energies

Article
Prolongation of Battery Lifetime for Electric Buses through
Flywheel Integration
Philipp Glücker 1,2 , Klaus Kivekäs 1 , Jari Vepsäläinen 1, * , Panagiotis Mouratidis 2 , Maximilian Schneider 2 ,
Stephan Rinderknecht 2 and Kari Tammi 1

1 Department of Mechanical Engineering, School of Engineering, Aalto University, 02150 Espoo, Finland;
philippgluecker@gmx.net (P.G.); klaus.kivekas@aalto.fi (K.K.); kari.tammi@aalto.fi (K.T.)
2 Institute for Mechatronic Systems, Technical University of Darmstadt, 64289 Darmstadt, Germany;
panagiotis.mouratidis@tu-darmstadt.de (P.M.); maximilian.schneider@tu-darmstadt.de (M.S.);
stephan.rinderknecht@tu-darmstadt.de (S.R.)
* Correspondence: jari.vepsalainen@aalto.fi

Abstract: Electrification of transportation is an effective way to tackle climate change. Public

transportation, such as electric buses, operate on predetermined routes and offer quiet operation,
zero local emissions and high energy efficiency. However, the batteries of these buses are expensive
and wear out in use. The battery ageing is expedited by fast charging and power spikes during
operation. The contribution of this paper is the reduction of the power spikes and thus a prolonged
battery lifetime. A novel hybrid energy storage system for electric buses is proposed by introducing a
flywheel in addition to the existing battery. A simulation model of the hybrid energy storage system
is presented, including a battery ageing model to measure the battery lifetime. The bus was simulated



during its daily driving operation on different routes with different energy management strategies

 and flywheel configurations. These different flywheels as well as the driving cycle had a significant
Citation: Glücker, P.; Kivekäs, K.; impact on the battery life increase. The proposed hybrid battery/flywheel storage system resulted in
Vepsäläinen, J.; Mouratidis, P.; a battery lifetime increase of 20% on average.
Schneider, M.; Rinderknecht, S.;
Tammi, K. Prolongation of Battery Keywords: hybrid electric bus; hybrid energy storage system; flywheel; battery lifetime; rule-
Lifetime for Electric Buses through based control; model predictive control
Flywheel Integration. Energies 2021,
14, 899. http://doi.org/10.3390/
en14040899

1. Introduction
Academic Editor: Daniel J. Auger
In the wake of climate change and the turnaround in energy policy within numerous
Received: 21 December 2020 countries, research focus has shifted towards green technology over the last decade. This
Accepted: 3 February 2021 environmental development has led to a rapid transformation of transport in recent years,
Published: 9 February 2021 including the increase of hybrid electric and battery electric passenger vehicles. To comply
with the climate targets stated in the Paris agreement in 2015, the European Council
Publisher’s Note: MDPI stays neu- promotes renewable energy sources and electric transportation as the transport sector was
tral with regard to jurisdictional clai- responsible for 27% of the total greenhouse gas (GHG) emissions within the 28 countries
ms in published maps and institutio- of the European Union in 2017 [1,2]. As part of this promotion, public transport has
nal affiliations. likewise shifted towards the electrification of public bus fleets. Due to the main operation
characteristics of battery electric buses (BEBs) within cities and the simpler realisation of
charging infrastructure for regular bus routes, the range limitations of electric powertrains
have less impact for BEBs than for passenger vehicles. Besides their range, other significant
Copyright: c 2021 by the authors.
Licensee MDPI, Basel, Switzerland.
aspects of battery electric vehicles (BEVs) are the costs and the limited lifetime of the
This article is an open access article
battery. As the battery life depends on various factors such as its chemistry, the operating
distributed under the terms and con-
temperature or peak currents, it seems beneficial to hybridise the battery by introducing
ditions of the Creative Commons At- a second energy storage system (ESS) such as supercapacitor or flywheel (FW). This ESS
tribution (CC BY) license (https:// could supplement the battery and possibly improve the overall performance of the vehicle.
creativecommons.org/licenses/by/ This paper contributes to the extension of the battery lifetime of BEBs with the help of
4.0/). an integrated flywheel within the vehicle. The novelty is the investigation of the hybrid

Energies 2021, 14, 899. https://doi.org/10.3390/en14040899 https://www.mdpi.com/journal/energies

Energies 2021, 14, 899 2 of 19

battery/flywheel energy storage system during its daily driving operation, comparing
the hybrid configuration with the non-hybrid BEB. The results provide novel information
about the influence of the driving cycle and the size of the flywheel on the battery wear. A
rule-based control strategy is implemented to evaluate the benefit of the hybrid system.
Subsequently, a nonlinear model predictive control is developed, which is specifically
designed for the extension of the battery lifetime. The research is conducted with the help of
simulation models in M ATLAB R and Simulink. The models consider longitudinal dynamics
of the bus along a designated route, the ageing of the battery as well as the transient
behavior and energy flow between the energy storage systems and the electric drive.

2. State-of-the-Art
In recent years, research efforts have largely focused on enhancing lithium-ion batteries
due to their high specific energy as well as power density, high energy efficiency and low
self-discharge [3]. In this context, Farhadi et al. [4] compared the applications, advantages
and limitations of the high-power storage systems Li-ion batteries (LIBs), supercapacitors,
flywheels and superconducting magnetic energy storage (SMES). The results showed that
LIBs excel in their high energy density, long discharge time and low self-discharge rate,
allowing much longer storage periods in comparison to the other technologies. However,
among LIB chemistry variations, it is hard to achieve high power density, high energy
density and low cost in the same package. The study concluded that the suitability of each
storage technology for specific applications is defined by various requirements such as
power and energy density, efficiency, self-discharge rate and cycle life.
The integration of flywheel energy storage systems (FESSs) has lately been accelerated
due substantial improvements in fibers, high strength composite materials and technologies,
power electronics and magnetic bearings [5–7]. FESSs are often compared to ultracapacitors
(UCs) as their specifications in high power density, fast response time, costs and lifetime
are similar. Itani et al. [8] compared FWs and UCs as secondary energy storage systems
for a two-front wheel driven electric vehicle (EV). Based on an optimised design, the FESS
is advantageous regarding volume, energy density, power density and costs, whereas
the ultracapacitor excels in terms of weight, specific energy and specific power. Within
electrified railways, UCs are superior in maintenance costs, weight and size [9], whereas
FWs seem to excel in terms of power and energy density as well as their mass within
automotive applications [10]. Because of their excellent high power rating, FESS are
often combined with a high energy rated ESS to a hybrid energy storage system (HESS),
especially in stationary applications. The possible benefits of such hybrid systems are better
performance, increasing lifetime of the high energy rated ESS and cost savings, with the
latter two shown by a hybrid battery/flywheel system for a solar PV-powered application
in [11].
The energy management strategy (EMS) is a key part of a HESS as it controls the
power flow within the powertrain, affects the efficiency and the range of the vehicle and
the lifetime of its components [12]. EMSs can be broadly divided into rule-based and
optimisation-based strategies [3]. In the following, different EMSs for various HESS ap-
plications are briefly introduced. A flywheel/battery HESS controlled with a rule-based
algorithm was studied for primary control reserve by Mouratidis et al. [13], which suc-
cessfully improved the state of health (SOH) of the battery by 16% within four years. A
similar HESS was investigated as a buffer for all-electric ship propulsion systems. The
performance of the real-time optimisation-based model predictive control (MPC) proved ef-
fectiveness in terms of power-fluctuation compensation, HESS energy saving and reduction
of the battery usage, especially at high sea states [14]. A frequency control was applied by
Sessa et al. [15,16] on a battery/flywheel HESS during grid frequency regulation service.
The implemented low-pass filter forced the battery to supply the low frequency and the
FESS to supply the high-frequency components of the required power, leading to a signifi-
cant reduction of the lithium manganese oxide (LMO) battery ageing of around 22%. A
similar control including partially charging the flywheel by the batteries was carried out
Energies 2021, 14, 899 3 of 19

for a hybrid locomotive including diesel generators, batteries and flywheel. The frequency
approach-based EMS which focused on optimal sizing and operation resulted in a reduced
number and improved lifetime of the battery cells [17].
Besides stationary applications, the integration of FESS within the transport sector
was examined as well. Dhand et al. [18] integrated a flywheel into a BEV by a mechanical
continuously variable transmission system. The dynamic programming control strategy
reduced battery peak loads during all cycles, leading to potentially reducing the energy
consumption in extra-urban and highway cycles. GKN Hybrid Power successfully im-
plemented an electrical flywheel in various hybrid endurance racing cars to assist the
internal combustion engine as the prime mover, e.g., Audi’s R18 e-tron as the first hybrid
car winning the Le Mans 24 h endurance race in 2012. The advantage of this carbon-fiber
flywheel is its compactness with a power output of 120 kW while weighing only 55 kg [19].
The GKN Gyrodrive flywheel hybrid system is an adapted version of the aforementioned
FESS which was introduced into mass market by the installation into 500 diesel driven
buses in the UK between 2014 and 2016 [5].
An overview of flywheels in racing cars and vehicles is given in Table 1. The FESSs
were designed for hybrid electric vehicles such as passenger cars, urban transport buses
and light rail applications, depending on the required peak power and available energy.
The defined mass includes rotor and stator of the electric machine (EM), bearings and the
containment mass, but exclude the power electronics.

Table 1. Overview of flywheels used in racing cars and vehicles [5,19,20].

Application Name Peak Power in kW Energy in Wh Mass in kg Max. Speed in rpm

GKN Porsche
180 375 57
GT3R Flywheel
Racing cars GKN Audi e-tron
150 97 27
2013 Flywheel
Flybrid Systems LLP 110 111 25 60,000
GKN Gyrodrive FW
120 360 60 36,000
Hybrid System
Light-duty & Ricardo UK Ltd. 60 220 30 60,000
heavy-duty Powerthru 190 667 147 52,500
vehicles L-3 CMM * 300 2000 400 12,000
HyKinesys 100 300 50 20,000
Flywheel Energy
120 750 150 28,000
Systems Inc.
* L-3 Communications Magnet-Motor GmbH.

A conceptual design of an efficient flywheel battery of 200 Wh as an additional ESS for

common vehicles was carried out in [21], while only commercially available components
for hybrid and electric vehicles were employed. A research group of Heilbronn University
performed a range-extension simulation of a plug-in hybrid electric vehicle (PHEV) with
an additional flywheel by collecting comprehensive experimental data of a battery-driven
26 kW powered electric car [22]. Briat et al. [23] examined the hybridisation of heavy-duty
vehicles with high peak-to-average battery power ratio, including the control strategy
between battery and FW. Depending on the required traction current and the flywheel
speed, the rule-based operating mode was divided into 12 states which corresponded
to either charging, discharging or speed maintenance of the flywheel. Itani et al. [24,25]
designed a flywheel/battery HESS with a special focus on the traction and regenerative
braking strategy. The main electrical source was the battery, but it only contributed if the
FESS could not absorb the whole regenerative braking or deliver the whole traction power.
Furthermore, a controlled dissipative resistor was added to lower the electrical stress on
the battery during low-speed high-power braking.
Energies 2021, 14, 899 4 of 19

The implementation of flywheels in the transportation sector is often focused on the

addition to a combustion engine for the recuperation of braking energy. There is only
limited research on battery/flywheel electric vehicles to extend the lifetime of the battery.
On the one hand, the simplistic rule-based control strategy of Itani et al. [8] focused on the
reduction of battery use only during regenerative braking and the startup of the vehicle
during intervals of a few seconds. On the other hand, elaborate energy management
strategies were only applied for a battery/supercapacitor hybrid system, e.g., the nonlinear
model predictive control (NMPC) for a fully electric hybrid vehicle for various driving
cycles by Santucci et al. [26].
A battery/flywheel hybrid energy storage system for heavy-duty vehicles within
urban and suburban areas with a special focus on battery lifetime increase has not been
analysed. The study presented here aims to narrow this gap by integrating a kinetic energy
storage system (KESS) into an existing battery electric bus, examining the results on the
battery lifetime for its daily driving operation. Furthermore, various flywheel sizes are
taken into account within this paper to study their influence on the battery lifetime.

3. Materials and Methods

3.1. Bus and Routes
This study is based on the operation of a battery electric bus on the bus route 11 in
Espoo (E11), Finland. It is a typical suburban Finnish bus line which was operated until early
2018, starting at Tapiola station and ending at Friisilä station as shown in Figure 1.

Figure 1. Bus line 11 in Espoo, Finland (Map data c 2020 OpenStreetMaps).

Lajunen [27] has noted that end-terminus charging results in the lowest lifecycle costs
for BEB systems, thus it was used for this route with a high-power charging station being
located at the Tapiola station where the buses were charged during a dwell-time of a few
minutes. Besides the driving cycle, this charging process was considered in the simulation
as well, as its contribution to the battery ageing was significant due to its high power.
The characteristic parameters of route E11 are compared to the well-known Braunschweig
driving cycle (BR) in Table 2. This reference test route represents a mid-size European city
with similar characteristics to E11 and is therefore used as a comparative cycle. Further
details as well as the speed profile of both driving cycles can be found in [28].
Energies 2021, 14, 899 5 of 19

Table 2. Characteristic parameters of the BR and E11 driving cycle [29].

Parameter Value Unit

BR E11
Duration 1740 1548 s
Distance 10.9 10.2 km
Max. speed 58.2 58.4 km/h
Average speed 22.5 23.8 km/h
Number of stops 28 18 -
Stops per km 2.6 1.7 -
Max. acceleration 2.4 1.6 m/s2
Max. deceleration 3.6 1.9 m/s2
Aggressiveness 0.24 0.15 m/s2

3.2. Simulation Model

The simulation model of this study is based on the non-hybrid battery electric bus
model developed by Vepsäläinen et al. [30]. It is built within M ATLAB R /Simulink and
was validated to measurement data of a BEB on the E11 bus route in the previous work by
Kivekäs et al. [28]. This model represents the system at the level of components, such as the
battery, motor, motor controller, internal bus heating and air conditioning, etc. The novelty
of this study is the addition of the kinetic energy storage system as a second ESS besides
the existing battery. The topology of this hybrid battery/flywheel system comprises of the
parallel configuration of the two storage systems which is shown in Figure 2.

Battery Converter

KESS Electric
Inverter Inverter Gearbox
Drive Drive

HESS

Figure 2. Topology of the electric powertrain, consisting of the hybrid energy storage system, the
battery and KESS feeding inverter and the electric drive connected to the final drive.

The parameters of the simulation model are presented in Table 3. They are based on
the BEB providing the on-board measurement data on the E11 bus line. The auxiliary power
equals the average demand measured in the validation cycle, excluding the non-available
measurement data from the separate diesel heater of the BEB.
Energies 2021, 14, 899 6 of 19

Table 3. Parameters of the battery electric bus model [28,30].

Parameter Symbol Value Unit

Curb mass mv 10,500 kg
Vehicle frontal area Av 6.2 m2
Coefficient of drag Cd 0.5 –
Differential gear ratio ig 4.93 –
Differential gear efficiency ηg 98 %
General
Tire dynamic radius rt 0.43 m
Total inertia at output axle Jt 1.95 kgm2
Rolling resistance coefficient f rr 0.008 –
Air density (for Ta = −6 ◦C) ρa 1.32 kg/m3
Ambient temperature Ta −6 ◦C
Auxiliary power demand Paux 5.16 kW
Maximum motor power Pmax 180 kW
Number of pole pairs p 6 –
Motor
Stator armature inductance Ls 0.3 mH
Stator resistance Rs 157 mΩ
Number of cells in series x1 300 -
Number of cells in parallel x2 4 -
Nominal voltage ub 690 V
Battery Energy capacity Eb 55.2 kWh
Coulombic nominal capacity Qnom 80 Ah
Internal resistance Rint 87.5 mΩ
Internal capacitance Cø 0.8 F

One of the main disadvantages of BEBs is the degradation of the battery. It is caused by
various factors such as high temperatures, wide state of charge (SOC) ranges, deep cycles
and high peak currents [31,32]. Besides, the material of the anode and cathode is pivotal to
the capacity fade of LIBs, which is predominantly caused by the impedance rise at both
electrodes and the growth of a solid electrolyte interface (SEI) on the anode, resulting in
the loss of active lithium [33,34]. The end of life (EOL) of a battery is reached when the
remaining capacity has degraded to 80% of its original one [31,35]. The used battery was
Toshiba’s rechargeable battery SCiBTM which is a LIB with a lithium-titanate (LTO) anode.
This kind of battery is suitable within the transport sector due to their long cycle lifetime,
good deep temperature behaviour and high power capability [36,37]. The LTO battery was
modelled with the help of the Thévenin model as presented in Figure 3a, which consists of
the steady-state and the transient response of the battery. Furthermore, the relationship
between the open-circuit voltage uoc and the SOC of the battery is depicted in Figure 3b.
This enables the precise battery SOC estimation as well as the dynamic voltage drop. The
internal temperature of the battery was assumed to be constant at 20 ◦C. The governing
equations of the Thévenin model in generator convention are the following:

ducτ 1  uc 
= · ibat − τ (1)
dt Cτ Rτ
ubat = uoc − ibat · Rss − ucτ (2)
Z t
1
SOC (t) = SOC (t0 ) − · ibat (t̃) dt̃ (3)
Qnom t0

where ibat and ubat represent the battery current and output voltage, uoc is the open-circuit
voltage, ucτ represents the capacitor voltage, Rss is the steady-state and Rτ the transient
component of the battery resistance, Cτ represents the internal capacitance and Qnom is the
coulombic nominal capacity of the battery [38].
Energies 2021, 14, 899 Energies 2021, 0, 0 7 of 19
Energies 2021, 0, 0 7 of

800
800
Rτ
Rτ

ibat Rss 700

ibat Rss 700

uoc in V
Cτ

uoc in V
+
Cτ +
+ 600
+ uoc ubat 600
uoc ubat
− −

− −
500 500
0 20 0
40 20
60 8040 10060 80
SOC in % SOC in %

(a) (a) (b) (b)

Figure 3. The Thévenin equivalent circuit model
Figure 3. The Thévenin equivalent circuit model of the battery of
and the battery and the relationship between battery
relationship between battery open-circuit open
voltage
uoc and SOC.uoc
The
Figure 3.(a) Thévenin
Thévenin
equivalent
equivalent
circuit
circuit model.
model
(b)
of the battery
Open-circuit
andu theover
voltage
relationship
SOC [28].
between battery
and SOC. (a) Thévenin equivalent circuit model. (b) Open-circuitoc voltage uoc over SOC [28].
open-circuit voltage uoc and SOC. (a) Thévenin equivalent circuit model. (b) Open-circuit voltage
uoc over SOC [28]. To examine the To influence
examine of thethe KESS integration
influence of the KESS on the battery ageing,
integration on theabattery
weightea
charge throughput model was implemented. It assumes that under
charge throughput model was implemented. It assumes that under st standard condition
To examine the a battery reaches
influence an KESS
aofbattery
the overall charge
integration
reaches throughput
an overalloncharge
the Q by its
battery EOL. Q
ageing,
throughput
tot An important
atotweighted
by its EOL. paramete
An im
charge throughputinmodelthis context is the
wasinimplemented.C-rate, which
It is
assumes defined
that by the
under ratio between
standard
this context is the C-rate, which is defined by the ratio between the current
conditions, and th th
nominal capacity
a battery reaches an overall charge of the battery
throughput Q . For instance, a C-rate of 3 C is equivalent to a curren
nominal capacity ofQthetot by
nom its EOL.
battery QnomAn important
. For instance, parameter
a C-rate of 3 C is equ
of 240 A for this battery. Under the nominal conditions of 25 ◦C and a C-rate of 3 C, th
in this context is the C-rate, which
of 240 isA defined by the ratio
for this battery. Underbetween
the nominalthe current
conditions andofthe 25 ◦C and
manufacturer states that the given LTO battery can withstand 17,000 equivalent full cycle
nominal capacity of the batterymanufacturer
Qnom . For instance, a C-rate
states that of 3 CLTO
the given is equivalent
battery cantowithstand
a current17,000 eq
(EFC) until its EOL. The weighted charge throughput ◦Ccharge model considers the deviation o
of 240 A for this battery. Under the
(EFC) nominal
until its conditions
EOL. The of
weighted25 and
the C-rate from the nominal conditions with a weighting factor σ, whicha C-rate
throughput of 3 C,isthe
model considet
multiplied
manufacturer statesthe that the the
given C-rate
LTO from
battery the
can nominal
withstand conditions
17,000 with a
equivalentweighting
full
actual charge through the battery. Once the weighted charge Qw equals the equivalen factor
cycles σ, wh
(EFC) until its EOL. The the
weighted actual
chargecharge through
throughput
charge Qtot , the EOL of the battery is reached. the
model battery. Once
considers the
the weighted
deviation charge
of Q w eq
charge Qtotwith
the C-rate from the nominal conditions , the aEOL of the battery
weighting is reached.
Z t factor σ, which is multiplied to
the actual charge through the battery. Once the weighted
Q= (icharge
bat ) dt̃
QwZequals
t
the equivalent (4
charge Qtot , the EOL of the battery is reached. 0
Q= (ibat ) dt̃
Qtot = 2 · Qnom · EFCN 0 (5
Z t Qtot = 2 · Qnom · EFCN
N
Q= (ibat ) dQt̃ w = ∆T · ∑|σ(k) · Q(k)| N (4) (6
0
Qtot = 2 · Qnom · EFCN
k Q = ∆T ·
w ∑|σ(k) · Q(k)| (5)
k
The influence of the C-rate is based on the results of Namor et al. [39] and was adjuste
N
to the given battery
QwTheand
= ∆Tthe nominal
· ∑|σ(of
influence conditions
k)the
· QC-rate of its data sheet.
(k)| is based on the resultsThis leads to(6)
of Namorthe et
followin
al. [39
linear weighttofunction:
the given battery
k and the nominal conditions of its data sheet. This lea
linear weight function: 0.57 + 0.14
σ (Crate )of=Namor (7
The influence of the C-rate is based on the results et al.· C[39]
rate and was adjusted

to the given battery and the nominal conditions of its data sheet. (CThis
rate ) =leads
0.57to+the
0.14following
· Crateand the secon
where the constant term represents the C-rate σ independent ageing process
linear weight function:
term models the effect of the C-rate. For a median charge/discharge current of 3 C, th
where the
nominal conditions constant
are met term represents
and therefore the C-rate
the weighting factorindependent
approximately ageing
equalsproc
on
term
σ ( C models
rate ) = 0.57
the + 0.14
effect of
· C the
rate C-rate. For a median
leading to the number of cycles provided by the manufacturer for this current rate. Th (7)
charge/discharge
bus route as nominal
well as the conditions
end-terminusare met and therefore
charging the weighting
to the original battery factor approx
SOC before th
where the constantdriving
term represents
leading
are both theto C-rate
considered independent
theinnumber
the ageing of cyclesageing
process. Thisprocess
provided model and
byonly the second
the manufacturer
focuses for thi
on cycle-relate
term models the effect of the
capacity C-rate.
bus route
degradation For
andasadoes
median
well charge/discharge
as consider
not the end-terminus
calendar ageing. currenttoofthe
charging 3 C,original
the batte
nominal conditions areThe metKESS
and therefore
driving
is the are theenergy
both
second weighting
considered
storage factor
in system approximately
the ageing whichprocess. equals
This
complements one,battery.
model
the only focuA
leading to the number of machine
electric cycles provided
capacity
converts by the
degradation
the manufacturer
electricand does to
energy not for this
consider
kinetic current
calendar
energy rate.
and vice The and store
ageing.
versa
bus route as well asthethe
latter within aThe
end-terminus rotating
KESS flywheel.
charging The
the stored
is thetosecond energy
original kinetic energy
storage
battery depends
system
SOC onthe
which
before the square o
compleme
the rotational
driving are both considered speed
electric
in the and
ageing the moment
machine
process. Thisofmodel
converts inertia. Due focuses
the electric
only to the linear
energy relationenergy
to kinetic
on between
cycle-related and powe
vic
capacity degradationandand
rotational speed
doesthe
not latterwithin
within
consider the abase speed
rotating
calendar range of aThe
flywheel.
ageing. synchronous machine
stored kinetic and to
energy remai
depend
operational attheallrotational
times, there is a and
designated minimum rotational speed ω whic
The KESS is the second energy storagespeed system the moment
which complementsof inertia. theDue to theAn
battery. linear
m,min relati

and rotational
electric machine converts the electric energyspeed withinenergy
to kinetic the base andspeedvicerange
versaofanda synchronous
stores mac
operational at all times, there is a designated
the latter within a rotating flywheel. The stored kinetic energy depends on the square of minimum rotational sp
the rotational speed and the moment of inertia. Due to the linear relation between power
and rotational speed within the base speed range of a synchronous machine and to remain
Energies 2021, 14, 899 8 of 19

operational at all times, there is a designated minimum rotational speed ωm,min which
defines the available energy Eavl of the KESS. This energy and the SOC of the KESS are
described as the following:

1 2 2
Eavl = · J · (ωm,max − ωm,min ) (8)
2
ω2
SOCfw = 2m (9)
ωm,max

where J represents the moment of inertia, ωm is the rotational speed and SOCfw represents
the state of charge of the flywheel.
Three mobile KESS configurations were designed by a simulation tool at TU Darmstadt
as listed in Table 4. The permanent magnet synchronous machines as the electric machines
of the KESS were designed specifically for mobile applications according to the work of
Schneider [40]. The losses of the EM are included in the simulation model as a loss map
of 100 equally weighted operating points, which depend on the power output and the
rotational speed of the KESS.

Table 4. Parameters of the mobile KESS configurations.

Parameter Symbol Value Unit

FW1 FW2 FW3
Maximum power Pmax 100 150 130 kW
Available kinetic energy Eavl 1.10 1.50 0.75 kWh
Maximum kinetic energy Emax 1.93 2.38 1.40 kWh
Inertia of rotor Jr 4.63 6.28 4.37 kg m2
Energy density of rotor ur 7.43 8.72 5.43 Wh/kg
Maximum speed nm,max 16,552 15,790 14,520 rpm
Base speed limit nm,fwk 11,606 8898 8923 rpm
Minimum state of charge SOCmin 41 35 45 %
Number of pole pairs p 5 6 6 -
Inner diameter of rotor di 332 360 342 mm
Outer diameter of rotor do 435 467 430 mm
Height of rotor hr 743 768 720 mm
Diameter of containment dc 465 497 460 mm
Height of containment hc 833 858 810 mm
Mass of rotor mr 148 172 138 kg
Mass of stator ms 161 204 165 kg
Mass of containment mc 60 67 58 kg
Overall mass of KESS m KESS 368 442 361 kg

The parameters of the maximum power and available energy of the stationary proto-
type KESS ETA290 were taken as the framework for the first flywheel (FW1). This prototype
is designed as an outer-rotor setup with a hollow cylinder rotor made of fiber reinforced
plastic (FRP). Furthermore, the permanent magnetic bearing prevents rotor-stator contact
during regular operation by axial levitation [41]. The auxiliary losses for magnetic bearings,
vacuum pump and the inverter of all three configurations were assumed to be equal to
the measured auxiliary losses of the aforementioned stationary prototype. All three KESS
configurations operate within the field-weakening range where the maximum power out-
put is constant. However, they vary in their SOC range due to their different speed range.
The influence of the maximum power Pmax and its available energy Eavl of the flywheel is
shown within this study.
Energies 2021, 14, 899 9 of 19

3.3. Energy Management Strategy

3.3.1. Rule-Based Control Strategy
The flow-chart of the implemented rule-based strategy is presented in Figure 4, which
has been adapted from the battery/supercapacitor HESS in [42]. To control the power
flow of the HESS, this strategy defines three adjustable values, each in kW: the traction
threshold (TH) value Pthr,trac , the threshold value for recuperation Pthr,rec as well as the
power of the charge controller Pch , which is delivered to the flywheel by the battery.

Figure 4. Flow-chart of the rule-based control strategy.

If the vehicle is recuperating energy and hence the requested power of the electric
drive PED is negative, the battery is charged with up to Pthr,rec and the remaining power
charges the KESS. During motor operation, the battery supplies Pthr,trac and the KESS
supplies the remaining power as far as possible. To keep the flywheel SOC within an
operating range, a charge controller is implemented which is displayed in the lower right-
hand part. This ensures that enough power can be supplied at all times from the flywheel.
The threshold value SOCthr for the KESS charge controller is set at 20% above the respective
minimum SOC of the KESS configuration. The battery charges the KESS with Pthr,trac − PED ,
but never exceeds the maximum charging power Pch . To finish the driving cycle close to
the minimum SOC of the KESS, the charge controller is switched off after 80% of the bus
cycle.
The values for the three adjustable parameters were determined by a sweep within a
reasonable range for both driving cycles individually. The traction threshold Pthr,trac was
varied in 10 kW increments from 20 kW to 120 kW and the recuperation threshold Pthr,rec
simultaneously from 0 kW to 70 kW in 10 kW increments. The power for the KESS charge
controller Pch was tested in 5 kW increments starting from 0 kW.

3.3.2. Nonlinear Model Predictive Control

The (nonlinear) model predictive control is an optimisation-based strategy which can
take system limitations into account while optimising a defined multivariable problem
over a prediction horizon [43]. The algorithm, depicted in green, consists of the following
three steps as shown in Figure 5: First, the simplified model of the system is used to predict
the future output over the prediction horizon. Secondly, the cost function for the given
future output is evaluated. Thirdly, the first element of the optimal control policy with
minimum cost is applied to the system.
Energies 2021, 14, 899 10 of 19

Cost
Constraints
function
Future
Predicted Optimal System
reference Optimizer
Model of output Control output
(Quadratic System
the system
Programming)
Future
optimal control

Figure 5. Layout of the nonlinear model predictive control algorithm.

This control strategy makes use of the future reference speed of the driving cycle
which can be converted to an estimation of the reference power given to the NMPC model
over the prediction horizon. To predict the future output of the system, the actual system
depicted in blue is modelled as a simplified version within the NMPC. Based on the
predicted output of the NMPC model, the optimisation algorithm calculates the future
control sequence for each time step over the prediction horizon to minimise the cost
function while simultaneously satisfying the system constraints. Once the first control
element was applied to the system, the prediction horizon—which can be specified within
the controller—is shifted to the next step. At the next time step, the problem is updated
with new measurement data and the optimisation is executed again. In other words,
the algorithm optimises the current time slot while keeping future time slots within the
prediction horizon in account [44].
The nonlinear model predictive control was implemented in M ATLAB R and Simulink
with the help of the Model Predictive Control Toolbox [45]. The implemented optimiser in
the Simulink controller is the sequential quadratic programming (SQP) algorithm. Reduced
order models were adopted for the HESS components to keep the computational cost low
while predicting accurately the system response.

Simplified Battery and KESS Models for the NMPC

The simplified battery model is based on the Thévenin circuit model, but it excludes
the transient response by combining the steady-state and the transient resistance to the
equivalent internal resistance Rbat [26]. This leads to the following dynamics of the bat-
tery [46]:
2
Pbat = uoc · ibat − Rbat · ibat (10)
p
˙ bat = dSOCbat = ibat uoc − u2oc − 4 · Rbat · Pbat
SOC 6
= (11)
dt 3.6 × 10 · Qnom 2 · Rbat · 3.6 × 106 · Qnom

Moreover, the dependence of the open-circuit voltage on the battery SOC was linearly
approximated for the operating range between 30% and 70%. Similarly, the state equation
of the flywheel SOC can be expressed as follows:

˙ fw = dSOCfw = Pfw − Ploss (SOCfw , Pfw )

SOC (12)
dt 3.6 × 106 · Emax

The losses of the EM and the inverter—the power for magnetic bearing and vac-
uum pump is supplied by the battery—are implemented as a third-degree polynomial
approximation to reduce the computing time.

NMPC Implementation
The HESS model within the NMPC algorithm is implemented as a state-space repre-
sentation reported in Equation (13). The states x are defined as the state of charge of the
battery SOCbat and the KESS SOCfw , the control variables u as the respective output power
Energies 2021, 14, 899 11 of 19

Pbat and Pfw , and the battery current ibat as well as SOCfw comprise the NMPC output
variables y:

           
x1 SOCbat u1 Pbat y1 ibat
x= = , u= = , y= = (13)
x2 SOCfw u2 Pfw y2 SOCfw

The operational limits of the system and its components are included within the
NMPC model as inequality constraints as follows:

ω · Tgen,max ≤ Pfw ≤ ω · Tmot,max

Tgen,max ≤ Tfw ≤ Tmot,max

(14)
SOCmin,bat − ce1 · e ≤ SOCbat ≤ SOCmax,bat + ce1 · e

SOCmin,fw − ce2 · e ≤ SOCfw ≤ SOCmax,fw + ce2 · e

where ω is the mechanical angular velocity of the flywheel, Tgen,max and Tmot,max represent
the maximum EM torque values in generator (negative) and motor mode for the KESS,
Tfw is the actual KESS torque, SOCmin and SOCmax represent the minimum and maximum
values for the state of charge of the respective ESS, e is the slack variable used for constraint
softening and ce are slack coefficients for the respective ESS.
The NMPC control at instant k is calculated by the minimisation of the following cost
function along the control horizon, being subject to the above given constraints:
p 

2
J= ∑ c1 · u1 (k + i |k) + u2 (k + i |k ) − u3 (k + i |k) − Paux
i =1

2
+c2 · e(k + i |k) + c3 · σ(k + i |k) · |y1 (k + i |k)| (15)


2
+c4 · y2 (k + i |k) − y2,ref (k)

where (k + i |k) represents the value predicted for time (k + i ) based on the information
available at time k, p denotes the prediction horizon as the number of time steps, Paux
is the auxiliary power supplied by the battery, σ represents the weighting factor for the
battery ageing and cn is the respective coefficient for the n-th part of the cost function.
The first term gives a penalty for not meeting the requested power of the electric drive
and the auxiliary devices. The purpose of the second term is to respect the soft constraint,
whereas the third term considers the battery ageing by penalizing the weighted energy
throughput of the battery. The fourth term penalizes both rapid FW discharging in the
beginning and a high SOC at the end of the driving cycle. The reference SOC for the FW
y2,ref is set at its initial value at the start and degrades linearly to SOCmin,fw over the time
of the driving cycle.
4. Results
4.1. Energy Management Strategies
The results of the parameter sweep for the rule-based control strategy regarding the
battery lifetime can be seen in Table 5. The values for the recuperation threshold are all set
to 0, hence the total recuperating energy only charges the KESS. The values for E11 vary
slightly depending on the chosen flywheel, whereas the TH values remain the same for
the BR driving cycle independent on the FW. This can be partially explained by the chosen
increment of 10 kW and 5 kW respectively, as the exact values might differ slightly from
each other, but did not become apparent for the chosen increments.
Energies 2021, 14, 899 12 of 19

Table 5. Optimal threshold values of charge controller for the KESS configurations.

Parameter Symbol E11 BR Unit

Configuration FW1 FW2 FW3 FW1 FW2 FW3
Charging power Pch 0 15 0 15 0 10 0 20 0 20 0 20 kW
Traction TH Pthr,trac 40 30 30 30 40 30 50 30 50 30 50 30 kW
Recuperation TH Pthr,rec 0 0 0 0 0 0 0 0 0 0 0 0 kW

The first column of each flywheel represents the rule-based control without KESS
charge controller (RB1), whereas the one including the charge controller is shown in the
respective second column (RB2) with a charging power of Pch = 15 kW for low SOC. The
shown values are the optimal threshold values for the rule-based control and are chosen
for further studies.
The battery current for the first flywheel configuration is shown in Figure 6. The
battery-only configuration is the original BEB without the additional KESS, whereas the
other three represent the HESS with different control strategies. Positive battery current
implies discharging, whereas negative values are equivalent to recharging the battery. All
three configurations show a significant reduction of the peak battery current compared to
the battery-only bus. Furthermore, nearly all the recharging energy was supplied to the
flywheel for the HESS in contrast to the BEB, resulting in no negative battery current for
the three configurations of the HESS. Aside from the different threshold values, the course
of RB1 and RB2 are very similar, whereas the battery current for the NMPC shows more
low frequency behavior and appears smoother.

Battery-only
300
RB1
RB2
200 NMPC
ibat in A

100

−100

200 250 300 350 400 450 500 550 600

t in s

Figure 6. Extract of battery current ibat along the E11 driving cycle for FW1.

Figure 7 presents the respective state of charge of the battery and the flywheel de-
pending on the control strategy. The difference between the battery SOC at the end and
the beginning of the driving cycle is the depth of discharge (DOD) of the cycle. The DOD
plays a role in the amount of battery recharging, but it is not equivalent to the ageing of
the battery which depends on the energy throughput. This fact can be observed by com-
paring the battery-only configuration and the NMPC controlled HESS which both result
in similar DOD. However, the course of SOCbat for the battery-only configuration shows
more high-frequency components which is a sign for frequent charging and discharging.
This is confirmed by the higher peaks of the battery current for the non-hybrid electric bus
shown above.
Energies 2021, 14, 899 Energies 2021, 14, 899 13 of 19 13 of 19

60 Battery-only
RB1

SOCbat in %
RB2
55
NMPC

50

45
0 200 400 600 800 1000 1200 1400 1600
RB1
RB2
80
NMPC
SOCfw in %

60

40
0 200 400 600 800 1000 1200 1400 1600
t in s
Figure 7. State
Figure of charge
7. State ofofbattery
of charge batterySOC and KESS
bat and
SOCbat KESSSOC
SOC along
along
fwfw thethe
E11E11 driving
driving cyclecycle for FW1.
for FW1.

The lower part The lower part

of Figure of Figure
7 shows 7 showsofthe
the course thecourse of theSOC.
flywheel flywheel
It isSOC. It is noticeable
noticeable
that for the NMPC, the KESS comes close to its lower SOC limit
that for the NMPC, the KESS comes close to its lower SOC limit much earlier than for the much earlier than for the
rule-based control strategies, but all of them finish close to each other at SOCfw ≈ 50%. Due
rule-based control strategies, but all of them finish close to each other at SOCfw ≈ 50%. Due
to the implemented slack variable for the NMPC, it briefly falls below the lower limit of
to the implemented slack variable for the NMPC, it briefly falls below the lower limit of
41% at t ≈ 1350 s during a power peak before rising again. Nevertheless, the comparability
41% at t ≈ 1350 sbetween
during the
a power peakcontrols
rule-based before rising
and the again.
NMPC Nevertheless,
is still given asthe comparability
this drop below the lower
between the rule-based controls and the NMPC is still given as this drop below
limit was very brief and hence the operating limits can be considered equal. the lower
limit was very brief and hence the operating limits can be considered equal.
4.2. Flywheels
4.2. Flywheels The influence of the three KESS configurations is examined within this part. Therefore,
The influencetheofbattery current
the three KESS along driving cycleisE11
configurations for the NMPC
examined withinisthisshown
part.inTherefore,
Figure 8. It can be
seenalong
the battery current that for all three
driving configurations,
cycle the battery
E11 for the NMPC currentinremains
is shown Figurepositive
8. It canwith
be a short
seen that for all three configurations, the battery current remains positive with a short that the
exception at the end of the driving cycle for the third configuration. This means
battery always supplies power to the electric drive or the flywheel and all the recuperation
exception at the end of the driving cycle for the third configuration. This means that the
power recharges the respective KESS. During acceleration phases such as around t ≈ 160 s,
battery always supplies power to the electric drive or the flywheel and all the recuperation
the battery current of FW3 was the lowest, followed by FW1 and last by FW2. This order is
power rechargesreversed
the respective
for low KESS.
batteryDuring
currentsacceleration phases
or standstill such as atsuch as around
t ≈ 400 t ≈ 160the
s, representing s, order of
the battery current
theof FW3 was
available the lowest,
energy followed
of the KESSs. by FW1
During and last the
recuperation, by battery
FW2. This orderthe
supplied is greatest
reversed for low current
batterytocurrents
the KESS orwith
standstill suchavailable
the lowest as at t ≈energy
400 s, (FW3),
representing
whereas the orderacceleration
during of
the available energy of the
the HESS KESSs.
with During
the highest recuperation,
available the battery
energy (FW2) resulted supplied the greatest
in the lowest battery current.
current to the KESS withFurthermore,
the lowest there are two unique
available energypeaks
(FW3),at t whereas
≈ 170 s and 320 s for
during configuration three,
acceleration
the HESS with the which consists
highest of the KESS
available energy with the lowest
(FW2) resultedavailable
in the energy. These peaks
lowest battery are caused by
current.
the fact that this KESS reached its minimum SOC rather quickly
Furthermore, there are two unique peaks at t ≈ 170 s and 320 s for configuration three, and therefore the battery
supplied the high-power peaks. Moreover, configuration one shows battery current peaks
which consists of the KESS with the lowest available energy. These peaks are caused by
at the beginning of several acceleration periods such as at t ≈ 340 s. As this KESS has the
the fact that this KESS reached its minimum SOC rather quickly and therefore the battery
lowest maximum power of 100 kW, the battery must supply the remaining power between
supplied the high-power
the demand peaks.
of theMoreover, configuration
electric drive one shows
and the maximum battery
possible powercurrent
of thepeaks
KESS. This is
at the beginningconfirmed
of severalbyacceleration periods such as at t ≈ 340 s. As this KESS
a smaller peak at the same time instant for FW3 which has a maximum has the power
lowest maximumofpower130 kW. of 100 kW, the battery must supply the remaining power between
the demand of the electric drive and the maximum possible power of the KESS. This is
confirmed by a smaller peak at the same time instant for FW3 which has a maximum power
of 130 kW.
Energies 2021, 14, 899 14 of 19

FW1
FW2
FW3
100

ibat in A
50

0 200 400 600 800 1000 1200 1400 1600

t in s

Figure 8. Battery current ibat along the E11 driving cycle for the NMPC.

Table 6 reports the overall results for the E11 driving cycle, while Table 7 reports the
detailed results along the BR driving cycle. The first column represents the non-hybrid
BEB for the respective driving cycle. It can be seen that the NMPC as the control strategy
increased the battery lifetime the most, as well as the HESS including FW2 achieved the
longest battery lifetime out of the KESS configurations. For some HESS configurations,
the maximum battery current for the rule-based control is higher than for the stand-alone
battery system. This effect is due to a high-power peak with the KESS being already
fully discharged at this point, leading to a higher battery peak current because of the
additional bus weight due to the KESS. Additional data about the average (AVG) and
standard deviation (SD) of the C-rate of the battery can be found in Appendix A.

Table 6. Comparative results of the mobile KESS configurations along the E11 driving cycle.

Parameter FW1 FW2 FW3 Unit

BEB RB1 RB2 NMPC RB1 RB2 NMPC RB1 RB2 NMPC
Max. battery current 272 151 153 123 302 154 68 304 304 90 A
RMS battery current 62.5 38.6 36.2 34.3 40.4 34.6 32.1 42.2 38.2 38.8 A
Battery energy losses 147 56 49 44 62 45 39 67 55 57 Wh
KESS energy losses - 903 905 916 1026 1066 1050 938 954 977 Wh
Energy throughput 29.1 24.9 24.5 23.6 24.2 24.0 23.2 25.9 25.7 24.9 Ah
Battery life increase - 16.9 18.7 23.4 20.4 21.4 25.4 12.3 13.3 17.0 %

Table 7. Comparative results of the mobile KESS configurations along the BR driving cycle.

Parameter FW1 FW2 FW3 Unit

BEB RB1 RB2 NMPC RB1 RB2 NMPC RB1 RB2 NMPC
Max. battery current 346 350 286 157 286 328 95 352 331 120 A
RMS battery current 78.8 49.7 43.7 40.4 48.2 42.6 37.7 53.7 45.7 45.3 A
Battery energy losses 263 105 81 69 98 77 60 122 88 87 Wh
KESS energy losses - 1002 1046 1060 1174 1197 1201 1059 1109 1123 Wh
Energy throughput 42.2 34.8 34.4 33.1 34.3 33.9 32.9 36.2 35.6 34.5 Ah
Battery life increase - 21.0 22.5 27.4 22.8 24.5 28.3 16.6 18.3 22.1 %

Figure 9 shows the estimated battery lifetime increase for both driving cycles depend-
ing on the control strategies and the HESS configurations. The prolongation of the battery
lifetime for each control strategy is bigger for the BR driving cycle than for E11, which is
caused by its more intense cycling characteristics. The NMPC produced the best results
through all KESS configurations and the two driving cycles. Furthermore, FW2 increased
the battery lifetime the most, closely followed by FW1 and then by FW3. Overall, an
estimated battery lifetime increase of over 25% can be achieved for both driving cycles.
Energies 2021, 14, 899 Energies 2021, 14, 899
15 of 19 15 of

Estimated lifetime increase in %

Estimated lifetime increase in %

30
25
25
20
20
15
15
10
10
5 5

0 0
FW1 FW2 FW3 FW1 FW2 FW3

(a) E11 driving cycle (b) BR driving cycle

Figure 9. Battery life increase for KESS configurations (left: RB1, middle: RB2, right: NMPC).
Figure 9. Battery life increase for KESS configurations (left: RB1, middle: RB2, right: NMPC).
5. Discussion
5. Discussion The main research question of this paper was whether the estimated battery lifetim
The main research of question
a BEB could ofbethis paper was
prolonged by thewhether
additionthe of aestimated
flywheel asbattery lifetime
a secondary energy storag
The presented
of a BEB could be prolonged by theresults
additionindicate
of a that both the
flywheel as aRMS and the energy
secondary peaks ofstorage.
the battery curre
The presented resultswere significantly
indicate that both reduced
the along
RMS both and examined
the peaksdriving of thecycles,
battery taking into account th
current
increased curb mass of the bus. The lowest energy throughput was achieved by th
were significantly reduced along both examined driving cycles, taking into account the
NMPC for KESS configuration two with an extension of the estimated battery lifetime
increased curb mass 25.4%
of thefor bus.
the E11Theand lowest
28.3%energy
for the BR throughput
driving cycle. wasThis achieved by the
clearly demonstrates that
NMPC for KESS configuration
flywheel can two with an extension
substantially increase theof the estimated
lifetime of the battery battery
withinlifetime of
a BEB. However, the
25.4% for the E11 andwere 28.3% for the
various BR driving
simplifications made.cycle.TheThis clearly
reference speeddemonstrates that a power
and thus the requested
the electric
flywheel can substantially increasedrivethefor the NMPC
lifetime of thewas assumed
battery to be aperfectly
within BEB. However,known beforehand,
there whic
does notmade.
were various simplifications reflect The
the real operation
reference speedof a and
service
thus bus.theUncertainty
requested factorspowersuch of as traffi
passenger load, outside temperature, bus stops, and aggressiveness of the driver have
the electric drive for the NMPC was assumed to be perfectly known beforehand, which
significant impact on the power demand profile of the electric bus [47]. Therefore, th
does not reflect the real operation of a service bus. Uncertainty factors such as traffic,
power demand prediction should be investigated in the future and implemented into th
passenger load, outside NMPC temperature,
algorithm tobus stops,some
consider anduncertainty
aggressivenessfactors of ofthethedriving
drivercycle.
haveInacompariso
significant impact on tothe thepower
NMPC,demand profile
the rule-based of thestrategies
control electric resulted
bus [47]. Therefore,
in shorter thelife increas
battery
power demand prediction but bothshould be investigated
prolonged the battery in the future
lifetime by over and 20%implemented
for FW2. To furtherinto theimprove th
rule-based
NMPC algorithm to consider somecontrol strategies,factors
uncertainty smallerofincrements
the driving for cycle.
the threshold optimisation valu
In comparison
could be applied.
to the NMPC, the rule-based controlMoreover,
strategies improvements
resulted in in the charge
shorter controller
battery of RB2 could includ
life increase,
charging during low recuperation or a variable charging power depending on the curre
but both prolonged the battery lifetime by over 20% for FW2. To further improve the
SOC of the flywheel.
rule-based control strategies, smaller the
Furthermore, increments
battery ageing for model
the threshold optimisation
could be improved as well.values
Even though th
could be applied. Moreover,
applied improvements
energy throughput in model
the chargewhichcontroller
includes a of RB2 could
weighting include
factor depending on th
charging during low recuperation
battery currentor a variable
seemed charging
sufficient for thepower depending
first general study, moreon the current which als
parameters
SOC of the flywheel. contribute to the battery ageing should be included as weighting factors as well. Th
Furthermore, thebattery
batterycell’s temperature,
ageing model could the SOC and the DOD
be improved as are
well. suchEvenageing factors.
though theIn additio
applied energy throughput model which includes a weighting factor depending on the could b
an ageing model including the two-stage linear ageing process of LTO batteries
considered according to Han et al. [35,36]. Furthermore, the calendar ageing could b
battery current seemed sufficient for the first general study, more parameters which also
implemented as it was implemented in the weighted energy throughput model.
contribute to the battery The ageing should
evaluation of be
the included
influence ofas theweighting
KESS sizingfactors
showed as an well.
extensionTheof the batte
battery cell’s temperature,
lifetimetheforSOC and with
flywheels the DODhigherare such
energy ageingdespite
capacity, factors. theirInincreased
addition, overall ma
an ageing model including
which ledthetotwo-stage
a higher powerlinear ageingThus,
demand. process of LTO
it appears thatbatteries
the masscould be only ha
of the KESS
considered accordingato small
Han impact
et al.as[35,36].
the curb mass of the bus of
Furthermore, 10.5
the t was much
calendar heavier
ageing than the
could be KESS ma
implemented as it wasThe correlation between
implemented in the aweighted
higher KESS energythroughput
energy capacity and model.a longer battery lifetime seem
The evaluation ofplausible as SOCfw at the start of the driving cycle was always set at 90%, and therefo
the influence of the KESS sizing showed an extension of the battery
there was more energy available for the KESS with a higher capacity. This addition
lifetime for flywheelsenergy
with higher energy capacity, despite their increased overall mass
was used instead of the battery, resulting in a reduced battery energy throughpu
which led to a higher power demand. Thus,
Although the operating strategy it appears thatcharged
of a fully the mass KESSofin thetheKESS onlyand
beginning hada discharge
a small impact as the curb mass of the bus of 10.5 t was much heavier than the KESS mass.
The correlation between a higher KESS energy capacity and a longer battery lifetime seems
plausible as SOCfw at the start of the driving cycle was always set at 90%, and therefore
there was more energy available for the KESS with a higher capacity. This additional
energy was used instead of the battery, resulting in a reduced battery energy throughput.
Although the operating strategy of a fully charged KESS in the beginning and a discharged
one in the end of the driving cycle is indisputable, the advantage of a higher amount of
energy stored initially should be corrected in further examinations. This could be realised
Energies 2021, 14, 899 16 of 19

by ensuring the same SOC at the beginning and the end of the driving cycle. Moreover, the
peaks of the battery current were reduced to a higher degree by the KESSs with a higher
maximum power. However, the PMSM of these systems had higher losses which resulted
in increased overall power losses. Due to the correlation between maximum power and
available energy as well as the limited number of examined KESSs, the influence of the
maximum power on the battery lifetime should be exactly derived in the future. Therefore,
the investigation of the maximum power of the FW on the battery ageing should be carried
out in future studies.
The next step after the presented variation of maximum power and energy capacity of
the KESS would be a proper sensitivity analysis regarding the KESS sizing. In addition to
the KESS sizing and battery ageing, the efficiency map of both storage systems, ecological
aspects, the sizing of the battery and the lifecycle costs of the whole system can be included.
Within this scope, the aforementioned parameters could be added to the cost function of
the NMPC to improve this control strategy. By including, e.g., the efficiency of the PMSM
of the flywheel, the overall losses could be reduced by avoiding inefficient operating points
of the electric machine. Similarly, operating points of the battery which have a bigger
impact on its lifetime can be avoided, based on a more elaborate battery ageing model
which considers influential parameters such as its SOC. The sensitivity analysis should
further be carried out both for a higher quantity of driving cycles and for each driving
cycle individually.

6. Conclusions
A hybrid energy storage system consisting of a kinetic energy storage system and a
battery was investigated for electric buses, with a special focus on the lifetime extension of
the battery. The simulation analysis was mainly based on the battery electric bus operating
on the E11 route in Finland. Therefore, model-based design was used to simulate the mobile
KESSs. The implemented battery ageing model considered the energy throughput of the
battery and the C-rate with a weighting factor. Two different types of control strategies
were developed and applied, namely a rule-based and a nonlinear model predictive control.
A version of the rule-based one included a charge controller which kept the KESS within an
operating range by the battery for certain conditions. The NMPC made use of the reference
speed of the driving cycles and adjusted the power of the two ESSs accordingly.
The energy management strategies were applied to the HESS along the E11 and BR
driving cycle. The analysis regarding the battery ageing in comparison to the non-hybrid
battery electric bus resulted in a significant battery life increase of over 25% for the NMPC
for both cycles. The rule-based strategies prolong the battery lifetime by over 20% as
well, with the one including the KESS charge controller achieving slightly better results.
Moreover, the influence of the maximum power and the available energy of the KESS
was examined. The results showed that a higher energy capacity reduced the energy
throughput of the battery the most, despite having a higher overall power demand due to
their increased mass.
The research question of this study, whether the battery lifetime of an electric bus
can be increased by the addition of a flywheel, was answered with promising results.
Furthermore, the influence of the KESS size as well as the driving cycle was demonstrated.
Nonetheless, there are various topics regarding this paper which could be investigated in
the future. First, the total cost of ownership of the vehicle should be examined in detail.
Second, a proper sensitivity analysis regarding the sizing of the KESS could be conducted
as well. Third, the design of the flywheel’s PMSM should further include the operating
points of the energy management strategy. Finally, the battery ageing model could also be
improved by including more operating parameters, e.g., the temperature and the SOC of
the battery.
Energies 2021, 14, 899 17 of 19

Author Contributions: Conceptualization, P.G., K.K. and J.V.; Investigation, P.G.; Methodology, P.G.,
K.K., J.V., P.M. and M.S.; Project administration, S.R. and K.T.; Resources, K.K. and J.V.; Software, P.G.;
Supervision, S.R. and K.T.; Writing—original draft, P.G.; Writing—review & editing, K.K., J.V., P.M.,
M.S., S.R. and K.T. All authors have read and agreed to the published version of the manuscript.
Funding: This research received no external funding.
Conflicts of Interest: The authors declare no conflict of interest.

Abbreviations
The following abbreviations are most common in this manuscript:

BEB Battery electric bus

BR Braunschweig driving cycle
E11 Espoo bus line 11
FW1 Flywheel configuration one
FW2 Flywheel configuration two
FW3 Flywheel configuration three
NMPC Nonlinear model predictive control
RB Rule-based
RB1 Rule-based control without KESS charge controller
RB2 Rule-based control with KESS charge controller
TH Threshold

Appendix A

Table A1. Average and standard deviation of the battery C-rate along the E11 driving cycle.

Parameter FW1 FW2 FW3 Unit

BEB RB1 RB2 NMPC RB1 RB2 NMPC RB1 RB2 NMPC
AVG traction C-rate 0.60 0.36 0.35 0.35 0.35 0.35 0.34 0.37 0.37 0.37 C
SD traction C-rate 0.64 0.32 0.28 0.26 0.37 0.26 0.22 0.37 0.30 0.33 C
AVG recup. C-rate 0.31 - - 0.003 - - - - - 0.01 C
SD recup. C-rate 0.24 - - 0.002 - - - - - 0.01 C

Table A2. Average and standard deviation of the battery C-rate along the BR driving cycle.

Parameter FW1 FW2 FW3 Unit

BEB RB1 RB2 NMPC RB1 RB2 NMPC RB1 RB2 NMPC
AVG traction C-rate 0.68 0.44 0.44 0.42 0.43 0.43 0.42 0.46 0.45 0.45 C
SD traction C-rate 0.77 0.44 0.32 0.28 0.42 0.31 0.21 0.49 0.36 0.36 C
AVG recup. C-rate 0.61 0.14 0.14 0.12 - - - - - 0.01 C
SD recup. C-rate 0.47 0.03 0.03 0.03 - - - - - 0.04 C

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