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Wheel Motors to Drive Dutch Buses

The technology moves out of the lab and into commercial vehicles.

By Kevin Bullis

Monday, March 23, 2009

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A company based in the Netherlands called e-Traction has developed a new kind of hybrid bus that uses in-wheel electric motors to improve efficiency and a GPS system to reduce pollution in congested areas of a city. The bus is a series hybrid: a diesel generator charges a battery, which in turn supplies electricity for two motors, one in each rear wheel. Thanks largely to its in-wheel motors, the bus can travel twice as far as a conventional bus on a liter of diesel, says Arend Heinen, who is both an engineer and spokesperson for the company. That translates into a reduction in fuel consumption of 50 percent. The company has been awarded contracts to retrofit seven commercial buses with its technology, with the first to be completed next month.

Hybrid commuter: One of the buses that e-Traction has retrofitted with its prototype hybrid system is shown above (top). The company is now retrofitting buses for commercial use. Behind the hubcap (bottom) is the motor that makes the new hybrid possible.
Credit: E-Traction

In-wheel motors have been around for some time: they have been used in several concept cars and experimental, low-production vehicles. But with the exception of electric bicycles, the idea has never found its way into a mass-production vehicle, says John Boesel, the president and CEO of Calstart, a nonprofit based in Pasedena, CA. The use of e-Traction's system in commercial buses would be a step toward more widespread use.

As with other hybrid buses, thousands of which are already in use in the United States, e-Traction's design saves fuel by capturing energy from braking, using it to generate electricity that can later be employed for acceleration. The in-wheel motors confer additional savings by eliminating the need for a transmission, differential, and related mechanical parts. That reduces both the overall weight of the bus and energy losses due to friction. Hybrid buses typically see fuel-cosumption reductions of about 25 to 30 percent compared with conventional buses, but e-Traction's design offers 50 percent reduction. In certain conditions--at low speeds in frequent stop-and-go traffic--some other hybrid buses have seen similar fuel-economy improvements. The in-wheel motors can also improve traction by allowing precise control over each wheel, and they allow for greater flexibility in vehicle design since there is no need to mechanically link the wheels to an engine.

Story continues below


The bus also incorporates a GPS-based system that changes the way that the bus operates in congested areas. In ordinary operation, the generator cycles on and off, keeping the battery at an optimal state of charge. But when the GPS system senses that the bus has entered an area of the city that usually sees a lot of traffic, the generator switches off to reduce emissions. The battery stores enough power to propel the bus for an hour without the generator running to recharge it.

Comments

  • More substance, please
    Very interesting subject, but the article could do with a bit more substance.

    For example, what's the innovation that allowed e-Traction's design to succeed? Just building a larger diameter engine can't be all.

    Then how about economic viability, how long until (fuel-) savings justify the extra cost of retrofitting? I haven't got a clue how much diesel a bus is using to start with.

    Which company is buying the new technology and in which city will they operate?

    What happens if one of the engines fails, can the other still get the bus to the next bus stop bay without veering of the road?

    Buses are big contributors to particulate matter in cities. If you want to be perceived as environmental friendly you'll have to use diesel particulate filters. Where is the diesel engine coming from and how clean is it? I guess it runs at optimal revs that should make it easy to deal with the exhaust fumes. 

    Can anyone provide some more facts, please?

    Cheers.
    Rate this comment: 12345

    SimonHoer
    03/23/2009
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    • Re: More substance, please
      The innovation is the combination of the wheel motor and control system, but the company doesn't want to give away details.

      I'll check about the particulate filter / engine--I'm assuming the bus will be equipped to meet European standards, so may need some changes for the U.S.  That's a good point about the revs.  The GPS system for turning off the engine completely in congested areas should also help.

      The motors are in the rear wheels, so it should be able to limp home if one fails. I imagine you could just correct by steering. But I'll check on that, too.
      Rate this comment: 12345

      Kevin Bullis
      03/23/2009
      Posts:101
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      4/5
    • Re: More substance, please
      Response from Arend Heinen:
      I do not know what the U.S. emission stands are, but we can fit any type of energy supplier in the back of our vehicle. From biodiesel engine to hydrogen stack.

      If we build a bus for the U.S. market it will meet U.S. standards. At this moment we build them according to European standards.

      Anyway, we have 50% of the emissions of a standard diesel bus and save at least 70 tons of co2 per year in standard operation.


      We can use the same particle filter as normal engines have. We have the extra benefit that the engine will run at a specific rev number to ensure the most efficient burning of the diesel.

      Yes we can drive on with one motor easily. The top speed can be reached but the acceleration is less.
      Rate this comment: 12345

      Kevin Bullis
      03/23/2009
      Posts:101
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    • Re: More substance, please
      If one follows the news he can read about Hybrid Bus Technology.  Therefore predict the next production inovation.  Example: A Hybrid Bus Company in San Diego who retrofits used buses and recycles them into city transit buses.
      danahyatt.mail@gmail.com
      Rate this comment: 12345

      danahyattg
      03/23/2009
      Posts:1
  • Why?
    Wheel motors are an interesting concept, but surely there are power and fiscal benefits from having larger single motors and a drive train. Moreso when you consider the additional protextion need against water, salt, minor knocks, re-balancing, vibrations and shocks from the road. Solution might be to move the motor inboard and use a long shaft to drive the wheel?
    Rate this comment: 12345

    Roy One
    03/23/2009
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    • Re: Why?
      Good question. I doubt that the reduction in parts of two U-Joints per drive wheel will make much cost difference between a wheel motor and an inboard more conventional electric motor in a better protected location. Additionally, when applied to lighter vehicles such as passenger cars, wheel motors increase the sprung weight making for a harsh ride. Inboard motors would decrease the sprung weight and make for a better ride. (Kind of like the reason to use light-weight alloy wheels instead of heavy steel wheels.) I am in favor of using 4-wheel electric drive and eliminating the steering system by using control of revolution speed and direction at each wheel under direction of the on-board computer.
      Rate this comment: 12345

      dickcaro
      03/23/2009
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  • Wheel Motors to Drive Dutch Buses
    The motor in the wheel is is great for this application , no argument , less parts and more efficient .
    <b>
    I am just wondering if you use Ultra capacitors to capture the power generated by regenerative breaking which will capture all that generated power as it is made by the motors , whereas the battery pack will only capture some of it because of the nature of the batteries physical limitations to fast charging large amounts of electrons in a short time ( seconds of slowing down ) Check out Maxwell BoostCaps  ultra capacitors they are ideal for this application .
    Rate this comment: 12345

    Keith Tomils...
    03/23/2009
    Posts:9
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  • some answers
    Why in wheel? Because an electric motor that has to provide enough torque to drive a vehicle without gears has a large diameter. Building it inside the vehicle will take allot of space and is negative for your building flexibility.

    Shocks en water ingress? We are already driving for 4 years with our city bus with the electronics fitted inside of the wheel. Shocks and water have till thus far never been a problem.

    Boostcaps? At this stage we have an lithium-ion pack of 30 12,8volt 130Ah valence batteries onboard. These batteries can absorb all the energy that is coming from the wheels in normal breaking situations. For emergency braking we use mechanical brakes(demanded by law).
    We also need the longer power of the battery to drive zero emission, which the boostcaps can not provide.

    Steering by controlling the speed of the motor? We already have a software differential that helps to steer the bus actively thru a corner. But regulations keep us for steering the complete bus with software instead of mechanically.

    Arend Heinen
    Rate this comment: 12345

    Heinen
    03/24/2009
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    • Re: some answers
      Thank-You Arend Heinen ,

      Yes , with that many cells even though the cells take the power slower than ultra capacitors a little power in each one will work just fine .
      Looks like you have a winner here . I would do the same thing , if I was working on the project .
      I would still want to take a bus and put some capacitors in it with the batteries just to know for sure that it didn't make any difference . That is the Engineer thinking in me .
      They will also make the batteries last a lot longer .
      Rate this comment: 12345

      Keith Tomils...
      03/25/2009
      Posts:9
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    • Re: some answers
      Mr Heinen, could you provide more detailed explanation and maybe some basic calculations to substantiate the fact that the batteries used in your bus can "absorb all the energy that is coming from the wheels in normal breaking situations."

      The matter is five days ago I created a topic at one Russian forum for discussing the news on your leading-edge technology, and the discussion is still goin on. Today I was nonplussed by a forum member's critical post as rendered by me in English:

      The bus is normally braking by recuperating energy, say from 72 km/hr to zero, i.e. its initial speed is some 20 m/s. Its total weight (including the bus itself and its passengers) is at least 20 metric tons, maybe more.
      Hence we can calculate the energy to be absorbed (and later on to be spent on acceleration) as follows:
      1/2 * 20,000 * (20 * 20) = 4,000,000 J = 4 MJ
      Let's assume that the braking takes about 8 seconds (emergency braking should take some 2.5 seconds, but that surely involves some mechanical braking system). Hence the power the batteries being absorbed for 8 seconds amounts to some 500 kW (the more the better; a little less is admissible too, but only a little: we should always keep in mind that lower power absorbtion rates means longer braking).
      What does this 500 kW mean for 30 batteries? It means 17 kW per battery. If we divide that amount by the rated voltage we get the charging current: some 1300 A. You can beleive me, that's a heck of a current!
      If we can halve the deceleration (acceleration) rate, the charging (discharging) current will amount to 650 A. Believe me, even for the best batteries with storage capacity of 130 Ah the current of 650 A is just too much. It's possible to meet even such harsh requirements but only at the cost of much lower efficiency, below 50%.
      Sure if acceleration and deceleration is done very very smoothly, even 100 kW might be enough, meaning some 250 ... 260 A per battery, which is roughly sufficient to fully charge the battery in 30 minutes. Such batteries do exist but their efficiency is rather low. I tell you again, nowadays' technology can provide high efficiency (up to some 70 percent) only if the charging (discharging) current is below the current necessary to fully charge the battery in 30 minutes.


      Your reply will be appreciated.
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      validator
      04/02/2009
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  • Eliica
    Check out this wheel-motor electric race car:

    http://en.wikipedia.org/wiki/Eliica
    Rate this comment: 12345

    coffeetime
    03/28/2009
    Posts:2
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    2/5
  • Unsprung Weight
    One inherent problem with wheel motors is that they increase unsprung weight thus adversely affecting handling and comfort.  Also, the fast up and down motion of the wheels puts added stress on the motor.
    Rate this comment: 12345

    rzimmerle
    03/29/2009
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    • Re: Unsprung Weight
      Unsprung weight worries?  This is a bus, not a sports car.  I don't think you would notice any changes in handling ability or increased braking distances.  The limiting factor is the original design; a rather large, heavy, high center of gravity vehicle.
      Rate this comment: 12345

      lasertekk
      03/30/2009
      Posts:88
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      • Re: Unsprung Weight
        People always come up with bull$#!% objections and kneeJERK reactions to new ideas. "Unsprung weight" is an engineering problem far less challenging then the wheel motor it self. It's just retarded to raise that as an objection, especially since it's already been solved.

        http://www.spectrum.ieee.org/print/2059

        "Traditionally, the drawback to wheel motors is what designers call "unsprung weight," or the relatively high mass of the motor components in addition to that of the wheels, whose movements the suspension must accommodate. The more mass in the wheels, the beefier the suspension must be—increasing weight and complexity. Michelin's Varenne, however, notes with pride that the mass of each wheel and its motor unit is just 30 kg, roughly comparable to that of a wheel in a standard vehicle. "
        Rate this comment: 12345

        DarQDawG
        03/30/2009
        Posts:1
  • The business Side
    I am thinking about the business side,
        Unlike buses which are mostly owned by cities, and towns; garbage trucks in many cases are maintained by private entities that have a strong business interest to hedge their bets against future increases in the prices of fuel.
    Private entities that collect garbage are much more likely to adopted hybrid garbage trucks because:
    1) The garbage trucks burn up more gas due to frequent stopping,
    2) Many times they are larger and increases in fuel cost dramatically affect their bottom line profits (like airlines),
    3) These garage companies are actively looking for ways to cut costs and make their fleet more efficient, unlike cities which are notorious for wasting money

    Brian Glassman
    Innovation Management
    Commercialization of technology
    Rate this comment: 12345

    briang1621
    03/29/2009
    Posts:124
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