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Comparison of Flywheels and Supercapacitors for Energy Saving in Elevators

Konstantinos Kafalis Athanasios D. Karlis

Student Member, IEEE Senior Member, IEEE
Democritus University of Thrace Electrical and Computer Democritus University of Thrace Electrical and Computer
Engineering Dept., University Campus Kimmeria Xanthi, Engineering Dept., University Campus Kimmeria, Building
67100, Greece B, Office 0.20 Xanthi, 67100, Greece
konskafa@gmail.com akarlis@ee.duth.gr

Abstract -- A traction elevator system is analytically high energy requirements. In recent years there is a lot of
simulated in this paper, driven by an induction motor, in order research on efficient energy storage. Some of these
to study possible energy saving modes of operation in terms of technologies employ Battery Systems (BS), Fuel Cells (FC),
returning energy to the DC link of the drive system during Supercapacitors (SC), Flywheel Energy Storage Systems
regenerating braking with two possible methods, i.e. with
(FESS) and Compressed Air Energy Storage (CAES) [2].
supercapacitors or with a Flywheel driven by a permanent
The supercapacitors technology base energy storage purely
magnet motor. The efficiency of the two proposed methods is
in the electric field, thus avoid chemical processes. Their
investigated and useful conclusions are extracted.
advantages over batteries are: their longer life time, the
smaller discharge/charging time, the less need for
Index Terms - Mechanical Elevator, Regenerative Brake,
Supercapacitor, Flywheel, Energy Efficiency, Energy maintenance and the better performance. This technology is
also easy to adapt to the needs of each application by varying
I. INTRODUCTION the number of capacitor elements and as it is a technology
that is appropriate for applications with relatively low energy
needs, more and more work on regenerative braking, focus
The vast growth of population, along with the growing
on the use of this energy storage method. It is also suitable in
phenomenon of urbanization and the expensive land prices in
particular for lifts applications as they are characterized by
urban centers are the main factors contributing to the
frequent decelerations accompanied by the appearance of
construction of ever higher buildings. Thus, the elevator,
high currents [3] to reduce the peaks of the energy needs
which is the main technology that allows the vertical
during the start-up with high loads and fix the rate of system
transport of people or goods, is an important part of modern
power making it more efficient [4]. They are connected at the
life. It is estimated that the energy requirements of the
inverter DC Bus via a DC-DC Back Boost converter, and
elevator systems are approximately 8-10% of the total
they absorb or offer the regenerated energy through them [5]­
consumption of the buildings (the figure includes the
[7].
consumption of escalators) globally. Based on the major
Flywheel Energy Storage Systems (FESS) consist of a
�nvironmental problems �reated by the modern way of life, it magnet (an electric motor) and a mechanical part, a rotating
IS necessary to find solutIOns to reduce their consumption. In
mass, wherein the regenerated energy is stored in the fonn of
this study, an elevator system is simulated, in order to check
kinetic energy. The size, shape and material of the rotating
the results of the use of regenerative braking systems with
mass determine the maximum energy that can be stored and
different modes of operations.
can be divided into high speed and low speed Flywheels [8].
Each elevator system can be considered unique, as they
For the electric motor, many works have been published that
may differ from the others in terms of transportation distance,
make use of Pennanent Magnet Synchronous Motor
the frequency of use, the maximum transport load and thus
(PMSM), Brushless DC Motor (BLDCM) [9], Induction
the nominal rating of the system's motor, the motor drive, the
Motor (1M) [10] or Switched Reluctance Motor (SRM) [11].
priority strategy of servicing the users, the use or not of
However, for the purposes of this paper, a PMSM was
regenerative braking and the energy consumption in the rest
selected, as appropriate for low speed Flywheels and as more
of the electrical equipment. Thus the classification of lifts in
efficient. Other advantages are the high energy density, the
energy classes is reduced to a complex problem, which the
absence of the need for excitation and the low complexity of
Guideline VDI 4707 has effectively solved [1]. The guideline
the design. Nevertheless the big disadvantage is that it is the
has classified elevators (or lifts) into classes according to
most sensitive of all the others, both in mechanical and
energy consumption in terms of the load and the
thermal stresses [8], features which are not relevant to this
transportation distance, and taking into account the frequency
work though.
of use.
According to [12] the FESS are mainly used for power
By the use of regenerative braking is necessary to employ
applications from lkW up to 1 MW and energy storage
an energy storage bank for storing the energy regenerated
during braking, in order to be used later when there will be

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Reversed Gearbox

Brake Chopper

Cabin

Sl.percapacitors

Prograrrrnable
Voltage Source

Flywheel

Fig. I Simulation System

between lkWh-1MWh, while supercapacitors for l-100kW (4)

and 200Wh-500Wh respectively. So according to the above,
the supercapacitor system is most suitable for an elevator
system. The purpose of this paper is to check whether a FESS (5)
with a low energy storage capacity, i.e. in the order of some
where: F is the vertical force imposed on pulley's
Wh [13], to be used for an elevator system. For this purpose
circumference, T is the load's torque, J is the moment of
an elevator system was simulated.
inertia, TMG is the load's torque with gearbox included and gw
Two regenerative braking systems have been modeled, one
the specific mass of the rope, L is the total length of the rope,
with supercapacitors and one with Flywheel, which are x is the distance between cabin and friction pulley, Wp is the
connected to the DC Bus of the inverter. The two different passenger's weight, WCA is the cabin's weight, Wcw is the
cases were compared. Also, to detennine the total energy weight of counterweight, R is the pulley's radius, 0)\, 0)2 is
saving of each application a comparison is made to a system angular velocities, N is the gearbox's ratio, ng is the
using a Brake Chopper [14]The supercapacitor of the system gearbox's efficiency factor.
uses a half bridge DC-DC back boost converter, while the In Table 1 all load sizes used for the simulations are
FESS uses a rectifier for connecting the PMSM with the DC­ shown. The weight of passengers is set to zero because this
Bus. Then, the analysis, and comparison of the two systems case is considered the most efficient for regenerative braking
follows along with a discussion of their results. The total systems, and as a maximum value a weight of 630 kg is
created model is shown in Fig. 1. considered. In Fig. 2 shows the desired speed of the chamber,
used as a reference signal for the control of the elevator
II. LOAD EVALUATION motor.
TABLE I
SAMPLES OF TIMES ROMAN TYPE SIZES AND STYLES
The basic elements, which must be taken into
Cabin's Weight (kg) 800
consideration in order to extract the equations for the load of
Passenger's Weight (kg) 0
a traction elevator are: the cabin, the counterweight, the
friction pulley and the passengers. On the other hand, Counterweight (kg) 1175
important may be considered the equations for the gear box, cable length (m) 28
since it's use affects not only the size of the load for the Cable specific mass 1
motor but the total efficiency as well. The pertinent equations (Kg/m)
for the load simulation are presented below: Diameter of pulley (m) 0.9
F= gw . (L - 2x) + Wp + WCA + Wcw (1)
Initial floor
System's efficiency
10
0.8
T = F·R (2) Gearbox ratio 1/30

J = R2 ·(I Wp l + I WCA I + I Wcwl + gw·L )

Gearbox efficiency 0.8
(3)

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TABLE I
REGENERATlYE BRAKE PARAMETERS
2.0
Energy storage (Wh) 40
Vmax (V) 430
1.5
Vmin (V)
�

� co
!il 230
�� COl (F) 0.4583
.. �

1,0
�g Protection resistance R (ohm) 50
a;
>
0.5

DC+

4
Time(s)
Fig. 2 Velocity Reference
Buck Boost
III. REGENERATIVE BRAKE WITH SUPERCAPACITORS [15] Control

The Buck Boost converter was modeled to accommodate

the needs of the regenerative brake with a supercapacitor as
shown in Fig.3� It is actually a Half Bridge converter that Lf

uses two IGBTs [16]. The upper IGBT is activated to

downgrade the voltage of the DC-Bus to the appropriate
Supercapacitor
value, charging the supercapacitor. The lower IGBT is
activated when the elevator's system has high energy
demands, supplying it with the energy that is stored in the
supercapacitor. The IGBTs are controlled through PWM From4
techniques and the duty cycles for the buck and boost
functions are given by the following equations [17]: DC-
Fig. 3 Subsystem of regenerative brake with supercapacitor
Veap
DBliCk = V­ (6)
de IV. REGENERATIVE BRAKE WITH FLYWHEEL

Vcap
Dboosl = 1- -­ (7)
Vde
where Vcap and Vdc are the voltages at the supercapacitor and
DC-Bus respectively.
The aim of this set-up is not only to store the energy that
was regenerated but fIrstly to accommodate the fIrst reason
for braking, i.e. to protect the windings of the machine from
overcurrents. Thus, when the DC-Bus surpasses a certain
limit the pertinent IGBT is activated. Furthermore, for the
better control of the set-up, the upper and lower limit of
charge of the supercapacitor is taken into consideration. In
that case the IGBT of protection is activated and current is
transmitted to a resistance [18].
For this case study a 40Wh storage capacity is considered,
which is sufficient to cover the energy needs of an elevator
for a 10-store elevation in power deficit. The characteristics
of the set-up appear in Table II and the capacity of the
supercapacitor is calculated based on the equation [19]:
2 2
Vmax Vmin( _ )
C101 = (8)
esl 2. E
Where Vmax. Vnun the limit of charging and discharging
voltage respectively and Eesl is the estimated energy storage.
A. Flywheel
The Flywheels consist of two parts, the energy storage
(rotating mass) and the energy converter (electrical to
mechanical energy). The components of the Flywheel are
shown in Fig.4. For the reduction of the losses of the system
the whole set-up is placed inside a vacuum space while the
support for the set-up is done with magnetic bearings to
avoid direct contact [8], [20].
The Flywheels are a promising technology that is under a
lot of research. It has many advantages in comparison to the
conventional batteries, e.g. among others, a bigger lifetime
(�20 years), cheap maintenance, stable power capacity and
output that does not decline as the time goes by and is
independent from temperature factors. They are also
characterized by a quick response time to charging and
discharging [21]. Furthermore Flywheels are a technology
friendly to the environment.
Comparing the use of a Flywheel to a supercapacitor,
Flywheels are used in bigger power applications, they have
better power density but they are generally less effIcient and
have a higher response time [22]. Supercapacitors have
smaller lifetime (�15 years) and more expensive maintenance
but their initial cost is a bit lower compared to the Flywheel.
This difference in initial costs is declining as the size of

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storage system is increasing [23]. Also, Flywheel's biggest
disadvantage is the very high self-discharge [24]. For
example during 2 standby hours Flywheel may lose 10-20%
of the energy stored in the rotating mass and during 1 day
they will surely lose all the energy. For super capacitors these
percentages are 5% and 40%, respectively. In Fig.5 some of
the main and most common uses of an FESS are shown [25]­
[29].
1---: --- (3)
(7)
---- (4 )
Fig. 4 Flywheel Schematic: (I) Vacuum chamber, (2) Chiller, (3) Magnetic
bearings, (4) Flywheel, (5) PMSM's rotor, (6) PMSM's stator, (7) Vacuum
pump.
---{>
."
Among these set-ups, the (c) case is selected, as the
efficiency in transformation and transfer of energy depends
only on a single machine (in this case, the PMSM has the
highest efficiency), there is no need for manual speed
regulator for transferring energy from the main motor to the
FESS during braking, which would further reduce efficiency,
and finally the control of the energy flow in the FESS is
much easier and more effective. The advantage of the cases
(a) and (b) is that they can also serve as mechanical brake for
the motor by reducing energy needs during braking with a
large load.
B. Energy storage
A FESS stores energy as kinetic energy in a rotating mass.
Depending on the network needs of the grid, the machine of
the FESS can provide either kinetic energy to the rotating
mass and, thus, operate as a motor, or receive kinetic energy
from the mass and supply the network, reducing the power
requirements, operating as a generator.
The kinetic energy that can be stored in a rotating disc is
equal to [30][31]:
1
E
k
=_·J·OJI2 (9)
2
where J, O}[ the moment of inertia and the angular velocity of
the rotating mass respectively. In the case of low energy
levels, the rotating mass and the machine rotor can be
compact, so there is no need for a speed regulator. Hence, the
maximum rotating speed of the FESS should preferably be
equal to the nominal speed of the PMSM. The maximum
energy that can be stored in the rotating mass is:

1 1
E max
k . =_·J·OJj2 .max =_·J·OJn2 (10)
<J--
2 2
Where O}n the nominal angular speed of the PMSM. A hollow
(a)
cylinder is used as the rotating mass, with moment of inertia
equal to:
G) G)
:::::!. -,
0.. c.: (11)

where p is the mass density, Hthe height of the cylinder and

(b) Ro, Ri the output and the inner radius of the cylinder,
respectively. Thus, besides the rotational speed, the
maximum energy storage depends on the mass of the cylinder
1 2 2
M= "2 .n.p.H.(Ro-R/) (12)

Depending on the material that is used as a rotating mass,

the maximum energy storage depends also on the energy
density of the material, Esp, that is determined by the shape of
the rotating mass with shape factor Ks and is proportional to
the tensile strength (Jm:
(c )
(13)
Fig. 5 Regenerative Braking Topologies with Flywheel

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= / ' at OJr +F OJr

Higher tensile strength results in higher maximum rotating
speed of the Flywheel and, thus, larger maximum energy Te -TL
storage [32]. As this paper simulates a low speed FESS with a
- ·

maximum energy limited by the machine parameters, and

since the chosen material has high tensile strength, there is no
need for further investigation of the level of maximum speed.
(17)
The material used for the simulation of Flywheel is the S
glass, due to its high fracture toughness and low cost. The
material specifications are given by Table III, and the
simulation parameters for the rotating mass are shown in
Table IV.

TABLE III Where: TL the mechanical torque of the rotating mass, I the
S GLASS-CHARACTERISITCS FRP [33]
inertia of the rotor, F the viscus friction of the rotor and Bf
Tensile strength (MPa) 330
the friction factor imposed by the magnetic bearings.
Fracture toughness (MPa/mA( l/2» 50
Concerning the breaking control, the energy storage
Density (Kg/mA3) 2000 system is charged when the DC-bus voltage is higher than a
Price ($/ton) 4095 threshold, in order to protect the main machine of the
Table IV
elevator and discharged when the elevator system requires
FL ¥WHEEL SIMULATION PARAMETERS [34] energy. The upper charge limit is set by Eq. (10).
Height of Flywheel (cm) 9.53 Fig. 6 shows the FESS subsystem and Fig. 7 shows the
Outer radius of Flywheel (cm) 15 rotating mass subsystem in Matlab/Simulink. The machine
Inner radius of Flywheel (cm) 14 specifications are shown in Table V.
Moment of Inertia (Kg*mA2) 0.868
Maximum angular velocity (rad/s) 628
Energy storage (Wh) 47.545 In2 �-----,

Control of PMSM

C. PMSM simulation and Flywheel control

Wm f-------.
A block from the Matiab/SimulinkiSimPowerSystems
library was used as a PMSM machine for the FESS f--�� l n1
simulation. Nevertheless, the characteristic equations of the
PMSM that are required for the control of the FESS should
be noted. The electrical equations of the system are given Permanent Magnet
Synchronous Machine
below: Calculation ofTe Flywheel's Load

a ld. = 1 'Vd - R 'ld. + Lq ' P OJr 'l.q

Subsystem

III
at T T T d d d
· (14)
III
rIl+
a.q = 1 'Vq - R 'l.q - Ld ' p OJr 'ld. - A,' p OJr
a/ Tq Tq Tq ·

Lq
.

(15) 1,+--
1 -----I)
---<l �
Fig. 6 FESS subsystem in Matlab/Simulink.
where: id, iq the currents on d and q axis respectively, Ld, Lq
the inductances on d and q axis respectively, Vd, Vq the
TABLE V
voltages on d and q axis respectively, R the resistance of PMSM CHARACTERISTICS [32]
stator windings, p the number of pole pairs, O)r the rotor's Rated power (kW) 5.5
angular velocity and A the amplitude of the flux induced by Rated Voltage (V) 400
permanent magnets of the rotor in the stator phases. All the Nominal Speed (rpm) 6000
above quantities in the rotor reference frame are referred to Resistance (Ohm) 0.44
the stator. The angular velocity of the Flywheel can be
Inductance (mH) 2.88
calculated by the equations of electromagnetic torque Te [27]:
Flux (Wb) 0.2465
� =1.5.p{ A, iq + ( Ld -Lq).id .iq]
· (16)

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Flywheel consume less energy. This fact can be clearly

l-------.--j� Wf
observed in Fig. 8.
w 650

Calculation of free
600
�
Energy Storage
CD
Ol
1!!
"0
>
U> 550
:>
CD
U
0
Moment of Regenerative
Intertia Brake Control 500

0 10 20 30

Time(s)

(a)
2 650

Te
Calculation of
Angular Velocity

Fig. 7 Rotational mass subsystem and calculation of FESS angular 600

velocity. �

V. RESULTS

The simulation results are presented below. It is noted that

the elevator moves upwards without passengers, with a
500
reference velocity as shown in Fig. 2. In this case,
regenerative breaking operates on the highest efficiency. Fig.
'0 20 30
8 shows the total energy consumption of the elevator system.
Time(s)
A reduction of the system energy requirements by almost
38% was achieved by using Flywheel, while supercapacitor (b)
results in approximately 32% reduction. Both systems protect
the elevator machine effectively, as shown by the DC-bus
600
voltage in Fig. 9.
- Flywheel 1
- Supercapacitor

�
'0L£ - Brake Chopper]
10�-o=�======��-------����

o.

21 U n JO

�' +-----�----r---------�----�----
o m 20
j30
Time(s)

10 20
Time(s)
Fig. 8 Elevator's total energy consumption.
As it is presented, the Flywheels brake system offers the
best behavior to DC-bus which results in a more pure
waveform. This conclusion doesn't mean that the other brake
systems, i.e. the brake chopper and the regenerative brake
with supercapacitors, don't operate efficiently too, but
(e)
Fig. 9 DC Bus voltage (a) with brake chopper, (b) with regenerative brake
30
with supercapacitors, (c) with regenerative brake with Flywheel
Fig. 10 shows the energy flow in the PMSM of the FESS
while the stator current is shown in Fig. 11, where it is
obvious that, for a short period of time, there is peak higher
than the rated current of the PMSM, i.e. from the value of
16A. This phenomenon occurs because during this period the
elevator's load is rapidly decelerating. This can be solved
with the use of a PMSM with higher nominal power or with a

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better control of the present machine, as the peak isn't that On the other hand, due to the high self-discharge that
high. characterizes FESS, these could only be used in lift systems
The simulation results presented in Figs. 12-14 include: the with high frequency of use, e.g. in an elevator of a company
velocity of the Flywheel, the torque and the energy stored in or public service.
the rotating mass. FESS, as a braking system, protect the elevator machine
very efficiently. Compared with the other two braking
systems they offer a relatively better performance in dealing
with the DC-bus voltage. Finally, an optimization of both the
control of the PMSM, and the rating of the PMSM and the
energy storage capacity could possibly provide even better
results in the energy requirements of the overall system
e;6
Q)
co
W

10 20 30

Time(s)
Fig. 10 Energy flow to FESS

Time(s}
Fig. 13 Angular velocity of FESS rotational mass

5: '0000
>.
10 20 30 E?'
Time (s)
Q)
<:
W
Fig. II Current of PMSM of FESS "000

VI. CONCLUSIONS

According to the above results, the FESS operates more

effectively as a regenerative braking in an elevator system Time(s)
since by its use we retrieve approximately 6% more energy Fig. 14 Kinetic energy on the storage system
compared to the use of regenerative braking by
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