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Hybrid Vehicle Power Generation

Hybrid Vehicle Power Generation

Kollmorgen's new Power Generation System, introduced at the recent Hybrid Truck Users Forum (HTUFa" cent ), is a complete power platform optimized to meet virtually any heavy-duty vehicle's energy requirements, with flexibility to fit into applications where space is at a premium. The system was installed on a Kenworth D300 diesel truck to enable HTUF attendees to experience the system in action with live "ride and drive" demonstrations.

"We provide an optimized solution by generating power at the voltage that customers need. With our newest solution, we are able to produce approximately twice the power that an alternator is generating today," says Brandon Edlefsen, business unit director for Kollmorgen's vehicle power generation business. "We also provide that power at low voltage (28V) which eliminates the need for complex cooling systems and power conversion equipment."

Hybrid Vehicle Power Generation

Consisting of a Kollmorgen permanent magnet ac generator, generator controller, software and cables, the system has the flexibility to support a broad range of heavy-duty hybrid vehicle power needs at low or high voltage, ac, dc or both. Its modular design readily accommodates vehicle upgrades and retrofits with limited changes to the vehicle system architecture.

The generator provides twice the power density within the same space as a traditional alternator, using air- or liquid-cooled designs, and can be mounted in belt-driven, PTO or inline configurations. The generator controller is rooted in a product platform with more than one million units delivered since 1996. The controller features a robust, modular architecture that is engineered to withstand the most demanding commercial and military environments, and that facilitates easy expansion as vehicle needs evolve. Cables are shielded and optimized for heavy-duty vehicle applications. They consume minimal space and weight, while delivering maximum performance and reliability even in temperatures up to 260C.

Electrical power is an ideal technology partner to the internal combustion engines in heavy-duty hybrid vehicles. It offers outstanding torque, efficiency, economy and cleanliness to supplement fossil fuels on urban buses, agricultural vehicles, military vehicles and other heavy-duty hybrids. Electric power is also an increasingly significant tool for powering auxiliary equipment, from trash compactors on garbage trucks to armored doors on defense vehicles.

"The key innovations with this technology provide more power per unit volume and the flexibility to deliver that power at the voltage our customers need," says Edlefsen. "This is a huge breakthrough for OEMs when space and weight are at a premium but we can also do this in a cost-effective manner."
Hybrid Vehicle Power Generation

Edlefsen says the modularity and flexibility of the electronics establish a core architecture that meets our customer's immediate requirements while enabling a core platform that grows with the vehicle's future needs. Kollmorgen has been intentional with the electronics to build scalable10 KW modules that support multiple voltage requirements from 24-80V dc. So if a customer needs 30 KW, three units provide the power needed.

The Power Generation System provides solutions to meet a variety of customer needs ranging from low (24V dc) to high (750V dc) voltage, from 10 to 250 KW and in different mechanical configurations, including belted and PTO (power takeoff) generators, as well as inline generators that mount between the engine and transmission. The power generated can be used to run onboard systems, charge batteries for engine-off operations and start the internal combustion engine.
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