The invention relates to a flywheel with a rotating element that rotates in relation to an axis of rotation, which exhibits a radially outer flywheel mass member that tapers in the radial direction and adjoins an inner shaft connection member, wherein hollow projecting end pieces are formed.
Such a flywheel is known from McGroarty et al., “Flywheel Energy Storage System for Electric Start and an All-Electric Ship”, Electric Ship Technologies Symposium, 2005 IEEE, pp. 400-406, Jul. 25-27, 2005.
Also known from DE 196 51 668 A1 is a flywheel for high rotational speeds. In this flywheel, a flywheel mass generally resembling a hollow cone joins to a shaft at an inclination. At high speeds, this may cause gaping at the joint between the flywheel mass and shaft.
Further known from US 2010/0231075 A1 is a flywheel with a hollow cylindrical flywheel mass, which is joined to a shaft via a hollow hub. The hollow nub is intended to enable a flexible attachment to the shaft, wherein an in particular electromagnetic bearing in combination with a superconductive bearing is provided for the shaft. US 2010/0206126 A1 discloses a similar flywheel with a general hollow cylindrical flywheel mass, which is joined to the shaft by means of a generally shell-shaped, separate hub, which allows relative movements between the shaft and flywheel mass. Then known from U.S. Pat. No. 5,628,232 A is a flywheel, again with a hollow cylindrical flywheel mass, wherein this flywheel mass is secured to a shaft via a hub shaped like a hollow cone. As with the flywheels described above, the disadvantage here involves a complicated manufacturing process, in that a flywheel mass and a separate hub must be individually provided, and especially made out of different materials.
Flywheels are used in rotating machines, in particular electric motors/generators, for storing energy, and comprise the central component of a flywheel energy storage system, FESS (flywheel energy storage system) for short. Due to its shape and mass, the rotor has a significant influence on the energy content and energy density (energy content per mass), on the overall costs of the system, and on the power dissipation of the bearing. In light of the outstanding material properties, flywheels are made out of composite materials (most often carbon fiber composite materials, CFK, or a combination of CFK and glass fiber composite materials, GFK). These materials exhibit outstanding material properties in the fiber direction, but only a low strength transverse to the fiber direction, thereby yielding a suboptimal material utilization for many conventional rotor designs, since very high mass forces act in a radial direction.
In rotor designs, a distinction can basically be made between an internal and external rotor. In the internal rotor, a solid shaft acts as the carrier for bearing and motor/generator components. In the external rotor, a hollow shaft is used, and the electrical machine and the bearing engage the inner radius of the hollow shaft.
As mentioned, flywheels made out of fiber-reinforced materials and having rectangular (axial) cross sections are used in commercially available flywheels apart from the internal rotors made entirely out of steel and most often having a rectangular flywheel mass cross section. Another known rotor design involves an internal rotor with an H-shaped cross section and composite flywheel mass.
Current research projects are generally focused on rotors made out of fiber composite materials (carbon fibers, glass fibers). These again include internal rotors with a rectangular cross section (Herbst et al., “Design, Fabrication, and Testing of 10 MJ Composite Flywheel Energy Storage Rotors, SAE Technical Paper 981282, 1998; Jansen et al., “G2 Flywheel Module Design”, NA-SA/CR-2006-213862) or with an H-shaped cross section (Park et al., “Development of 5 kWh flywheel energy storage system using MAT-LAB/xPC Target”, World Congress on Computer Science and Information Engineering 2008 IEEE, (2009): pp. 701-705; McGroarty et al., “Flywheel Energy Storage System for Electric Start and an All-Electric Ship”, Electric Ship Technologies Symposium, 2005 IEEE, pp. 400-406, Jul. 25-27, 2005.
The external rotor exhibits a completely different structural design. In place of a shaft, the latter has a central stator unit, which is encircled by the flywheel mass. The most common cross sectional shape for this rotor design is rectangular (e.g., Beno et al., “End-of-life design for composite rotors”, IEEE Transactions on Magnetics, 37 (1) (2001): 284-289) or H-shaped.
In this structural design, given a configuration with magnetic bearings, the general problem is that the air gap of the magnetic bearing as well as of the motor/generator increases due to the arising expansion of the rotor. In order to ensure a sufficient air gap even at a minimum speed, a significantly larger air gap thus comes about at a maximum speed, which leads to a reduction in energy efficiency because of the required larger magnetomotive force, or to a power reduction. Another major problem involves the nearly direct contact between the motor/generator and the composite material. The lost heat of the magnetically soft motor/generator rotor can only be released via radiation anyway in light of the vacuum; in addition, composites can only be exposed to a low temperature load. Furthermore, the carrier structure poses a big challenge in terms of its construction. The comparatively large inner radius also gives rise to very high stresses in the metal.
Taking into account only the functionality of the flywheel mass and not the motor/generator and bearing functionality, the theoretically ideal design for a flywheel rotor is a thin-walled hollow cylinder made out of composite material as the external rotor, whose interior accommodates the bearing in the upper and lower areas, and the motor/generator in the middle. This is because only slight radial stresses can form in a thin-walled hollow cylinder, so that the largest stresses arise in the circumferential direction, and thus in the fiber direction (see Arnold et al., “Deformation and life analysis of composite flywheel disk system”, Composites: Part B 33 (2002): 433-459).
Based upon the problems outlined above, the typical rotor shape for modern flywheel structures is most often an internal rotor comprised of a metal shaft used to secure the bearing and motor/generator modules, and a cylindrical or H-shaped composite material flywheel, joined to the shaft by an annular connecting or joining part.
In an H-shaped rotor viewed in an axial section, a majority of the mass is situated far to the outside to achieve the highest possible moment of inertia. The arising characteristic frequencies here limit a junction with a very small axial length relative to the length of the cylindrical flywheel member. The areas exposed to the highest load are here located at the height of the junction, since the largest mass forces come about here. High stresses arise at the transition from the joining part to the hollow cylinder due to the state of bending stress. The outer areas of the H-shape where the largest percentage moments of inertia can be achieved are only exposed to a slight load. As a direct consequence, only inadequate use can be made of the strength properties of the composite material given the geometries for the flywheel mass that can be fabricated with conventional production methods. This gives rise to higher material costs and, in light of the heavier flywheel mass, larger required dimensions for the bearing; this again yields higher costs and reduced energy efficiency for the bearing.
An object of the invention is now to propose a design for a flywheel as indicated at the outset in which the highest possible energy density can be achieved depending on the material and dimensioning, and which enables good material utilization or use of material strength properties.
The inventive flywheel of the kind mentioned at the outset is characterized in that the external face of the outer flywheel mass member exhibits a radial indentation that extends all around. As explained below, this radial indentation leads to a significant rise in energy density, both for internal and external rotor configurations.
Advantageous embodiments and further developments are indicated in the dependent claims.
It may be beneficial, for example for production reasons, for the outer flywheel mass member to exhibit a generally hollow cylindrical shape where it axially adjoins the indentation.
On the other hand, it is advantageous in terms of additionally optimizing the energy density for the outer flywheel mass to exhibit legs that generally extend outwardly at an inclination away from the center of the indentation on opposite sides as viewed in axial section. One or both of the projecting end pieces can here extend axially parallel, and thereby define a hollow cylinder.
The shaft connection part can also exhibit a smaller axial extension than the outer flywheel mass member for purposes of good space utilization in the machine (motor/generator).
A “soft” or continuous progression is best imparted primarily to the outer contour of the flywheel, but additionally or alternatively to the inner contour as well. It is here advantageous that the outside and/or inside of the flywheel mass member exhibit a contour with one or more straight segments. It is further beneficial for the outside and/or inside of the flywheel mass member to exhibit a contour with one or more curved segments. At least one circular arc segment is preferably present here. However, it is also possible to provide at least one segment that runs along a higher-order curve, e.g., an ellipse or polynomial. To make production simple, it is also advantageous for the outside and/or inside of the flywheel mass member to exhibit a stepped contour. It here also makes sense for the flywheel mass member to be designed with separate rings joined to each other.
In order to eliminate any potential imbalances, it is further advantageous for the flywheel mass member to exhibit at least one ring with receptacles, e.g., boreholes, for the attachment of balancing weights.
The design of the flywheel mass element can be symmetrical or, given a corresponding layout of accompanying system components (electrical machine, bearing), advantageously also asymmetrical in relation to its central plane (specifically the plane with the smallest outer radius). The preferred design involves a fiber composite material, in particular CFK or a combination of CKF and GFK.
From the standpoint of material utilization, the invention thus represents an advantageous structural solution for the optimal shaping of flywheels, e.g., of the kind used in FESS.
Contrary to a technically obvious configuration with the highest possible mass at a large radius, the essence of the invention involves a receding, e.g., tapering, outer contour in the shaft joining direction.
As mentioned, the outer contour is ideally designed with a “soft” or continuous progression, and consists of circular segments and straight segments, for example. Discontinuous progressions or curves of a higher order (ellipses, polynomials, etc.) are also advantageous for functional (transport restraints, etc.) and/or manufacturing reasons. In addition, the rotor needs not be symmetrical in relation to its central plane. As mentioned, the flywheel mass can further also exhibit a cascading design, wherein the rings can be separately fabricated and then joined together.
The tapering of the outer contour in the shaft joining direction reduces the mass forces in the shaft joining area, causing the radial stresses to drop. The load in the central plane area shifts in the circumferential direction, where the material strength is significantly higher. As a result, better use is made of the strength properties of the material.
It is important that, while the “absent” mass caused by the tapering of the outer contour in the shaft joining direction leads to a reduction in the moment of inertia, this makes it possible to achieve higher speeds based upon lower radial stresses. However, since the effect of increasing the speed is more crucial than the effect of reducing the moment of inertia, the energy content can be increased at the same mass. For this reason, the non-cylindrical design of the outer contour results in a better material utilization and concomitant rise in energy density.
The invention will be described in even more detail below based upon the drawing, and making reference to designs in prior art on the one hand, and to preferred, advantageous embodiments of the invention on the other. Shown on:
Table 1 below lists the most important material data for the CFK (epoxy resin-reinforced HTS40 carbon fibers from TohoTenax) and aluminum used in this and the other enumerated rotors.
The rotor on
The highest load arises at an average radius of approx. 0.22 m, and is roughly constant in an axial direction, leaving aside edge effects, as evident from
The additional rotor types enumerated here are intended to provide a better comparison with the same mass as the rotor according to
In a schematic view similar to
The components of the magnetic bearing system secured on the shaft 12, i.e., on the rotor 11, are usual, and are schematically illustrated on
The shaft 12 is preferably designed as a solid shaft, so that it can serve as a supporting structure for the required bearing and motor/generator components, as well as a bearing surface for the safety bearings 19, 20.
The flywheel 13 or its rotating element 13′ (
The rotor 11 rotates inside the housing 23, which is vacuum-sealed and evacuated, and which also serves as a carrier for the stator components (see carrier sleeves 14, 15), around the X-X axis. As mentioned, the carrier sleeves 14, 15 have attached to them the stator sheets of the bearing and electric machine, windings along with sensors 21 and 22.
Suitable for manufacturing such a rotor 11 with flywheel 13 is a known winding method, in which the fibers (carbon fibers, glass fibers) are guided through an impregnating bath and then deposited wet upon a rotating core. A fiber angle of 90° relative to the X-X axis of rotation is ideal as regards the strength of the rotor 11. As an alternative, use can also be made of pre-impregnated fibers, so-called prepregs.
As further evident from
The described and illustrated tapering or indentation of the flywheel running all around in the circumferential direction makes it possible to achieve a significant improvement in material utilization.
In a depiction similar to
The advantages to the invention can be used to an even greater extent by inclining the projecting parts 24′ as shown on
This may be gleaned in particular from the schematic view on
In the previously shown images, the rotor contour is always composed of straight segments Gn and circular segments Kn. However, discontinuous progressions or curves of a higher order, as e.g. ellipses, polynomials, etc. may be advantageous for functional (transport restraints, etc.) and/or manufacturing reasons; for example, see the embodiments according to
In any event, one essential advantage to be noted from the images according to
An additional advantage to the rotor structures according to
The thickness selected for the “projecting” member 24′ (
The strong anisotropy resulting from the lamellar molecular buildup of carbon fibers yields a low strength for the composite material transverse to the fiber direction, so that only low radial stresses are permissible. The very high radial stresses owing to the mass forces at the required maximum speeds can be reduced by smaller wall thicknesses. This yields a more favorable stress state, since the circumferential stresses rise, and the strength in this direction is significantly higher. However, lower wall thicknesses also lead to lower characteristic frequencies. In flywheel applications with a low motor power, operation beneath flexible characteristic features is intended, since it is critical to run through the characteristic rotor frequencies given the time required for that purpose. A fiber angle deviating from 90° can bring about an additional rigidity in the direction of the X-X axis. A compromise must here be found between strength and dynamic requirements.
In light of the enumerated advantages, better material utilization allows the invention to increase the energy density, and hence lower material costs by comparison to conventional rotor structures.
The significantly better material utilization, up to and including a “fully-stressed design”, makes it possible to significantly reduce the investment costs due to the higher energy density on the one hand, and to increase the overall energy efficiency on the other, making highly efficient flywheels economically feasible for use in a wide range of applications. The basic objective function is to minimize the mass at a given energy content, and to maximize energy efficiency. This ideally yields a geometry in which each area is exposed to a maximum load according to a suitable failure criterion, thus resulting in the best possible material utilization.
The composite material cited above (CFK or combinations of CFK-GFK) exhibits a strong anisotropy, but also outstanding material properties in the fiber direction. Mere glass fiber composites (GFK) are less anisotropic, and also more cost-effective. However, their rigidity properties and especially their densities are less ideal for flywheel applications by comparison to CFK.
A “concentric runout” of the rotor, i.e., the balancing quality, has an important influence on the arising bearing forces of the rotor, or on the required air gap during the magnetic bearing of the rotor, and hence on the energy efficiency of the overall system, which holds true to a special extent for the present flywheels with the mentioned high speeds. Positioning the balancing weights in areas with high radial stresses detracts from strength. This hampers assembly, since notches or a weakened material must be avoided. In addition, it would have to be ensured that the applied balancing weights remain at exactly the same location for the entire lifecycle.
In order to resolve these problems, the present flywheel 13 can integrate special rings 27 (e.g., see
The ring 27 can exhibit different embodiments (see
Even though the invention was described above based upon preferred exemplary embodiments, further modifications and variations are possible within the scope of the claims. In particular, it is also conceivable to provide the present flywheel in conjunction with an external rotor 11′ (see
Number | Date | Country | Kind |
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A 50183/2012 | May 2012 | AT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/AT2013/050106 | 5/13/2013 | WO | 00 |