybrid Power
CONTENT
GKN
WELCOME TO GYRODRIVE BY GKN HYBRID POWER
BACKGROUND
4
HOW AND WHERE DOES IT WORK
6
INSTALLATION SOLUTIONS
7
THE DIFFERENCE BETWEEN A BATTERY AND A
FLYWHEEL
8
COSTS AND SAVING POTENTIALS
SPECIFICATION
GKN PLC
GKN LAND SYSTEMS
9
10
GKN Hybrid Power
WELCOME TO GYRODRIVE BY GKN HYBRID POWER
GKN Hybrid Power is proud to introduce the innovative hybrid
flywheel technology, specifically designed for use in public
transport applications.
GKN Hybrid Power’s hybrid flywheel technology is ideally suited to urban buses
because of their high mass and stop-start nature, helping to deliver improved fuel
economy and a reduction in CO2 emissions. It achieves these benefits at a much
lower cost and weight than using the equivalent battery based hybrid systems.
Using unique Formula One know-how and engineering expertise, developed and
available for the first time is Gyrodrive, a hybrid system that can be retrofitted
to existing vehicles with minimal re-engineering as well as an OEM fitment and
provides a low cost, efficient solution to today’s rising fuel prices.
Innovative flywheel technology
BENEFITS INCLUDE
>
Low cost
> up to 25% fuel improvement
> Minimal re-engineering
Low Carbon Certified
> World class British engineering and
innovation
>
BACKGROUND
Williams Hybrid Power was established in 2008 to develop a new flywheel energy
recovery system for the Williams F1 team and immediately saw its potential in the
commercial world.
The system developed has a number of unique features and the core of the hybrid
system is the Magnetically Loaded Composite rotor. Gyrodrive provides a highly
efficient electrical energy storage capability which is both cheaper and lighter than
battery equivalents. Through motorsport development, including programmes with
Porsche and Audi in endurance racing, Williams Hybrid Power developed a system that
can deliver high, continuously cycling power output over an extended operating life
which far exceeds that of current, battery based hybrid applications.
In April 2014 GKN Plc announced that it had acquired Williams Hybrid Power from
Williams Grand Prix Engineering Ltd. The business is at the point of broader market
commercialisation and GKN has the resources and expertise to fully realise the
enormous potential of the motorsport proven flywheel technology, primarily within a
variety of public transport applications.
4
The Hybrid Power team worked closely with
Audi engineers to fully integrate its unique
electric flywheel into the Audi R18 e-tron
quattro - three time winner of Le Mans
24 hour race.
“
THIS ACQUISITION IS A GREAT OPPORTUNITY
FOR GKN TO BRING A UNIQUE TECHNOLOGY
TO A RANGE OF GLOBAL MARKETS,
HELPING THE EMISSIONS AND EFFICIENCY
CHALLENGES FACED BY MASS TRANSIT &
COMMERCIAL VEHICLE COMPANIES AROUND
THE WORLD.”
5
HOW AND WHERE DOES IT WORK?
GKN Hybrid Power’s Gyrodrive electric flywheel technology is a Kinetic Energy
Recovery System (KERS). When a vehicle brakes, it harvests the energy normally
lost as heat. The flywheel stores the energy and returns it to the wheels on
demand, boosting power, saving fuel and reducing emissions. When the driver
brakes, a traction motor within the drivetrain slows the vehicle, generating
electricity. This electricity is used to charge the flywheel, spinning it at up to
36,000rpm. When the driver accelerates, the system works in reverse. The
energy is drawn from the flywheel and converted back into electricity to power
the traction motor. This reduces the work done by the internal combustion
engine, improving fuel economy by up to 25%, depending on the application.
Photo Credit: Flickr - EDDIE, eastleighbusman
Flywheel
Braking
GKN Evo
Motor &
Gearbox
Accelerating
Power Electronics
Driveshaft
Motor
Inverter
Motor
Motor
Phase Cables
GKN Hybrid Power
Flywheel
Inverter
DC Bus
6
Flywheel
Energy
Store
Flywheel
Phase Cables
INSTALLATION SOLUTIONS ARE AVAILABLE FOR THE FOLLOWING VEHICLE TYPES
“
> ADL E200
> Scania Omnicity
> ADL Enviro 400
> Volvo B9TL
> Mercedes Citaro
IN THE ON-GOING QUEST TO SIGNIFICANTLY REDUCE THE CO2 EMISSIONS OF THE
GO-AHEAD GROUP WE ARE VERY EXCITED TO BE WORKING WITH GKN HYBRID
POWER, A BRITISH TECHNOLOGY COMPANY AT THE CUTTING EDGE OF ALTERNATIVE
ENERGY SOLUTIONS. THE EXPERIENCE AND EXPERTISE THEY HAVE GAINED FROM
DEVELOPING AND USING THE FLYWHEEL TECHNOLOGY IN MOTORSPORT WILL DELIVER
A GROUND BREAKING SOLUTION TO THE ISSUE OF FUEL EFFICIENCY, FOR THE MASS
TRANSIT MARKET”
- PHIL MARGRAVE, GROUP ENGINEERING DIRECTOR, GO-AHEAD
Gyrodrive can be built into new vehicles or retro-fitted into any commercial or mass transit vehicle, with relatively little
re-engineering of the existing vehicle. This means that it can be quickly fitted, reducing the down time of vehicles in the
field. The conversion fitment is undertaken by GKN Hybrid Power and its approved agents.
For further information relating to solutions for your vehicle type and suitable installation packages
please contact us on +44 (0) 1235 468 200
Solutions are available across a variety of transport and commercial applications
7
COMPARISON BETWEEN A BATTERY AND AN ELECTRIC FLYWHEEL
The GKN Hybrid Power flywheel has four distinct advantages over a battery based hybrid system:
Weight
The flywheel system is a fraction of the weight of equivalent battery systems. A flywheel system has a considerably higher
specific power density. This means that for applications requiring relatively short bursts of energy at higher power, the
flywheel system is a fraction of the weight, volume and cost (by as much as a third) of a battery.
Size
> The flywheel is compact and can be packaged anywhere on the vehicle without any loss of passenger capacity.
> A flywheel can be right-sized for the application and will happily deep cycle for the lifetime of the vehicle.
Cost
The flywheel is a fraction of the cost of a comparable battery system (by as much as a third) and is commercially available
today with a realistic payback period. This is achievable by following:
> Material costs are considerably lower.
> A flywheel can operate at full charge/discharge capacity more than 1000 times that
of an equivalent Lithium Ion Battery, this means it can endure longer than the life
of most commercial vehicles.
> Full life cycle costs are lower. The recycling process is greener, less expensive
and lower risk compared to batteries.
Safety and Environmental
> Almost all flywheel components are readily recyclable, less expensive and
lower risk.
> Storage and handling at zero charge state is intrinsically safer than for a
typically partial or fully charged high voltage battery.
> The flywheel can operate through a broader range of operating temperature (-20°C to +45°C) compared to battery alternatives.
HOW MUCH DOES IT COST AND WHAT ARE THE SAVING POTENTIALS
The system is priced to provide a payback based on certain fuel price assumptions
of between 4-6 years. It also has the potential to be Low Carbon Certified, which
demonstrates up to 25% improvement in fuel efficiency as verified by Millbrook
Proving Ground against the UK Department for Transport’s drive cycle when
compared to a Euro III vehicle.
KEY
One bus = one mile
Standard bus one gallon travel
Gyrodrive one gallon travel
POTENTIAL SAVINGS
UP TO 25% IMPROVEMENT IN FUEL ECONOMY > The average bus produces 77 – 100 tonnes of CO2 per annum.
> The GKN Hybrid Power system reduces the CO2 by 15-20 tonnes.
> Low Carbon Certification increases BSOG subsidy by 6p/km where applicable.
GKN Hybrid Power
8
SPECIFICATION
Energy Storage Unit
GKN HP MK4
Max Power
120kW
Total Energy Storage
1.8 MJ
Max Operating Voltage
700 VDC
Cooling System
Transformer Oil Cooled
Operating Speed
15000 – 36000 RPM
Motor
GKN EVO 130HT
Max Operating Voltage
700VDC
Max Operating Speed
8000 RPM
Peak Torque
390 Nm
Cooling System
Glycol/Water Cooled
Inverters (Flywheel & Motor)
Max Operating Voltage
800 VDC
Nominal Current
300 Amps
Height
109mm
Width
244mm
Length
475mm
Hybrid System Controller
Processor
MPC5554
Interface to Bus
J1939 CAN Bus
Operating Temperature
-40 C to 105 C
Operating Voltage
9 – 16V , 4.5V crank
Hybrid System
Operating Temperature
-10 to +40 ˚C
Delta weight
350 kg
Round trip system efficiency
86%
9
Every day
at GKN…
We drive the wheels
of hundreds of
millions of cars…
A leading global engineering g
of quality and innovation, op e
Every day
at GKN…
We drive the wheels
of hundreds of
millions of cars…
We help thousands
of aircraft to fly…
We help thousands
of aircraft to fly…
Technology and engineering from GKN is at the heart of the vehicles and aircraft pro
defence manufacturers. More than 40,000
people
We drive the
wheelswork in GKN companies and join
Every day
at GKN…
of hundreds of
GKN operate in four key business areas:
millions of cars…
We help thousands
of aircraft to fly…
GKN Driveline
GKN Land Systems
GKN Aerospace
GKN Powder Metallurgy
GKN Driveline is the world’s
leading supplier of automotive
driveline systems and solutions.
As a global business serving the
leading vehicle manufacturers,
GKN Driveline develops, builds
and supplies an extensive
range of automotive driveline
products and systems – for use
in the smallest ultra low-cost
car to the most sophisticated
premium vehicle demanding
the most complex driving
dynamics.
GKN Land Systems is a
leading provider of technology
differentiated power
management solutions
and services. It designs,
manufactures and supplies
products and services for
the global agricultural,
construction, transportation
vehicles and industrial
machinery markets. In addition,
it provides global aftermarket
distribution and comprehensive
through-life support.
GKN Aerospace is a
world leading global first
tier supplier of airframe
and engine structures,
components, assemblies
and transparencies to a wide
range of aircraft and engine
prime contractors and other
first tier suppliers. It operates
in three main product areas:
aerostructures, engine
components/sub-systems
and special products.
GKN Powder Metallurgy is the
world’s largest manufacturer
of sintered components. It
comprises Hoeganaes and
GKN Sinter Metals. Hoeganaes
produces the metal powder
that GKN Sinter metals uses
to manufacture precision
automotive components for
engines, transmissions and
body and chassis applications.
It also produces a range of
components for industrial and
consumer applications.
Armstrong, Wichita: Wheels
Dayton: Clutches, Brakes
Rockford: Driveshafts
Woodridge: Driveshafts, Wheels
GKN Land Systems offer an integrated Powertrain solution from the power source through to where the power is applied.
“Supporting customers in meeting the demands of a crowded planet. Our product technology delivers the power
to harvest crops, move earth, mine resources, move people, handle materials and capture natural energy.”
Help leading global original equipment manufacturers keep the world running efficiently, reliably and safely.
Design, manufacture, market and service powertrain products and systems to transmit and control power
from source to application.
Enable agricultural, construction/mining and industrial customers’ machinery to propel, position and perform.
An Aftermarket & Services organisation ensuring that we continue to support customers and products to offer
through life support, using our own distribution and service centres across Europe.
GKN Hybrid Power
10
We deliver the power
to harvest crops
and move earth…
And we make essential
components for industries that
touch lives across the globe.
g group, with over 250 years heritage
p erating in more than 30 countries.
ousands
o fly…
ds
We deliver the power
to harvest crops
and move earth…
And we make essential
components for industries that
touch lives across the globe.
aft produced by the world’s leading automotive, off highway, aerospace and
and joint ventures in more
than 30
countries.
We deliver
the power
And we make essential
ousands
o fly…
to harvest crops
and move earth…
components for industries that
touch lives across the globe.
GKN Land Systems
– manufacturing locations
Couplings
Clutches
Driveshafts
Gearboxes
Brakes
Controls
Electrics
Wheels
Tractor Attachment Systems (TAS)
Nagbøl: Wheels
Telford: Wheels, Electrics, Structures
Abingdon: Electrics
La Guerche: Brakes
Ribemont: Reman driveshafts
– engineering centres
Armstrong
Auburn Hills
Bruneck
Cachoeirinha
Carpenedolo
Dessau
Huading
La Guerche
Liuzhou
Lohmar
Nagbøl
Rockford
Pune
Sohland
Taicang
Telford
Unna
Woodridge
Over 30 GKN service locations
Tokyo: Driveshafts
Carcastillo:
Reman driveshafts
Taicang: Brakes, Couplings,
Clutches, Controls
Huading: Wheels
Liuzhou: Wheels, Driveshafts
Bruneck: Driveshafts
Carpenedolo: Wheels
Cachoeirinha: Driveshafts
Clutches, Brakes, Couplings
Dessau: Clutches,
Lohmar: Driveshafts, TAS
Sohland: Gearboxes, Clutches,
Unna: Clutches, Brakes, Couplings, Controls, Discs
11
Pune:
Clutches,
Brakes
WWW.GKNHYBRIDPOWER.COM
WWW.GKNLANDSYSTEMS.COM
GKN Hybrid Power • Unit 1 Pentagon South • Abingdon Science Park • Barton Lane • Abingdon • Oxford OX14 3PZ • Telephone: +44 (0) 1235 468 200
Copyright by GKN Land Systems • We reserve the right to make changes due to technical progress. GKN HP/LS GB 0415 FL 1-1