CUAS Carinthian University of Applied Science Department Engineering

CUAS Carinthian University of Applied Science Department Engineering & IT Eng. IT „MOBILITY DISCUSSION ON EFFICIENT FUTURE HEAVY HYBRID VEHICLES“ Winfried Egger Power Electronics & Drives Tel. : +43 4242 90500 2131 e-mail. : w. egger@cuas. at http: //www. fh-kaernten. at

Efficient Future Heavy Wheight Vehicles “ … Whats an alternative power train to gear driven standard engines? MAN 530 HP Automatic. Gear & Hydraulic-Retarder

Efficient Future Heavy Wheight Vehicles Classic mechanical truck power train: … bad efficiency from fuel energy well to street under 9 % by truck represented by sum up from: • losses of serial mechanical rotating parts from primary and secondary gears, • clutches, hydraulic systems, retarder, differential gears, • multi parts on heavy axles and heavy rotation systems. By 11 k. Wh energy per liter Diesel per week: 4000 Liter means 44 MWh, 5200 € ! Questions on heavy duty applications efficiency: • How can emission losses be reduced? • How can tires more prevent from abrasion for longer using? • How the exhausting emission could be clearer? • How to reduce losses on power train? • How to reduce weight over all? • How can they utilize the stored energy? • Which will be that primary energy in future?

Efficient Future Heavy Wheight Vehicles One result on optimization: Serial Hybrids • Energy saving and exhausting efficiency with electric generator engines combination, well running on constant high efficient M-n-working points • Reducing losses on Power Trains by reducing heavy gear units • High efficient electric single wheel drives – anti slip self controlled • Fast changeable modules by clear defined electric mechanical (hydraulic) interfaces • Weight reducing over all • Minimizing Exhausting Emission and primary Energies in future! • No battery, super caps in dc-link converter actions, well in recuperation • Clear and easy mechanic electrical interfaces – well in production and variations

Efficient Future Heavy Wheight Vehicles Serial Hybrid Power Trains & Control Systems • Diesel generator composition • Electric braking energy storage units - recuperation on super cap stacks • Full dynamic single wheel control on tyres • Minimizing energy and for lowest friction controlled rubber abrasion, • Drive assistance by a multi level vehicle control unit • Full dynamic drive control in several levels from truck board computer. New construction structures results: we will get 15% more load volumes on frame, by 15% lower vehicle weight and 25% longer life period of tires! Table for Control Levels by W. Egger Single wheel drive structures by W. Egger

Efficient Future Heavy Wheight Vehicles Serial Hybrid Truck with fully single self controlled electric powered wheels … Diesel-Electric Traction EBS ABS … All Wheel Drive & Single Wheel Control ABS EBS … Standard one wheel suspension, lightly on wheel changing … Electric self powered all wheel trailer – for efficient slope climbing! !No Hub motors because of heavy swinging masses! E-Juggernaut by W. Egger

Efficient Future Heavy Wheight Vehicles Full electric All Wheel forced Power Train with trailer powering by W. Egger Very important for high energy saving: self powered trailer on juggernaut or trailer train èSelf powered and single controlled wheels forcing systems for trailer wheels. èTrailer with own diesel generator for self steering operation by loading acts èWell controlled over standard electronic juggernaut automotive bus system (CAN, Flex. Ray…) New electric powered Trailer for heavy Trailer Trains and Juggernaut Hybrids (US, Australia)

Efficient Future Heavy Wheight Vehicles The Future Heavy Truck System: The Serial Hybrid Power Train Variations

Efficient Future Heavy Wheight Vehicles DAF LF Hybrid medium duty truck system with storage Electric Hybrid Traction Study of Technische Universität München TUM and Siemens, Design Colani MAN Hybrid storage unit and electrical base frame

Efficient Future Heavy Wheight Vehicles Military Off Road Heavy Vehicles Oshkosh Hybrid heavy duty Military Trucks Magnet Motors Multi Wheel Military Vehicle 1995

Efficient Future Heavy Wheight Vehicles Electric safety Truck on Airports from Renault Z. E. E-Renault for support action on the France airport Charles de Gaulle. Fully explosion safety, no exhausting – well done! Pure Electric Heavy Duty Vehicles: Sanyo study of PV-charged e-Truck • Pure electric driven trucks are possible, but only on special using. … Question: how many expensive battery makes sense to be used in trucks? • Battery stacks on trucks are not cost effective for normal use of trucks. • Smaller stack packages for special energy braking saving or Super capacitors … only for maximal 15 seconds. (KERS) … be re-used breaking energy in generation way for acceleration on electric wheel drives. • Better, more lighter in weight: super capacitor stacks for short acceleration jump.

Efficient Future Heavy Wheight Vehicles E-Highway and E-Trolley Systems E-Highway Study by Siemens e. Trolley Bus – OBUS Salzburg OBUS SLB on Salzburg Town Tracks Battery puffered for accident bypass

Efficient Future Heavy Wheight Vehicles Hybrid Diggers Hybrid Chain Dredger Truck mounted Heavy Cranes Truck with mounted hydraulic cranes Hydraulic losses • Hydraulic motors to force the traction chains …. earth oil pollution by cutting off • Hydraulic regulated pumps • Long hydraulic lines with line losses • hydraulic motors have well to chain only under 5% efficiency. Alternative diesel generator serial hybrid supply • Main diesel generator • Self controlled e-machine drives for tower turning e. g. • PM-SM hub motor systems embedded in the chains …. No earth oil pollution by cutting off! • Hydraulic motion drives with electric pump-machines Liebherr 9 XX Class Chain Dredgers with Electric & Hydraulic Storage Systems seen on BAUMA 2013

Efficient Future Heavy Wheight Vehicles Railway Hybrid MTU Power pack for diesel electric train set Siemens SITRAS recovering braking energy for diesel locomotives Alstom Hybrid Diesel Power pack for Diesel Locomotives ÖBB Rail Cargo Economic Total Energy Rail Management: Electric locomotive fleet with recuperation on Taurus ÖBB 1216 -XXX new central control terminals in Vienna steered all accelerations and breaking actions over all running locomotives so, that every time 600 locomotives will be steady continuously supported by the same low energy level from Grids, so its done by ÖBB Cargo.

Efficient Future Heavy Wheight Vehicles Conclusion Pure Electric Heavy Duty Vehicles • Pure electric driven trucks are possible, but only on special using. … With the question: how many expensive battery makes sense to be used in trucks? • Battery stacks on trucks are not cost effective for normal use of trucks. • Smaller stack packages for special energy braking saving or Super capacitors … only for maximal 15 seconds, recuperation breaking energy for acceleration • Super capacitor stacks for that short acceleration jump. • Much more lighter in weight Heavy Hybrid Vehicles • Serial Hybrid with clear electric mechanic (hydraulic) interfaces in modules • Combustion engines has do be only driven on the most efficient running point • Mono wheel full control units for each wheel is saving tire abrasion • Multilevel power train control on high efficiency • Full modular unit construction with strictly defined interfaces saves production, service and recycling costs • Material savings and minimizing weight is the leading consequence • Self powered all wheel trailer for slope driving efficiency

Efficient Future Heavy Wheight Vehicles Thanks! Winfried Egger Power Electronics & Drives Tel. : +43 4242 90500 2131 e-mail. : w. egger@cuas. at http: //www. fh-kaernten. at

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