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Page 1 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Industry – Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Siemens has developed ELFA ®, a modular electric drive system for city buses and other commercial vehicles Hybrid means the combination of different kinds of energy supplies, like diesel generator sets, batteries, fuel cells. etc Based on the flexible energy management functions and the component platform of ELFA ®, nearly all kinds of energy supplies can be combined Mix of nearly all kinds of energy supplies
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Page 2 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Overall Situation Over 50% of the world population lives in urban areas and will increase Over 50% of inner urban public transport is provided by buses – even in industrialized countries like Germany Increasing demand for emission reduction noise reduction clean, quiet and comfortable public transport
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Page 3 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles The key components for the ELFA drive system Implementation of high efficient drive motors based on permanent magnets with efficiency up to 97% Using latest technology of power electronics in a robust, water- cooled and flexible design Developing of a Siemens Ultra- Capacitor energy storage system for series introduction in 2011 Sophisticated drive control and energy management software functions adapted to the vehicle requirements Inverter Permanent Magnet Motor Ultracapacitor Energy Storage System
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Page 4 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Technology – Permanent Magnet Motor Due to the frequent stop and go cycles of a city bus, permanent magnet motors save energy compared to fuel driven engines. Permanent magnet motor reaches 97% efficiency Due to the high torque, no gearbox necessary Significant noise reduction Low maintenance costs Due to lower current the converter size can be optimized Significant lower life operational costs compared to induction motors lead to a return on investment in less than two years Energy Losses Available electric motor 30.000 kWh @ 5.000 h/a Permanent Magnet Motor 19.000 kWh @ 5.000 h/a Energy Saving with PEM-technology approx. 11.000 kWh p.a. 3.650 liter diesel p.a. per bus Speed [km/h] Time [s] Example Munich line 66
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Page 5 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Technology – 4-phase Inverter Only one type of AC/DC – inverter due to flexible 4-phase structure supporting control of different kind of motors and generators. Robust automotive water-cooled design with e.g. high degree of protection, high mechanical and electro magnetic compatibility requirements. Easy power adaption due to parallel connection of inverters is possible. Modular and flexible software architecture supports all kinds of hybrid systems like diesel hybrid, fuel cell hybrids etc. Diagnostic interface based on state of the art automotive CAN (Controller Area Network) communication protocol. Operating Voltage DC:300V.. 750 V Max Current:350 A Max Power:320 kVA Switching frequency:2 kHz.. 6 kHz Weight:30 kg Dimensions:411 x 454 x 183 mm
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Page 6 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Technology – Ultra Capacitor System Energy storage system based on ultra capacitor cell technology supports 12-18 years of life in heavy duty city bus applications Significant lower life cycle costs as any other energy storage, due to high efficiency and long life-time High power capability enables the maximum recuperation of braking power Advanced ultra capacitor management software with clever limitation functions and easy integration into the hybrid drive system Diagnostic interface based on state of the art automotive protocol Roof mounted Ultra Capacitor System for MAN Series Hybrid Bus Operating Voltage:400.. 750V Max Current:400A Max charge power:180kW Max discharge power:180kW Usable energy content: 400.. 600Wh Weight:450 kg Dimensions:2,210 x 1,035 x 418mm
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Page 7 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Technology – Continuously Variable Transmission (CVT) A CVT provides fast, smooth and stepless ratio changes which lead to higher fuel efficiency A CVT has less parts than an automatic transmission resulting in lower cost and better reliability CVT prototype developed in context of a Siemens TTB project with technology from Efficient Drivetrain Inc. (EDI) in order to support parallel hybrid configurations The involute chain used in the EDI CVT helps transfer the large torque required for medium duty vehicles at record efficiency CVT integrated in a hybrid vehicle
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Page 8 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Market Segment – Delivery Truck and Shuttle Bus Drive cycles of shuttle buses and delivery trucks have stop & go as well as cruising speeds Projecting a 10% conversion ratio to hybrid by 2015, this market segment could represent 100,000 hybrid drive trains City driving cycles pure battery drive system Mixed driving cycles parallel hybrid system
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Page 9 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Market Segments – City Bus 100.000 buses p.a. in the developed areas in the world We estimate that by 2015 of the city buses 30% will be pure electric, fuel cell or combustion engine hybrid Up to 40 % fuel consumption reduction is possible High mileage p.a. and high fuel reduction allows ROI within less than 4 years
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Page 10 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Market Segment – Utility Vehicle Garbage trucks nearly noiseless garbage collection offers night operation strong stop & go cycles support high fuel reduction Utility vehicles with low daily mileage are also suited for pure battery electric operation, i.e. cleaning vehicles, bucket trucks, mobile crane
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Page 11 May 2010 © Siemens AG 2010 Industry / Drive Technologies Innovative Hybrid Drive Systems for Commercial Vehicles Sustainability Benefits for the operators, the passengers and the city inhabitants Reduction of fuel consumption by more than 40% Reduction of emissions, i.e. CO2 by more than 40% Significant noise reduction Comfortable and smooth acceleration without shifting gears and reduced vibration Jürgen Fetzer juergen.fetzer@siemens.com Eugen Holl eugen.holl@siemens.com
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