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Electrical Energy Storage System Characterization Studies for Hybrid Locomotive
Development
Tim Cleary – Pennsylvania State University
Harshad Kunte – Pennsylvania State University
Brent Ballew – Norfolk Southern
Outline
Hybrid Locomotive Design
Locomotive Simulation
o Locomotive Powertrain Model
o Energy Storage System Design
ESS Hardware In The Loop
o Locomotive Model Hybridization
Questions
2
Outline
Hybrid Locomotive Design
Locomotive Simulation
o Locomotive Powertrain Model
o Energy Storage System Design
ESS Hardware In The Loop
o Locomotive Model Hybridization
Questions
3
Hybrid Locomotive Design
4
Operational Impact
CostEnergy Storage System
Hybrid Locomotive Design
Unit Configuration
Prime Mover
Controls Integration
Powered Axles
Freight Service
5
Operational Impact
CostEnergy Storage System
Norfolk Southern Hybrid Concept. B. Ballew 2012
Hybrid Locomotive Design
Safety
Charge Acceptance
Depth of Discharge
Lifetime Energy
ESS Management
Shock and Vibe
6
Operational Impact
CostEnergy Storage System
Penn State University Battery Test Rack. T. Cleary 2012
Hybrid Locomotive Design
Total ESS Energy
ESS Management
Hybrid Platform
Locomotive Control
Maintenance
7
Operational Impact
CostEnergy Storage System
Fuel Savings
Emissions andNon-AttainmentAreas
Outline
Hybrid Locomotive Design
Locomotive Simulation
o Locomotive Powertrain Model
o Energy Storage System Design
ESS Hardware In The Loop
o Locomotive Model Hybridization
Questions
8
Project Overview
9
Locomotive Powertrain Modeling & Simulations
Hybridization, ESS modeling & Controller development
Component-in-Loop Testing
Prototype
Locomotive
Modeling in Simulink® and Simscape®
Model Overview
Model Overview
Diesel Engine With Governor
Main Generator & Load Regulator
Main Generator & Load Regulator
- Main Generator Abstracted as a DC Machine
Load Regulating Controller
Traction Motors & Road Load Model
Traction Motor with Dynamic Breaking Switchgear
Dynamic Braking & Auxiliary Loads
Outline
Hybrid Locomotive Design
Locomotive Simulation
o Locomotive Powertrain Model
o Energy Storage System Design
ESS Hardware In The Loop
o Locomotive Model Hybridization
Questions
20
Energy Storage System Design
21
Energy Storage System Analogy Diagram. L. Keegan and B. Ballew, Norfolk Southern RR. 2014
Energy Storage System Design
22
Energy Storage System Analogy Diagram. L. Keegan and B. Ballew, Norfolk Southern RR. 2014
Energy Storage System Design
23
90th Percentile Single Discharge/Charge Event Profile DB Event Exceedance
Intermodal Train
Energy: 250 kWhPower: 1600 kWESS: 2300 amps @ 700V
Energy Storage System Design
24
General Merchandise Train
Energy: 615 kWhPower: 2000 kWESS: 3000 amps @ 700V
Profile DB Event Exceedance90th Percentile Single Discharge/Charge Event
Energy Storage System Design
25
1Battery Types and Characteristics for HEV. ThermoAnalytics, Inc.2 Supercapacitor Perfomance Characteristics . MaxwellTechnologies, Inc.3 Utility Scale Energy Storage Systems – State Forcasting Group. Purdue University. 4 Overview of current and future energy storage technologies for electric power applications. Electricity Authority of Cyprus.
Technology Energy Density (Wh/kg)
Power Density (W/kg)
Cycle Life (cycles)
Efficiency (%) Cost ($/kWh)
Lead Acid1 30 100 200 70 $110
Lithium Ion1 125 300 800 85 $500
Nickel Metal Hydride1
65 200 1,000 80 $525
Super Capacitor2 30 10,000 1,000,000 95 $20,000
Flywheel3,4 100 5,000 100,000 85 $8,300
Typical Energy Storage Values
Outline
Hybrid Locomotive Design
Locomotive Simulation
o Locomotive Powertrain Model
o Energy Storage System Design
ESS Hardware In The Loop
o Locomotive Model Hybridization
Questions
26
Locomotive Model Hybridization
27
ConventionalConfiguration
Locomotive / Train Set(Power Requirement)
Engineer Diesel Power Plant
Dynamic Brake
DC DriveMotors
Logic
Electrical
Mechanical
Locomotive Model Hybridization
28
ConventionalMode: Propulsion
Locomotive / Train Set(Power Requirement)
Engineer Diesel Power Plant
Dynamic Brake
DC DriveMotors
Logic
Electrical
Mechanical
Locomotive Model Hybridization
29
ConventionalMode: Braking
Locomotive / Train Set(Power Requirement)
Engineer Diesel Power Plant
Dynamic Brake
DC DriveMotors
Logic
Electrical Mechanical
Locomotive Model Hybridization
30
Hybrid ElectricConfiguration
Locomotive / Train Set(Power Requirement)
Engineer Diesel PowerPlant
DC/DCConverter
DC DriveMotors
High VoltageBattery
Dynamic Brake
Hybrid Controller
Hybrid Controller
31
Hybrid ElectricConfiguration
Locomotive / Train Set(Power Requirement)
Engineer Diesel PowerPlant
DC/DCConverter
DC DriveMotors
High VoltageBattery
Dynamic Brake
Hybrid Controller
Hybrid Controller
32
Hybrid Controller
Limit Control Energy Power
o Voltage o Current
Thermalo Cooling Systems On/Offo De-rating limits
Hybrid Controller
33
Hybrid Controller
Optimal Operation
Blending liquid fuel and electrical energy consumption Efficiency of each component in a particular range Generate a map off line for use in the vehicle
Stochastic dynamic programing Maximize offset of diesel fuel and minimize emissions Minimize the cost function for optimal operation in all scenarios
Hardware-in-the-Loop (HIL) Testing
34
Computer Simulation of the
locomotive power plant
Simulation Computer
Electrical Power Processor
Replaceable Battery Under
Test
Questions?
35
Federal Railroad
Administration
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