AABC 2012. AABTAM Symposium: Advanced Automotive Battery Technology, Application and Market - Session 5

Commercial and heavy-duty vehicles entail additional challenges but also unique opportunities for vehicle hybridization and electrification. In this session we will review progress with the electrification of larger and specialty vehicles and analyze current and proposed energy-storage solutions for these vehicles.

Mr. Beaty joined Eaton Corporation as Business Unit Manager – Hybrid Electric Powertrains in March 2000 to lead the development and commercialization of Eaton's hybrid electric business. Prior to joining Eaton, he held positions of Research Engineer, Senior Research Engineer, Group Leader and Manager with Southwest Research Institute (SwRI) in the Engine, Fuel, and Vehicle Research Division. While at SwRI, Mr. Beaty conducted engine R&D projects for the government and industry clients primarily focused on alternative fuels, energy efficiency, and emissions reductions. After leaving SwRI, he converted vehicles to natural gas (CNG) as Vice President of Vehicle Operations (start-up Natural Fuels Corporation) and developed advanced CNG/LNG engine control systems for commercial vehicles as Business Unit Manager and Director (Woodward Governor Company).

1. Session Introduction
   Kevin Beaty, Manager, Global Operations and Strategic sourcing Hybrid Power Systems Division, Eaton Corporation
2. Battery Systems for Navistar HEVs / EVs / PHEVs
   Brian Conway, Electrical Energy Storage Functional Expert, Navistar
   Abstract 

   

   Navistar is a medium-duty and heavy-duty truck OEM with several vehicles in production with electrified powertrains. This presentation will include an overview of Navistar's HEV/EV/PHEV products, a specific overview of their lithium-ion battery systems, and a discussion of key issues faced when developing batteries for hybrid and electric medium and heavy duty trucks. The first vehicle covered will be Navistar's EStar electric van which achieves over 100 mile EV range on a single charge and features an 80kWh battery pack provided by A123 Systems. The electrified drive system on EStar is rated at 70kW and the vehicle also features high-voltage power steering and HVAC systems as loads on the battery system. The vehicle has a GVWR of 12,000 pounds. The second vehicle covered will be either Navistar's class seven plug-in-hybrid school bus or class five hybrid medium-duty truck.

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3. Battery Packs Systems for Chinese Electric Buses
   Denise Gray, Vice President, Atieva Inc.
   Abstract 

   

   • China Market Opportunity
     • Automotive Market
     • Cleaner air solutions
      
   • China Bus Industry Needs
     • Business Case
     • Total Cost of Ownership
     • Support of Local Manufacturers
      
   • China Bus Battery Pack System Requirements
     • EV
     • PHEV
     • HEV
      
   • Can the China Market Lead the Global Market?
     • Engineering Resources
     • Vertical Integration
     • Price pressures
     • Low cost solution innovativeness
     • Redefine the speed of refinement
     • Sources of raw material
      

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4. Battery Financing for Fleet Electric Vehicles
   Jeff Kessen, Director, Global Marketing, A123 Systems
   Abstract 

   

   As battery prices decline, the payback on electrified vehicles is improving but not yet below the threshold of the mainstream market. To spur market adoption, various battery financing alternatives are being explored, especially in the commercial vehicle sector. This presentation will explain why the commercial truck sector is the focus of this activity and assess which approaches to battery financing are most likely to succeed.

   • Economics of commercial EV fleets without battery financing
   • Battery financing models:
     • Leasing with residual value from secondary use
     • Income from grid usage of stationary vehicles
      
   • System differences between transportation and grid energy storage
   • Balancing of first and second use requirements
     • Matching of duty cycle and other technical requirements
     • Balancing of economic interests
      
   • Conclusion and outlook

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5. Traction Battery Requirements and Solutions for Trams
   Michael Meinert, Head of Energy Storage Systems, Siemens AG
   Abstract 

   

   Energy efficiency is the key to innovative railway systems. Energy Storage Systems (ESS) are one contribution which increases the energy efficiency while reducing overall energy consumption as well as the visual impact of a modern streetcar system. The use of ESS on trams and streetcars can avoid using the catenary's system entirely along segments of the track. This system helps to reduce the daily and overall system energy because it 'recycles' the vehicle's braking energy then stores it for later usage by the propulsion and other necessary vehicle auxiliary loads. Less energy consumption leads to lower CO₂ and "greenhouse gas" emissions. Reduced "visual impact" leads to an appropriate integration of Light Rail Vehicles (LRV) into the already existing infrastructure. Therefore a participation in environmental protection and "smooth" integration of newly established LRV-systems is guaranteed. In summary the advantages are:

   • Reduction of expensive line-side peak power,
   • Environmentally compatible solution
     • Reuse of braking energy,
     • Reduced overall energy consumption,
     • Reduced CO₂ and "greenhouse gas" emissions
      
   • Smooth" integration into the already existing infrastructure to establish environmentally-friendly public transport.

   A Hybrid Energy Storage (HES) system containing Double-Layer Capacitors (DLC) and a traction battery ensures both operations – energy-efficient and catenary-free operation in one system. All physical and operational requirements demand a high power and energy throughput as well as a high level on safety form the ESS. Experience with the HES-system used on a tram of the Portuguese operator Metro Transportes do Sul (MTS) south of Lisbon in revenue service since November 2008 indicates that the NiMH-technology is limiting the distances of the catenary-free operation. Lithium Ion-technology seems to be the key to fulfill the severe requirements derived from tram application in the future.

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6. Battery R&D Efforts of SK Innovation for xEV Applications
   Myounggu Park, Manager, Advanced Battery Development, SK Innovation, Co., Ltd.
   Abstract 

   

   The freedom of human mobility has been increasing in accordance with the advancement of automotive technologies (especially internal combustion engines) although, from a simple historical retrospection of important historical events in the electrical vehicle and battery fields, it is obvious that batteries and internal combustion engines are competing but combining together in a way to complement each other. However, in the wake of global environmental concerns, which is the real driving force for pure electric vehicles, the time has come for scientists and engineers to think seriously about new drivetrains for future transportation - i.e. revolutionary battery systems. Because the driving range has always been at the center of the EV problems, which dampen and tarnish the merits of EV, new battery systems are required to provide passengers with the equivalent driving range of today's common cars. In the current discussion we are going to talk about R&D efforts of SK Innovation regarding future EV battery technologies with additional support from our research partners.

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