Department of Mechanical Engineering

Machine design specialization

Flywheel as energy storage device

Prepared by
Nigussie Adem

April 5, 2017

Nigussie Adem
Table of Contents
Introduction .................................................................................................................................................. 1
Energy Stored in a Flywheel .......................................................................................................................... 1
Design steps and formulas ............................................................................................................................ 2
Dimensions of Flywheel Rim ......................................................................................................................... 3
Components of a flywheel energy storage system ....................................................................................... 4
Applications................................................................................................................................................... 7
References .................................................................................................................................................... 9

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 Introduction
A flywheel is a rotating mechanical device that is used to store rotational energy. Flywheels have
an inertia called the moment of inertia and thus resist changes in rotational speed. The amount of
energy stored in a flywheel is proportional to the square of its rotational speed. Energy is
transferred to a flywheel by the application of a torque to it, thereby increasing its rotational speed,
and hence its stored energy. Conversely, a flywheel releases stored energy by applying torque to a
mechanical load, thereby decreasing the flywheel's rotational speed.
Common uses of a flywheel include:
Providing continuous energy when the energy source is discontinuous. For example, flywheels are
used in reciprocating engines because the energy source, torque from the engine, is intermittent.
Delivering energy at rates beyond the ability of a continuous energy source. This is achieved by
collecting energy in the flywheel over time and then releasing the energy quickly, at rates that
exceed the abilities of the energy source.
Controlling the orientation of a mechanical system. In such applications, the angular momentum
of a flywheel is purposely transferred as a torque to the attaching mechanical system when energy
is transferred to or from the flywheel, thereby causing the attaching system to rotate into some
desired position.
Energy Stored in a Flywheel
A flywheel is shown as in fig below we have already discussed that when a flywheel absorbs
energy, its speed increases and
when it gives up energy, its speed decreases.
Let m = mass of the flywheel in kg
Ke = radius of gyration of the flywheel in metres,
I = Mass moment of inertia of the inertia of the flywheel about its axis of rotation in Kg-m2
= mk2

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 Design steps and formulas
Step-1: Coefficient of fluctuation calculation

Input required: Maximum & minimum speed

Flywheel inertia/size depends upon the fluctuations in speed. The difference between maximum
& minimum speeds during a cycle is called maximum fluctuation of speed.

The ratio between maximum fluctuations of speed to mean speed is called coefficient of
fluctuation of speed (Cs).

Consider, Ѡ max =Max. Speed during the cycle

Ѡmin = Min. speed during the cycle

Ѡmean =Mean speed = (Ѡ max + Ѡ min) /2…….eq.1

Therefore, Coefficient of Fluctuation of speed,

Cs = [2*(Ѡmax–Ѡmin)]/[Ѡmax+Ѡmin]…….eq.2

Note: The smaller the Cs value, larger the flywheel, but smoother the operation.

Step-2: Mass moment of inertia calculation

Input required: kinetic energy of the system

The general equation of kinetic energy for a flywheel system is given as,

Ke = 0.5* I* (Ѡmax2 – Ѡmin2) ………..eq.3

Rewriting eq.3, we get

Ke = 0.5 I (Ѡmax + Ѡmin) (Ѡmax – Ѡmin)…………eq.4

Substituting eq.1 & 2 in eq.4, we get

I = Ke / Cs Ѡmean2……………..eq.5

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 Dimensions of Flywheel Rim
A rim of flywheel is shown in fig below

Where: R = mean radius of the rim

A = cross- sectional area of rim

= density of material of the rim;

= angular velocity of the flywheel]

V= linear velocity of the flywheel at the mean radius = R

 = Centrifugal or hoop stress in the rim

Consider a small element of the rim shown shaded in the fig; subtending an angle  at
the center of the flywheel. Volume of the small element:
V= A X R d
Mass of the small element:
m = density X V

= V = AX  X R 

Centrifugal force acting on the small element:

F= m 2R

=  A X R2R

=  A X R2 2

In the limit when  → 0, then the centrifugal force dF will be supposed to be acting radially
outward in direction ON.

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 Vertical component of dF
= dF sin

=  A X R2 2 d sin

Total vertical upward force, tending to burst the rim across diameter x’ – x
𝝅
= ∫ 𝝆𝑨𝝎𝟐 𝑹𝟐 𝒔𝒊𝒏𝜽 𝒅𝜽
𝟎

= 𝟐𝝆𝑨𝝎𝟐 𝑹𝟐 … … … . (∗)

The vertical force will produce stress in the material of the rim which is known as centrifugal or
the hoop stress or the circumferential or the tangential stress denoted by 

Total resisting force = 2 X X A …..(**)

2 A R2 2 = 2  A

 =  x R2 2 = v2
𝜎
From which , 𝑉 = √𝜌.

Components of a flywheel energy storage system

A flywheel has several critical components.

a) Rotor – a spinning mass that stores energy in the form of momentum

The rotor, as the energy storage mechanism, is the most important component of the flywheel
energy storage system. The design of the rotor is the most significant contributor to the
effectiveness and efficiency of the system. Rotors are designed to maximize energy density at a
given rotational speed, while maintaining structural integrity in the face of rotational and thermal
stresses. Rotor designs can be divided into two broad categories of low-speed, vertical or
horizontal shaft and high-speed, usually vertical shaft rotors. Both types of rotors have advantages
and disadvantages, and the two find uses in different applications.

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b) Bearings– pivots on which the rotor rests

The bearings support the flywheel rotor and keep it in position to freely rotate. The bearings must
constrain five of the six degrees of freedom for rigid bodies, allowing only rotation around the axis
of the rotor. The construction of the bearings is important in flywheel performance. Speed of the
flywheel is limited in large part by the friction on the bearings, and the resulting wear on the
bearings often defines the maintenance schedule for the system.

There are several types of bearings used in flywheel construction. Mechanical bearings are the
simplest form of flywheel bearings. These might be ball, sleeve, roller, or other type of mechanical
bearing. These bearings are well understood, reliable, and inexpensive, but also suffer the most
wear and tear, and produce the largest frictional forces, inhibiting high rates of rotation.

Magnetic bearings are required for high-speed flywheel systems. These bearings reduce or
eliminate frictional force between the rotor and its supports, significantly reducing the intrinsic
losses. There are several types of magnetic bearings. Passive magnetic bearings are simply
permanent magnets, which support all, or part of the loads on the flywheel. Active magnetic
bearings, on the other hand, use controlled magnetic fields, where field strength on the bearing
axes is varied to account for the effect of external forces on the rotor. Superconducting bearings
are passive magnetic bearings, which use superconducting materials to produce the magnetic
repulsive force to support the rotor assembly. These materials operate at very low temperatures,
and so require cryogenic cooling systems to maintain.

c) Motor-Generator – a device that converts stored mechanical energy into electrical energy, or
vice versa

Motors convert electrical energy into the rotational mechanical energy stored in the flywheel rotor
during charge, and generators reverse the process during discharge. In many modern flywheels the
same rotating machine serves both functions. The machine is called a motor alternator or motor
generator and consists of a wound- or permanent magnet rotor, usually revolving within a stator
containing electrical winding through which charge (or discharge) current flows. Note that this
machine, along with any power electronics, limits the power rating of the flywheel system. And in
some practical systems the generator for discharging the wheel is higher power than the recharging
motor. Thus at full power charging the wheel will require more time than discharging. The starter
motor and alternator or generator are connected to the flywheel via the same steel shaft and may

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be either a single machine or two different machines. In both cases the rotor becomes part of the
flywheel mass. When separate, the starter motor is typically a simple induction motor that is able
to produce starting torque.

d) Power Electronics – an inverter and rectifier that convert the raw electrical power output of the
motor/generator into conditioned electrical power with the appropriate voltage and frequency

Most flywheel energy systems have some form of power electronics that convert and regulate the
power output from the flywheel. As the motor-generator or alternator draws on mechanical energy
in the rotor, the rotor slows, changing the frequency of the AC electrical output.

The main function of these devices is to allow energy to be taken from the wheel before its
frequency and power output drop below usable levels. In fact, the low-end (i.e., end-of-discharge)
cutout speed at which the flywheel is considered discharged is primarily dependent on the current
carrying capability of the electronics (or electromechanical coupling) and the size of the load. For
example, most flywheels have output current proportional to load and inversely proportional to
speed. This means a lighter load can go to a lower speed before the system cuts out on maximum
current.

e) Controls and Instrumentation – electronics which monitor and control the flywheel to ensure
that the system operates within design parameters

Flywheel systems require some controls and instrumentation to operate properly. Instrumentation
is used to monitor critical variables such as rotor speed, temperature, and alignment. Rotor speed
and alignment are also often controlled variables, through active feedback loops. The latter is
especially important for systems with magnetic bearings, and most magnetic systems have
complex controls to reduce precession and other potentially negative effects on the rotor. In many
systems, other instrumentation is used to monitor performance or design parameters related to
failure modes. In some composite flywheel systems, for example, instrumentation is used to
measure deformation of the rotor over time, alerting operators. When the rotor shape indicates
possible failure in the future.

f) Housing – Containment around the flywheel system, used to protect against hazardous failure
modes. It is sometimes also used to maintain a vacuum around the rotor to reduce atmospheric
friction.

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 Applications

A Landini tractor with exposed flywheel

Flywheels are often used to provide continuous energy in systems where the energy source is not
continuous. In such cases, the flywheel stores energy when torque is applied by the energy source,
and it releases stored energy when the energy source is not applying torque to it. For example, a
flywheel is used to maintain constant angular velocity of the crankshaft in a reciprocating engine.
In this case, the flywheel—which is mounted on the crankshaft—stores energy when torque is
exerted on it by a firing piston, and it releases energy to the crankshaft when a piston is in the
process of compressing a fresh charge of air and fuel. Other examples of this are friction motors,
which use flywheel energy to power devices such as toy cars. In uses like this, the distribution of
the mass of the flywheel toward the outside and away from the center is beneficial. Pushing the
mass away from the axis of rotation gives it greater rotational inertia without increasing its total
mass. This increases the efficiency of the flywheel, since it does not have as much difficulty driving
its own weight forward as well as that of the payload.

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Modern automobile engine flywheel

A flywheel may also be used to supply intermittent pulses of energy at transfer rates that exceed
the abilities of its energy source, or when such pulses would disrupt the energy supply (e.g., public
electric network). This is achieved by accumulating stored energy in the flywheel over a period of
time, at a rate that is compatible with the energy source, and then releasing that energy at a much
higher rate over a relatively short time when it is needed. For example, flywheels are used in
riveting machines to store energy from the motor and release it during the riveting operation.

The phenomenon of precession has to be considered when using flywheels in vehicles. A rotating
flywheel responds to any momentum that tends to change the direction of its axis of rotation by a
resulting precession rotation. A vehicle with a vertical-axis flywheel, that is rigidly attached to the
vehicle, would experience a torque applied to the body of the vehicle that would rotate with as the
flywheel precesses. This would produce an alternating rolling and pitching of the vehicle body as
it moved up the incline. The descent of the hill would produce the opposite effect and so it would
zero out the pitching and rolling (roll momentum in response to a pitch change). Two counter-
rotating flywheels may be needed to eliminate this effect. This effect is used in reaction wheels, a
type of flywheel employed in satellites in which the flywheel is used to orient the satellite's
instruments without the use of thruster rockets. Alternatively, the flywheel would be mounted in
two yokes, with axes at mutual right angles, and so allow limited changes to the orientation of the
vehicle body thereby eliminating precession

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References
1. http://www.climatetechwiki.org/technology/jiqweb-es-fw
2. http://en.wikipedia.org/wiki/Flywheel_energy_storage
3. http://blog.mechguru.com/machine-design/flywheel-design-calculation-simplified/

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