Powertrain - Tech Blog
Saft receives additional funding from BAE Systems for advanced Li-ion ESS
BAE Systems has awarded Saft $1.3 million in new funding to continue development of a lithium-ion (Li-ion) energy storage system (ESS) for the U.S. Army’s Ground Combat Vehicle (GCV) program. The new funding for the GCV project is an addition to the initial 2010 contract. Saft, which is designing and building ultrahigh-power cells for the vehicle’s hybrid-electric drive system, has already completed the demo battery system including hardware and software. Comprised of ultrahigh-power, high-voltage VL 5U cells, the Li-ion ESS supports the GCV’s electric drive system when the vehicle is not running on gasoline, such as during silent watch missions. Saft joins Northrop Grumman, MTU, QinetiQ, and L-3 Communications on the BAE Systems’ GCV team, one of two industry teams working on the technology development phase of the program. The 24-month technology development phase is aimed at completing preliminary design reviews to build prototype systems prior to the engineering and manufacturing phase. Saft believes it will likely be the battery supplier when production begins in 2019, if the BAE Systems/Northrop Grumman team is selected as the Army’s design and manufacturing partner.
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BAE Systems' solution for the U.S. Army’s GCV program—a nine-man Infantry Carrier (plus three crew members) that can protect against threats, move in urban and off-road terrain, and accommodate emerging technologies such as lightweight armor composites and electronics—includes a hybrid-electric drive system.
Motiv ePCS to power heavy electric trucks in Chicago
San Francisco Bay Area-based startup Motiv Power Systems has been chosen to supply its scalable electric Powertrain Control System (ePCS) to the City of Chicago for 20 all-electric garbage trucks, under an exclusive five-year, $13.4 million contract. The City of Chicago operates 600 garbage trucks in total. The ePCS uses off-the-shelf batteries and motors that can be configured to power medium-duty to Class 8 heavy-duty EV trucks, weighing from 15,000 to 52,000 lb (6800 to 23,500 kg). This design approach can cut operating costs by 50% over an eight-year period, according to Motiv. The company, which was founded in 2009, has been validating its ePCS since March 2012 with an all-electric pilot bus. Funded by a grant from the California Energy Commission, the 20-passenger bus contains five battery packs (125 kW·h) providing a range of more than 120 mi (193 km) on a single charge. The Motiv EV refuse trucks planned for Chicago will use the same ePCS system as the pilot bus, but with a larger motor and 10 battery packs, and will also employ an electric motor to drive the hydraulics system. Motiv will work with partner Detroit Chassis to install the ePCS onto a standard refuse chassis; Loadmaster will provide the truck bodies. Weighing 52,000 lb (23,500 kg), the EV refuse trucks will reportedly have a range of more than 60 mi (97 km), with a total energy storage of 200 kW·h. (Go to www.sae.org/mags/sohe/11486 to read about another recent electrified refuse truck project.)
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Weighing 52,000 lb, the Motiv-powered electric refuse trucks in Chicago will have a range of more than 60 mi (97 km), with a total energy storage of 200 kW·h.
Volvo ramps up production of world's first diesel plug-in hybrid
Volvo Car Corp. says it has successfully integrated production of what it claims is the world's first diesel plug-in hybrid into the assembly line with conventional models at its Torsland Plant in Gothenburg, Sweden. The company claims it is the first to accomplish such an integration. "The integration in the standard production flow gives the plug-in hybrid buyer the possibility to choose, in principle, all options available for the standard V60," said Peter Mertens, Senior Vice President Research and Development at Volvo Car Corp. The assembly line was rebuilt to accommodate production of the plug-in, which features 300 more parts than the conventional car models. After the first batch of 1000 MY2013 V60 Plug-ins are built, the plant will ramp up to as many as 6000 MY2014 units, according to the company.
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Sofia Nordgren and Apichat Khongkamnoed install the high-voltage cables (orange) and the cooling system for the V60 Plug-in's battery pack at Volvo's Torsland Plant in Gothenburg, Sweden.
SAE introduces certification for engineers involved in vehicle electrification
SAE International announced Nov. 14 that it will implement a personnel certification program that enables engineers, product development technicians, and associated personnel to earn a certificate of competency or certification in the area of vehicle electrification (VE). Through a process that engaged a group of auto industry subject-matter experts, a VE body of knowledge was developed and segmented into three distinct levels to meet the needs of specific personnel. Exam questions were generated to align with the body of knowledge to address each of the three levels. The VE Fundamentals and Safety Certificate of Competency is designed for individuals who require training and validation of knowledge in general electrified vehicle architectures, basic electricity and electronics, and critical safety precautions and procedures. Job roles include manufacturing personnel, procurement, sales, management, and engineering undergraduate students. This credential requires completing an online training course and passing an online exam. The VE Professional Certification level, due to launch in February 2013, is designed for individuals to validate mastery of knowledge in general VE safety and all major VE systems. Job roles include engineers, technicians, and other technical personnel assigned to electrified vehicle platforms but not involved with direct design of VE systems. Passing an online exam results in certification that remains in force for three years. The VE Engineer/Scientist Certification level will launch in March 2013 and is for individuals to validate mastery of knowledge in the science and design of all major VE systems. Job roles include engineers and R&D scientists engaged in focused research or product design of VE systems such as battery packs, motors, power electronics, and systems integration. Passing an online exam also results in certification that remains in force for three years.
Bobcat collaborates on non-DPF Tier 4 engine for 2014
Bobcat’s plan for Tier 4 solutions includes a Doosan-built engine added to some of its equipment lineup starting in early 2014. Development of the new Tier 4-compliant, non-DPF (diesel particulate filter) engine was a collaboration between engineers from Bobcat, Doosan (Bobcat’s parent company), and engine-development companies such as Ricardo and FEV. Bobcat says its customers and dealers prefer a non-DPF engine because it minimizes long-term Tier 4 parts and maintenance expenses, and reduces daily maintenance requirements and complexity. Three Doosan engine models will be available, between 1.8- to 3.4-L displacement and 33 to 99 hp (25 to 74 kW). The company will continue to provide parts, service, and warranty on Kubota engines, which represent the largest number of engines in Bobcat machines. Kubota engines will still be offered in select products. Bobcat plans to release more details—engine specs and customer features and benefits—on its Tier 4 machines and their engines over the next 18 months.
KLD Energy, Cenntro to develop specialized EVs for U.S., China
KLD Energy Technologies, Inc., an Austin, TX-based developer of electric propulsion and generation systems, has teamed up with Cenntro Group Ltd., a developer of diesel and liquid-propane powertrains for agricultural, transportation, and construction equipment, to jointly develop four-wheel electric vehicles (EVs) that will incorporate KLD’s EV drive system technologies. The companies plan to initially focus on the U.S., Europe, and China, with the launch of the Utility Electric Vehicle, an on- and off-highway work and maintenance vehicle; the low-speed Neighborhood Electric Vehicle; and the Intra-city Logistic Vehicle, a compact delivery vehicle. Cenntro Group owns a number of operations in China and the U.S., including Zenith Power Products, LLC and Xinchang Cenntro Machinery Co., Ltd., and is a major shareholder of Sinomachinery Group Ltd. In related news, KLD and Samsung SDI also recently entered into a cooperative relationship to jointly develop battery systems that will incorporate Samsung SDI’s lithium-ion battery cells and KLD’s EV drive technologies.
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KLD’s EV drive system—comprised of the battery pack, the electric motor, and the motor controller—is applicable in a range of products, including motorcycles and scooters, three- and four-wheel on- and off-highway vehicles, and equipment for wind-energy generation.
Rolls-Royce to power U.S. Navy’s new Ship-to-Shore Connector hovercraft fleet
Rolls-Royce won a contract to power the U.S. Navy’s future fleet of hovercrafts, known as the Ship-to-Shore Connector (SSC). It will work with Textron Marine & Land Systems, which has been selected to build the initial development craft, in a program that could extend to 73 craft. The SSC will replace the Navy’s current fleet of Landing Craft Air Cushion (LCAC) hovercraft over the next 20 years. The new hovercraft will be used to rapidly deploy personnel and vehicles between U.S. Navy ships and the shore. Each SSC will use multiple Rolls-Royce MT7 gas turbines, derived from the AE1107 engine, which powers the U.S. Marine Corps ’ V-22 Osprey tilt-rotor aircraft. Rolls-Royce will also design and manufacture the air intake and exhaust systems.
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On each hovercraft, the Rolls-Royce MT7 gas turbines will be connected to a sophisticated gearbox system providing both propulsion and lift.
ATK Awarded $50 Million Contract for NASA's Advanced Concept Booster Development for SLS
NASA has awarded ATK a $50 million contract to complete engineering development and risk reduction tests as part of the Advanced Concept Booster Development for the Space Launch System (SLS). ATK's effort focuses on overcoming key technological challenges in developing advanced booster requirements for NASA's SLS program. Tasks within the scope of ATK's award include development of a lithium-ion battery-powered electric thrust vector control system; high-performance propellant; lightweight composite rocket motor case; and an advanced nozzle. All of these developments will culminate with an integrated booster static test firing of these technologies. All of these tasks use cost-saving processes and materials that reduce cost and help lower risk as NASA moves toward a higher-performing booster in the future.
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Shown is an artist’s concept of ATK's Advanced Concept Booster in support of NASA engineering and risk reduction tests as part of its Space Launch System (SLS) program.
Johnson Controls to acquire bankrupt battery maker A123 Systems
A123 Systems announced on Oct. 16 that it is filing for Chapter 11 bankruptcy protection as part of a plan to sell its automotive business assets to Johnson Controls in a transaction valued at $125 million. Those assets include all of its automotive technology, products, and customer contracts; its facilities in Livonia and Romulus, MI; its cathode powder manufacturing facilities in China; and A123's equity interest in Shanghai Advanced Traction Battery Systems Co. The asset purchase agreement also includes provisions enabling Johnson Controls to license back to A123 certain technology for its grid, commercial, and government businesses. In conjunction with the proposed asset purchase agreement, Johnson Controls will provide A123 with $72.5 million in to support the latter's operations until the sale is finalized.
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A123 Systems makes lithium-ion battery cells in a number of different formats, sizes, and capabilities.
Algae.Tec, Lufthansa agree to build biofuel production facility in Europe
Algae.Tec and Lufthansa signed a collaboration agreement for the construction of a large-scale algae-to-aviation biofuels production facility. The site will be in Europe adjacent to an industrial CO2 source. Lufthansa will arrange 100% funding for the project. Algae.Tec will receive license fees and profits from the project, which will be managed by Algae.Tec. As part of the agreement, Lufthansa commits to a long-term offtake agreement of at least 50% of the crude oil produced at an agreed price. The agreement forms the base for a long-term cooperation between Algae.Tec and Lufthansa for the industrial production of crude algae suitable for conversion into aviation kerosene and conventional diesel fuels.
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Algae.Tec’s Shoalhaven One algae production facility in Bomaderry, New South Wales, Australia, is shown.
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