Electric and Hybrid Industrial Vehicle Technology Symposium
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2016 Conference Programme


Day 1

Wednesday 9 November

Keynote presentations
Congress Saal 1

Morning session

Chairman
William Van Amburg, senior vice president, Calstart, USA

09:00 - Innovation convergence: rapid, concurrent change for on and off-road
William Van Amburg, senior vice president, Calstart, USA
The pace of technology change has never been faster across the heavy-duty sector. It is being driven significantly by climate change and air quality imperatives, as well as by rapidly evolving customer needs and technical capabilities that quickly move across old industry sector lines. In this industry overview, we highlight the rapid changes now impacting off-road tech, and note that technology is no longer moving sequentially from cars to on-road to off-road but is evolving concurrently. We highlight key sectors of change and flag the next areas of parallel technology transition from buses and trucks and the high-tech sector.

09:30 - The future of the construction equipment industry
Dave Ross, vice president advanced technology & verification, Volvo Construction Equipment, BELGIUM
Dave will talk about technology shifts and Volvo CE’s focus areas for future technology developments. He will touch on everything from the company’s vision to hybrids, fully electric machines, connected sites, autonomous machines, sustainability and clean energy. He will also discuss the affordability, reliability and availability of new technology.

10:00 - Electrified powertrains for industrial vehicles – motivations, challenges and solutions
John O'Brien, e-technical advisor - powertrain systems research & technology, Cummins Inc, UK
Experimentation with hybrid and electric powertrain technologies has increased in recent years, and adoption is now under way in key applications and regions. Motivations and benefits vary widely, and adoption is increasingly governed by the convergence of capable technology and local needs. We will explore the keys to accelerating this adoption among commercial vehicles, and some solutions to the challenges of cost-effectively delivering advanced technologies in low production volume markets.

10:30 - 11:00 - Break

11:00 - Needs and potential: industrial vehicles in 13 categories 2016-2026
Dr Peter Harrop, chairman, IDTechEx, UK
This presentation shares some of the worldwide research carried out by IDTechEx in 2016 for its new reports highlighting new technologies and markets. The 13 sectors forecasted 2016-2026 span intralogistics, mining, construction, agriculture, marine, aircraft, etc., with major parts split out. Future energy storage, motor generators, energy harvesting and regeneration and power electronics are considered. New powertrain options are assessed, such as 48V mild hybrids to keep ICE powertrains legal under new laws. We foresee why and when non-plug-in electric vehicles such as energy-independent and dynamically charged ones will replace plug-in PHEV and PEV vehicles.

11:30 - Electrification off-highway – challenges and solution approaches
Dr Joachim Sobotzik, Electric drive systems lead - Enterprise Electric Drives Services Group, John Deere GmbH & Co. KG, GERMANY
Dr Martin Lenz, manager e-mobility business development EEA EMEA, Delphi Corporation, GERMANY
In the off-highway segment the technological development is driven to increase productivity and lower operating cost. Electrified drive topologies are a major focus in the automotive segment; they are also becoming cost-efficient when applied to increase the productivity of working machines. In the off-highway segment there are multiple applications for hybrid & electric drives: from electrification of subsystems & power take-offs or power assistance through to downsizing and downspeeding of the combustion engine by powertrain electrification. Functions such as start/stop, 48V e-charging or energy recuperation can be implemented. This presentation gives a brief overview based on joint work between John Deere and Delphi.

12:00 - AVL’s strategy for electrification and hybridisation in the large-engine business field
Wilhelm Müller, vice president Large Engines - Engineering and Technology Powertrain Systems, AVL List GmbH, GERMANY
Electrification and hybridisation have long been established in the automotive field. Now, the use of hybrid and electric drives has begun in large-engine applications. Simulation is very important for pre-calculation of the benefits of hybrid end electric drives, and to optimise the layout of the components. The presentation describes how AVL has used the successful experience of the automotive hybrid and electric designs and transferred this to the large-engine business field. The development process of simulation in the virtual design phase and the results of the later hardware design are described, and an outlook on the future will be given.

12:30 - 13:00 - Panel Discussion

William Van Amburg, senior vice president, Calstart, USA
Dave Ross, vice president advanced technology & verification, Volvo Construction Equipment, BELGIUM
Tom Dollmeyer, e-technical advisor - powertrain systems research & technology, Cummins Inc, UK
Dr Peter Harrop, chairman, IDTechEx, UK
Dr Joachim Sobotzik, Electric drive systems lead - Enterprise Electric Drives Services Group, John Deere GmbH & Co. KG, GERMANY
Dr Martin Lenz, manager e-mobility business development EEA EMEA, Delphi Corporation, GERMANY
Wilhelm Müller, vice president Large Engines - Engineering and Technology Powertrain Systems, AVL List GmbH, GERMANY

13:00 - 14:00 - Lunch


Congress Saal 1

Afternoon Session

Chairman
Mark Case, engineer principal III, Genie Industries / Terex, USA

14:00 - Are significant emission reductions possible in container handling equipment?
Johanna Pirinen, director corporate responsibility, Konecranes, FINLAND
In the era of the Paris Climate deal, companies and industries are taking CO2 emission tracking, reporting and reductions even more seriously than before. This case example examines how hybrid and electric technologies provide significant emission reductions in container handling equipment. The session will also discuss how emission reporting and reductions are visible on equipment manufacturers' corporate-level reporting and what would be available for customers.

14:20 - Energy saving hybrid technology on hydraulic construction machinery: Efficiency through modern technology
Burkhard Janssen, general manager product management and Engineering, Hitachi Construction Machinery (Europe) NV, NETHERLANDS
What are current and future opportunities for energy recovery? Why is this an important topic? In today’s world, there is an ever-increasing demand for energy – but we are faced with limited resources and stringent government regulations for sustainable energy. What does this mean for the construction machinery industry and how can customers keep up with these high demands and still focus on their bottom line? This presentation will give more insight into these questions and also give a detailed technical explanation of Hitachi’s hybrid technology for construction machinery.

14:40 - Hydraulic hybrid systems for excavators
Milos Vukovic, team leader systems and controls, Institute for Fluid Power Drives and Control - RWTH Aachen, GERMANY
Concerns over global warming and depleting fossil fuel reserves are forcing manufacturers of mobile machinery to improve the efficiency of their products. The use of hydraulic hybrid architectures may be a possible way forward. This talk aims to illustrate the potential of such systems and the challenges facing their implementation. As an example, the STEAM system developed in Aachen will be presented and discussed in detail.

15:00 - Electro-hydrostatic actuation – highly efficient implement solution with energy recovery
Dale Vanderlaan, senior program manager, Parker Hannifin, USA
Off-road industrial machines require multi-function implement operation with dynamic duty cycles. In many cases, machine implements demand short bursts of full engine power and brake dynamic loads requiring 50% or more of energy consumed. Many next-generation machines reduce energy loss and improve productivity by incorporating hybrid-electric approaches with energy storage. An efficient implement solution enabling the hybrid-electric approach is essential to achieve maximum improvement potential. This presentation will introduce electro-hydrostatic actuation, outlining basic operation, highlighting unique characteristics and comparing benefits with alternative approaches. A summary of test results from application experience will be included.

15:20 - Q&A

15:35 - 16:05 - Break

16:05 - Electric drive integration and control
Anthony Law, systems engineer - business development, McLaren Applied Technologies, UK
McLaren Applied Technologies has built on experience of integrating electric drive systems in motorsport and developed a flexible control platform for development and production vehicles. This presentation will describe the development process and demonstrate how to streamline the integration of complex electrical systems to deliver new functionality.

16:25 - High-efficiency flywheel system for hydraulic energy recovery
Steve Hughes, chief operating officer, Torotrak Ltd., UK
Joanna Brahova, hybridization specialist, Torotrak Ltd, UK
Torotrak has developed several flywheel-based energy recovery systems across a number of industries. This presentation will outline the design and development of a flywheel hybrid system for recycling hydraulic energy in the off-highway sector. This product can be successfully adopted by various construction, agricultural or industrial applications. Adaptation of this technology opens up future development possibilities for load levelling applications as well as energy recovery. This mechanical hybrid solution provides simplicity, reliability and, crucially, a short payback to end customers, enabling a novel fuel economy offering.

16:45 - Hybrid powertrain for off-highway applications
Vern Caron, electric vehicle engineer, Oerlikon Fairfield, USA
Off-highway applications benefit from hybrid-electric drives. These systems reduce fuel consumption by 30% with highly dynamic driving cycles and in start-stop activity. Benefits include downsized engines, reduced tyre wear and longer TBO. Oerlikon Drive Systems provides a series-electric drive for off-highway and material handling vehicles. Components include drive axles with geared motors, wet disk brakes and integrated dual inverters; engine mountable generator instead of a power shift transmission; ultracapacitor-based energy storage unit with vehicle control unit, DC-DC converter and protection circuitry. These components are quickly connected via power and CAN-link cables, and usable in a variety of applications.

17:05 - Digital Displacement hydraulics for off-road and on-road heavy hybrid vehicles
Dr Niall Caldwell, managing director, Artemis Intelligent Power Ltd, UK
Digital Displacement is a fundamental advance in fluid power, developed and commercialised by Artemis Intelligent Power Ltd. By combining robust hydraulic mechanisms with direct digital control, dramatic improvements in efficiency, controllability and noise are achieved compared with conventional hydraulics for on and off-road vehicles. Results will be presented of a parallel hybrid propulsion system for a city bus, which, unlike electric hybrids, shows a positive business case without subsidy, based on fuel saving alone. The outlook will be described for reducing fuel consumption of off-road vehicles, particularly excavators, by using Digital Displacement pumps for propel and working functions.

17:25 - E-motor emulation – testing power electronics without an e-motor
Dr Sebastian Liebig, project manager, SET Power Systems GmbH, GERMANY
Electrical powertrains are part of safety-critical vehicle functionality. The challenge is to increase test quality and test depth without increasing test effort, while the scope of functionality is increasing and development times are becoming shorter. A new method where the real e-motor is replaced with an e-machine emulator allows load and ambient conditions to be reproduced in the lab exactly as they occur in a drive inverter during a real-life driving situation: a P-HIL system using a virtual e-machine. This presentation explains the possibilities and benefits of e-machine emulation.

17:45 - Q&A

Day 1 Close

Day 2

Thursday 10 November


Congress Saal 1

Morning Session

Chairman
Dr Peter Harrop, chairman, IDTechEx, UK

09:00 - Testing of hybrid drivetrains in industrial vehicles – adapted strategies
Marc von Papen, system line manager - heavy-duty driveline, AVL, GERMANY
Hybrid components and other active drivetrain elements are a huge challenge to future development and testing of industrial vehicles. The development of shifting and driving strategies is not compatible with the typical conventional testing methods. Requirements for the test systems to reproduce dynamic drive cycles, parameter variation of load conditions and driver behaviour, optimisation of complex simulation models and reliable statements on the impact on fuel consumption at different driving cycles lead to fundamentally new demands on the test equipment. Necessary technical conditions and adapted solutions to bridge these contradictions are presented on the basis of sample projects from practice.

09:20 - Challenges and solutions to reducing the CO2 impact of vehicles
Prof Andrew Atkins, global technical lead - senior technologist, Ricardo Innovations, UK
The presentation will discuss issues around working from a pragmatic needs perspective and review of available media topologies to provide opportunities for reduction in carbon-bearing energy consumption. The configurations explored will include possible solutions to electrification and other, less conventional, energy vectors.

09:40 - The electrification of a construction site.
Johan Sjöberg, research engineer - system controls, Volvo Construction Equipment, SWEDEN
Johan will discuss a Volvo CE research project which involves using electricity instead of diesel to power construction machines in a quarry. The project aims to deliver significant reductions in fuel consumption, CO2 emissions, environmental impact, cost per ton and total cost of ownership while also improving productivity. He will talk about how electrification, automation and hybridization can work together.

10:00 - Advances in axial-flux motors for industrial vehicles
Dr Tim Woolmer, chief technology officer, YASA Motors Ltd, UK
Compact and lightweight, YASA axial-flux motors and generators allow designers of industrial vehicles to implement higher-power hybridisation and electrification without compromising critical vehicle space and weight. YASA’s unique Yokeless And Segmented Armature topology is described, along with recent developments that further improve traction and generation capacity and ease mechanical integration. The presentation also discusses how advanced materials and volume manufacturing techniques are used to reduce costs and improve value to customers.

10:20 - Q&A

10:35 - 11:05 - Break

11:05 - Emissions, electrification and the future of off-highway vehicles
Ananth Srinivasan, senior consultant, Frost & Sullivan, GERMANY
This presentation provides an insight on the electrification and hybridisation technologies for the heavy-duty off-highway industrial vehicle sector. The agenda is to first look at the mega-trends impacting the off-highway industry, and then outline emission challenges facing the industry today. Later, we proceed to understand the road to electrification in this sector including the trends, forecasts and recent innovations in this domain. A brief opportunity analysis for OEMs, suppliers and non-traditional players will follow. The presentation will conclude with an outlook for the future of off-highway vehicles – Clean, Connected and Smart.

11:25 - Energy management enabling lithium-sulfur batteries in industrial vehicles
Dr Daniel Auger, lecturer in Advanced Control and Optimisation, Cranfield University, UK
Lithium-sulfur (Li-S) batteries are lightweight, safe and potentially cheap. Until recently, Li-S existed as a largely experimental technology with niche applications. As part of a major project, a demonstrator Li-S battery pack is being developed for electric vehicles. Li-S has unique features, and conventional battery management (e.g. from lithium-ion batteries) does not work for lithium-sulfur. A family of chemistry-specific battery techniques has been developed, making Li-S as easy to use as any other battery type. Software tools have been developed to rapidly compare dynamic Li-S performance profiles with specific heavy-duty requirements, enabling rapid assessment for industrial vehicles.

11:45 - Tigon technology – for performance & environment
Lars Lindahl, CEO, Huddig AB, SWEDEN
In our concept machine built on Tigon Technology – a full hybrid technology – we have experienced tremendous benefits for the environment and for the customer. We will share some of these benefits and challenges that we have found while developing and evaluating the concept.

12:05 - Cable feed electric tractor for heavy field work
Kurt Anders Hansson, project initiator, Swedish University of Agricultural Sciences, SWEDEN
Can an electric tractor connected to the grid via a cable replace today's diesel-powered tractors? The aim of the project is to develop, test and demonstrate a tractor that is connected with a power cable to the electricity grid under actual field conditions. Full electrification of a tractor makes great technical demands. During heavy field work, current battery technology cannot store enough electricity for an entire shift. An alternative is connecting the tractor to the power grid via a cable winder.

12:25 - Q&A

12:40 - 13:40 - Lunch


Congress Saal 1

Afternoon Session

Chairman
Ryan Maughan, managing director, Avid Technology Limited, UK

13:40 - Modeling and simulation of hybrid-electric compactors and their controls
Dr Ashraf Zeid, principal engineer, Volvo Construction Equipment, USA
This paper describes modeling and simulation of hybrid-electric eccentric/drum drives for an asphalt compactor. The objective of the simulation is to size and evaluate, by simulation, the energy and fuel consumption, as well as the performance, of a hybrid-electric compaction machine. The focus here is to create a dynamic simulation to investigate the dynamics of such a design, with special focus on energy consumption and maximum power requirements. We describe the development of the hybrid-electric compactor controls that drive performance. We discuss the impact on engine power, energy and state of charge of the ultracapacitor.

14:00 - Flexible high-dynamic test rig for electrified commercial vehicles
Prof Moritz Gretzschel, professor, Hochschule Aalen, GERMANY
Innovative driveline concepts of electrified vehicles take vehicle test rigs to their limits and exceed the dynamics of conventional roller-type dynamometers. At Aalen University, a highly variable 4x4 high-dynamic full vehicle test rig (VAPS) overcomes these limits. One distinctive feature is the ability to reproduce manoeuvres up to the stability limit and the control range of the stability control, to take advantage of the high dynamic of electric drives. A unique feature is to keep the test rig flexible enough for testing of axles, drivetrains and transmissions of commercial vehicles.

14:20 - Development of hybrid aircraft pushback tug: modelling of hybrid powertrain
Chris Bayliss, technical director, Hyperdrive Innovation, UK
Norbet Seitzl, mechanical design engineer, Douglas Equipment, UK
This paper presents the results of modelling and simulation of a hybrid powertrain including genset, battery and drive motors in the design/development of a hybrid-electric airport pushback tractor. A Matlab/Simulink model was developed to simulate the existing powertrain as well as the hybrid drivetrain using extensive duty cycle data collected from existing vehicles (torque, speeds, etc.). After many iterations, optimised components were finalised. The optimised components (engine, battery, genset, etc.) enabled fuel savings of between 25% and 75% to be achieved depending on the tractor’s duty cycle.

14:40 - Electrification of engine ancillaries for more efficient off-highway applications
Ryan Maughan, managing director, Avid Technology Limited, UK
In addition to full machine electrification, there are significant advantages to partial electrification of the off-highway vehicle powertrain, so-called mild or micro hybridisation. This approach sees the diesel engine supported by electrified systems and energy recovery capabilities. One of the key objections to component electrification is the energy conversion efficiency from mechanical to electrical power at a steady state, this is compounded by the lack of transient condition modelling for these systems. Avid will present a paper discussing the practical application of this technology approach and the limitations of the typical systems simulation models in delivering representative real world results under transient conditions.

15:00 - Q&A

15:15 - 15:45 - Break

15:45 - Analysis of overcharge tolerance of aged LMO cells
Dr Bapiraju Surampudi, staff engineer, Southwest Research Institute, USA
Lithium manganese oxide (LMO) batteries have become popular due to their acceptance in plug-in electric vehicles like Chevy Volt and battery electric vehicles like the Nissan Leaf. Due to their balanced portfolio of power and energy density they can also be good candidates for off-road applications, provided their safety tolerance is managed. With battery age the inaccuracy in estimating state of charge increases, resulting in unintended overcharges. This work presents experimental data of overcharge in aged cells from two manufacturers, and analyses prognostics and trends in tolerance based on ageing stress.

16:05 - Advanced energy technologies for clean and efficient industrial vehicles – an implementation example
Matthieu Desbois-Renaudin, battery system expert, CEA Liten, FRANCE
CEA Liten is a major technology research laboratory in the field of lithium battery and fuel cell technologies. CEA helps various OEMs convert their classical vehicles into electric ones, integrating batteries and/or fuel cells. During the last two years, CEA and Metalliance have developed a new full-electric vehicle optimised for operation on tunnel worksites. The presentation will explain the various steps of electrification and the technology integrated into this new vehicle.

16:25 - Power electronic solutions for fuel cell vehicles
Dr Peter Barrass, vice president engineering, Sevcon, UK
Fuel cells can be an attractive alternative to hybrid or battery-powered vehicles for some applications that are trying to decarbonise. Captive fleets such as large warehouse forklifts or port drayage tractors are especially well suited to fuel cells. Electrification of combustion engine-powered vehicles with mechanical and hydraulic powertrains presents many challenges. Fortunately, modern power electronics and software can provide solutions. The presentation will show how novel use of power electronics can provide solutions for a wide range of vehicles. It will also show how these work with other active and passive parts of the system.

16:45 - Q&A

Conference close

*This Programme may be subject to change.

Day 1

Wednesday 9 November

Keynote presentations
Congress Saal 1

Morning session

Chairman
William Van Amburg, senior vice president, Calstart, USA

09:00 - Innovation convergence: rapid, concurrent change for on and off-road
William Van Amburg, senior vice president, Calstart, USA
The pace of technology change has never been faster across the heavy-duty sector. It is being driven significantly by climate change and air quality imperatives, as well as by rapidly evolving customer needs and technical capabilities that quickly move across old industry sector lines. In this industry overview, we highlight the rapid changes now impacting off-road tech, and note that technology is no longer moving sequentially from cars to on-road to off-road but is evolving concurrently. We highlight key sectors of change and flag the next areas of parallel technology transition from buses and trucks and the high-tech sector.

09:30 - The future of the construction equipment industry
Dave Ross, vice president advanced technology & verification, Volvo Construction Equipment, BELGIUM
Dave will talk about technology shifts and Volvo CE’s focus areas for future technology developments. He will touch on everything from the company’s vision to hybrids, fully electric machines, connected sites, autonomous machines, sustainability and clean energy. He will also discuss the affordability, reliability and availability of new technology.

10:00 - Electrified powertrains for industrial vehicles – motivations, challenges and solutions
John O'Brien, e-technical advisor - powertrain systems research & technology, Cummins Inc, UK
Experimentation with hybrid and electric powertrain technologies has increased in recent years, and adoption is now under way in key applications and regions. Motivations and benefits vary widely, and adoption is increasingly governed by the convergence of capable technology and local needs. We will explore the keys to accelerating this adoption among commercial vehicles, and some solutions to the challenges of cost-effectively delivering advanced technologies in low production volume markets.

10:30 - 11:00 - Break

11:00 - Needs and potential: industrial vehicles in 13 categories 2016-2026
Dr Peter Harrop, chairman, IDTechEx, UK
This presentation shares some of the worldwide research carried out by IDTechEx in 2016 for its new reports highlighting new technologies and markets. The 13 sectors forecasted 2016-2026 span intralogistics, mining, construction, agriculture, marine, aircraft, etc., with major parts split out. Future energy storage, motor generators, energy harvesting and regeneration and power electronics are considered. New powertrain options are assessed, such as 48V mild hybrids to keep ICE powertrains legal under new laws. We foresee why and when non-plug-in electric vehicles such as energy-independent and dynamically charged ones will replace plug-in PHEV and PEV vehicles.

11:30 - Electrification off-highway – challenges and solution approaches
Dr Joachim Sobotzik, Electric drive systems lead - Enterprise Electric Drives Services Group, John Deere GmbH & Co. KG, GERMANY
Dr Martin Lenz, manager e-mobility business development EEA EMEA, Delphi Corporation, GERMANY
In the off-highway segment the technological development is driven to increase productivity and lower operating cost. Electrified drive topologies are a major focus in the automotive segment; they are also becoming cost-efficient when applied to increase the productivity of working machines. In the off-highway segment there are multiple applications for hybrid & electric drives: from electrification of subsystems & power take-offs or power assistance through to downsizing and downspeeding of the combustion engine by powertrain electrification. Functions such as start/stop, 48V e-charging or energy recuperation can be implemented. This presentation gives a brief overview based on joint work between John Deere and Delphi.

12:00 - AVL’s strategy for electrification and hybridisation in the large-engine business field
Wilhelm Müller, vice president Large Engines - Engineering and Technology Powertrain Systems, AVL List GmbH, GERMANY
Electrification and hybridisation have long been established in the automotive field. Now, the use of hybrid and electric drives has begun in large-engine applications. Simulation is very important for pre-calculation of the benefits of hybrid end electric drives, and to optimise the layout of the components. The presentation describes how AVL has used the successful experience of the automotive hybrid and electric designs and transferred this to the large-engine business field. The development process of simulation in the virtual design phase and the results of the later hardware design are described, and an outlook on the future will be given.

12:30 - 13:00 - Panel Discussion

William Van Amburg, senior vice president, Calstart, USA
Dave Ross, vice president advanced technology & verification, Volvo Construction Equipment, BELGIUM
Tom Dollmeyer, e-technical advisor - powertrain systems research & technology, Cummins Inc, UK
Dr Peter Harrop, chairman, IDTechEx, UK
Dr Joachim Sobotzik, Electric drive systems lead - Enterprise Electric Drives Services Group, John Deere GmbH & Co. KG, GERMANY
Dr Martin Lenz, manager e-mobility business development EEA EMEA, Delphi Corporation, GERMANY
Wilhelm Müller, vice president Large Engines - Engineering and Technology Powertrain Systems, AVL List GmbH, GERMANY

13:00 - 14:00 - Lunch


Congress Saal 1

Afternoon Session

Chairman
Mark Case, engineer principal III, Genie Industries / Terex, USA

14:00 - Are significant emission reductions possible in container handling equipment?
Johanna Pirinen, director corporate responsibility, Konecranes, FINLAND
In the era of the Paris Climate deal, companies and industries are taking CO2 emission tracking, reporting and reductions even more seriously than before. This case example examines how hybrid and electric technologies provide significant emission reductions in container handling equipment. The session will also discuss how emission reporting and reductions are visible on equipment manufacturers' corporate-level reporting and what would be available for customers.

14:20 - Energy saving hybrid technology on hydraulic construction machinery: Efficiency through modern technology
Burkhard Janssen, general manager product management and Engineering, Hitachi Construction Machinery (Europe) NV, NETHERLANDS
What are current and future opportunities for energy recovery? Why is this an important topic? In today’s world, there is an ever-increasing demand for energy – but we are faced with limited resources and stringent government regulations for sustainable energy. What does this mean for the construction machinery industry and how can customers keep up with these high demands and still focus on their bottom line? This presentation will give more insight into these questions and also give a detailed technical explanation of Hitachi’s hybrid technology for construction machinery.

14:40 - Hydraulic hybrid systems for excavators
Milos Vukovic, team leader systems and controls, Institute for Fluid Power Drives and Control - RWTH Aachen, GERMANY
Concerns over global warming and depleting fossil fuel reserves are forcing manufacturers of mobile machinery to improve the efficiency of their products. The use of hydraulic hybrid architectures may be a possible way forward. This talk aims to illustrate the potential of such systems and the challenges facing their implementation. As an example, the STEAM system developed in Aachen will be presented and discussed in detail.

15:00 - Electro-hydrostatic actuation – highly efficient implement solution with energy recovery
Dale Vanderlaan, senior program manager, Parker Hannifin, USA
Off-road industrial machines require multi-function implement operation with dynamic duty cycles. In many cases, machine implements demand short bursts of full engine power and brake dynamic loads requiring 50% or more of energy consumed. Many next-generation machines reduce energy loss and improve productivity by incorporating hybrid-electric approaches with energy storage. An efficient implement solution enabling the hybrid-electric approach is essential to achieve maximum improvement potential. This presentation will introduce electro-hydrostatic actuation, outlining basic operation, highlighting unique characteristics and comparing benefits with alternative approaches. A summary of test results from application experience will be included.

15:20 - Q&A

15:35 - 16:05 - Break

16:05 - Electric drive integration and control
Anthony Law, systems engineer - business development, McLaren Applied Technologies, UK
McLaren Applied Technologies has built on experience of integrating electric drive systems in motorsport and developed a flexible control platform for development and production vehicles. This presentation will describe the development process and demonstrate how to streamline the integration of complex electrical systems to deliver new functionality.

16:25 - High-efficiency flywheel system for hydraulic energy recovery
Steve Hughes, chief operating officer, Torotrak Ltd., UK
Joanna Brahova, hybridization specialist, Torotrak Ltd, UK
Torotrak has developed several flywheel-based energy recovery systems across a number of industries. This presentation will outline the design and development of a flywheel hybrid system for recycling hydraulic energy in the off-highway sector. This product can be successfully adopted by various construction, agricultural or industrial applications. Adaptation of this technology opens up future development possibilities for load levelling applications as well as energy recovery. This mechanical hybrid solution provides simplicity, reliability and, crucially, a short payback to end customers, enabling a novel fuel economy offering.

16:45 - Hybrid powertrain for off-highway applications
Vern Caron, electric vehicle engineer, Oerlikon Fairfield, USA
Off-highway applications benefit from hybrid-electric drives. These systems reduce fuel consumption by 30% with highly dynamic driving cycles and in start-stop activity. Benefits include downsized engines, reduced tyre wear and longer TBO. Oerlikon Drive Systems provides a series-electric drive for off-highway and material handling vehicles. Components include drive axles with geared motors, wet disk brakes and integrated dual inverters; engine mountable generator instead of a power shift transmission; ultracapacitor-based energy storage unit with vehicle control unit, DC-DC converter and protection circuitry. These components are quickly connected via power and CAN-link cables, and usable in a variety of applications.

17:05 - Digital Displacement hydraulics for off-road and on-road heavy hybrid vehicles
Dr Niall Caldwell, managing director, Artemis Intelligent Power Ltd, UK
Digital Displacement is a fundamental advance in fluid power, developed and commercialised by Artemis Intelligent Power Ltd. By combining robust hydraulic mechanisms with direct digital control, dramatic improvements in efficiency, controllability and noise are achieved compared with conventional hydraulics for on and off-road vehicles. Results will be presented of a parallel hybrid propulsion system for a city bus, which, unlike electric hybrids, shows a positive business case without subsidy, based on fuel saving alone. The outlook will be described for reducing fuel consumption of off-road vehicles, particularly excavators, by using Digital Displacement pumps for propel and working functions.

17:25 - E-motor emulation – testing power electronics without an e-motor
Dr Sebastian Liebig, project manager, SET Power Systems GmbH, GERMANY
Electrical powertrains are part of safety-critical vehicle functionality. The challenge is to increase test quality and test depth without increasing test effort, while the scope of functionality is increasing and development times are becoming shorter. A new method where the real e-motor is replaced with an e-machine emulator allows load and ambient conditions to be reproduced in the lab exactly as they occur in a drive inverter during a real-life driving situation: a P-HIL system using a virtual e-machine. This presentation explains the possibilities and benefits of e-machine emulation.

17:45 - Q&A

Day 1 Close

*This Programme may be subject to change.

Day 2

Thursday 10 November


Congress Saal 1

Morning Session

Chairman
Dr Peter Harrop, chairman, IDTechEx, UK

09:00 - Testing of hybrid drivetrains in industrial vehicles – adapted strategies
Marc von Papen, system line manager - heavy-duty driveline, AVL, GERMANY
Hybrid components and other active drivetrain elements are a huge challenge to future development and testing of industrial vehicles. The development of shifting and driving strategies is not compatible with the typical conventional testing methods. Requirements for the test systems to reproduce dynamic drive cycles, parameter variation of load conditions and driver behaviour, optimisation of complex simulation models and reliable statements on the impact on fuel consumption at different driving cycles lead to fundamentally new demands on the test equipment. Necessary technical conditions and adapted solutions to bridge these contradictions are presented on the basis of sample projects from practice.

09:20 - Challenges and solutions to reducing the CO2 impact of vehicles
Prof Andrew Atkins, global technical lead - senior technologist, Ricardo Innovations, UK
The presentation will discuss issues around working from a pragmatic needs perspective and review of available media topologies to provide opportunities for reduction in carbon-bearing energy consumption. The configurations explored will include possible solutions to electrification and other, less conventional, energy vectors.

09:40 - The electrification of a construction site.
Johan Sjöberg, research engineer - system controls, Volvo Construction Equipment, SWEDEN
Johan will discuss a Volvo CE research project which involves using electricity instead of diesel to power construction machines in a quarry. The project aims to deliver significant reductions in fuel consumption, CO2 emissions, environmental impact, cost per ton and total cost of ownership while also improving productivity. He will talk about how electrification, automation and hybridization can work together.

10:00 - Advances in axial-flux motors for industrial vehicles
Dr Tim Woolmer, chief technology officer, YASA Motors Ltd, UK
Compact and lightweight, YASA axial-flux motors and generators allow designers of industrial vehicles to implement higher-power hybridisation and electrification without compromising critical vehicle space and weight. YASA’s unique Yokeless And Segmented Armature topology is described, along with recent developments that further improve traction and generation capacity and ease mechanical integration. The presentation also discusses how advanced materials and volume manufacturing techniques are used to reduce costs and improve value to customers.

10:20 - Q&A

10:35 - 11:05 - Break

11:05 - Emissions, electrification and the future of off-highway vehicles
Ananth Srinivasan, senior consultant, Frost & Sullivan, GERMANY
This presentation provides an insight on the electrification and hybridisation technologies for the heavy-duty off-highway industrial vehicle sector. The agenda is to first look at the mega-trends impacting the off-highway industry, and then outline emission challenges facing the industry today. Later, we proceed to understand the road to electrification in this sector including the trends, forecasts and recent innovations in this domain. A brief opportunity analysis for OEMs, suppliers and non-traditional players will follow. The presentation will conclude with an outlook for the future of off-highway vehicles – Clean, Connected and Smart.

11:25 - Energy management enabling lithium-sulfur batteries in industrial vehicles
Dr Daniel Auger, lecturer in Advanced Control and Optimisation, Cranfield University, UK
Lithium-sulfur (Li-S) batteries are lightweight, safe and potentially cheap. Until recently, Li-S existed as a largely experimental technology with niche applications. As part of a major project, a demonstrator Li-S battery pack is being developed for electric vehicles. Li-S has unique features, and conventional battery management (e.g. from lithium-ion batteries) does not work for lithium-sulfur. A family of chemistry-specific battery techniques has been developed, making Li-S as easy to use as any other battery type. Software tools have been developed to rapidly compare dynamic Li-S performance profiles with specific heavy-duty requirements, enabling rapid assessment for industrial vehicles.

11:45 - Tigon technology – for performance & environment
Lars Lindahl, CEO, Huddig AB, SWEDEN
In our concept machine built on Tigon Technology – a full hybrid technology – we have experienced tremendous benefits for the environment and for the customer. We will share some of these benefits and challenges that we have found while developing and evaluating the concept.

12:05 - Cable feed electric tractor for heavy field work
Kurt Anders Hansson, project initiator, Swedish University of Agricultural Sciences, SWEDEN
Can an electric tractor connected to the grid via a cable replace today's diesel-powered tractors? The aim of the project is to develop, test and demonstrate a tractor that is connected with a power cable to the electricity grid under actual field conditions. Full electrification of a tractor makes great technical demands. During heavy field work, current battery technology cannot store enough electricity for an entire shift. An alternative is connecting the tractor to the power grid via a cable winder.

12:25 - Q&A

12:40 - 13:40 - Lunch


Congress Saal 1

Afternoon Session

Chairman
Ryan Maughan, managing director, Avid Technology Limited, UK

13:40 - Modeling and simulation of hybrid-electric compactors and their controls
Dr Ashraf Zeid, principal engineer, Volvo Construction Equipment, USA
This paper describes modeling and simulation of hybrid-electric eccentric/drum drives for an asphalt compactor. The objective of the simulation is to size and evaluate, by simulation, the energy and fuel consumption, as well as the performance, of a hybrid-electric compaction machine. The focus here is to create a dynamic simulation to investigate the dynamics of such a design, with special focus on energy consumption and maximum power requirements. We describe the development of the hybrid-electric compactor controls that drive performance. We discuss the impact on engine power, energy and state of charge of the ultracapacitor.

14:00 - Flexible high-dynamic test rig for electrified commercial vehicles
Prof Moritz Gretzschel, professor, Hochschule Aalen, GERMANY
Innovative driveline concepts of electrified vehicles take vehicle test rigs to their limits and exceed the dynamics of conventional roller-type dynamometers. At Aalen University, a highly variable 4x4 high-dynamic full vehicle test rig (VAPS) overcomes these limits. One distinctive feature is the ability to reproduce manoeuvres up to the stability limit and the control range of the stability control, to take advantage of the high dynamic of electric drives. A unique feature is to keep the test rig flexible enough for testing of axles, drivetrains and transmissions of commercial vehicles.

14:20 - Development of hybrid aircraft pushback tug: modelling of hybrid powertrain
Chris Bayliss, technical director, Hyperdrive Innovation, UK
Norbet Seitzl, mechanical design engineer, Douglas Equipment, UK
This paper presents the results of modelling and simulation of a hybrid powertrain including genset, battery and drive motors in the design/development of a hybrid-electric airport pushback tractor. A Matlab/Simulink model was developed to simulate the existing powertrain as well as the hybrid drivetrain using extensive duty cycle data collected from existing vehicles (torque, speeds, etc.). After many iterations, optimised components were finalised. The optimised components (engine, battery, genset, etc.) enabled fuel savings of between 25% and 75% to be achieved depending on the tractor’s duty cycle.

14:40 - Electrification of engine ancillaries for more efficient off-highway applications
Ryan Maughan, managing director, Avid Technology Limited, UK
In addition to full machine electrification, there are significant advantages to partial electrification of the off-highway vehicle powertrain, so-called mild or micro hybridisation. This approach sees the diesel engine supported by electrified systems and energy recovery capabilities. One of the key objections to component electrification is the energy conversion efficiency from mechanical to electrical power at a steady state, this is compounded by the lack of transient condition modelling for these systems. Avid will present a paper discussing the practical application of this technology approach and the limitations of the typical systems simulation models in delivering representative real world results under transient conditions.

15:00 - Q&A

15:15 - 15:45 - Break

15:45 - Analysis of overcharge tolerance of aged LMO cells
Dr Bapiraju Surampudi, staff engineer, Southwest Research Institute, USA
Lithium manganese oxide (LMO) batteries have become popular due to their acceptance in plug-in electric vehicles like Chevy Volt and battery electric vehicles like the Nissan Leaf. Due to their balanced portfolio of power and energy density they can also be good candidates for off-road applications, provided their safety tolerance is managed. With battery age the inaccuracy in estimating state of charge increases, resulting in unintended overcharges. This work presents experimental data of overcharge in aged cells from two manufacturers, and analyses prognostics and trends in tolerance based on ageing stress.

16:05 - Advanced energy technologies for clean and efficient industrial vehicles – an implementation example
Matthieu Desbois-Renaudin, battery system expert, CEA Liten, FRANCE
CEA Liten is a major technology research laboratory in the field of lithium battery and fuel cell technologies. CEA helps various OEMs convert their classical vehicles into electric ones, integrating batteries and/or fuel cells. During the last two years, CEA and Metalliance have developed a new full-electric vehicle optimised for operation on tunnel worksites. The presentation will explain the various steps of electrification and the technology integrated into this new vehicle.

16:25 - Power electronic solutions for fuel cell vehicles
Dr Peter Barrass, vice president engineering, Sevcon, UK
Fuel cells can be an attractive alternative to hybrid or battery-powered vehicles for some applications that are trying to decarbonise. Captive fleets such as large warehouse forklifts or port drayage tractors are especially well suited to fuel cells. Electrification of combustion engine-powered vehicles with mechanical and hydraulic powertrains presents many challenges. Fortunately, modern power electronics and software can provide solutions. The presentation will show how novel use of power electronics can provide solutions for a wide range of vehicles. It will also show how these work with other active and passive parts of the system.

16:45 - Q&A

Conference close

*This Programme may be subject to change.

 
 

 

Topics under discussion:
  • Battery technology
  • Hybrid power systems
  • Fuel cells
  • Hybrid hydraulic systems
  • Electric motors
  • Range extenders
  • Supercapacitors
  • Power conversion
  • Charging solutions
  • Thermal management
  • Battery safety
  • Modelling and simulation
  • Future market predictions
  • Applications
  • In-wheel motors
  • Energy recovery solutions
  • Emission standards
 
Vehicle Applications:
  • Excavators
  • Construction
  • Open mining and quarrying
  • Forestry
  • Agricultural
  • Crane and heavy lift
  • Road building
  • Lawn and garden
  • Forklift trucks
  • Airport ground support
  • Container handling
  • Municipal and cleaning
  • AGV/SGVs
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