DESIGN AND IMPLEMENTATION OF A FLYWHEEL

ENERGY STORAGE SYSTEM

GUIDED BY: Dr. BHARAT SINGH RAJPUROHIT

PRESENTED BY: ABHINAV SINGH KASHYAP

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 FLYWHEEL ENERGY THEY ARE ALSO CONSIDERED FOR POWER REQUIREMENTS OF A
STORAGE SYSTEMS HAVE SPACE APPLICATIONS INSTEAD OF SMALL COMMERCIAL
BECOME AN IMPORTANT HAZARDOUS AND BULKY SATELLITE HAVE BEEN USED
AS THE STARTING POINT OF
RESEARCH SUBJECT IN ELECTROCHEMICAL BATTERIES.
THE DESIGN
RECENT YEARS.

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 The design requirements needed to be studied

The power requirement of the S-band transmitter of the

BiL-Sat satellite is used as the starting point of the
design[3]

OVERVIEW
The duty of the storage device is to provide the required
energy to satellite subsystems during the dark period in
orbit

The Transmitter consumes 23 W during data transfer

since the dark period is approximately 30 min for low
earth orbit satellites, the energy consumption for this
device is calculated to be 11.5 Wh 3
 • Parametric equation to be used in the design are derived
from the Energy balance equation
First step

• Parameters that affects the energy balance of the system are

determined
Second step

• System sizing and component selection is carried out using

these parameters
Third step

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•   Energy balance of the system

 The value of the kinetic energy stored in the wheel of the motor/generator unit
while it is rotating at the maximum speed. This value is given in Eq. (1)

= …………… eq1

 Flywheel speed can be varied between minimum speed and maximum speed

 The difference between the energy amounts at these two speeds is the energy that
can be usable by the system, Eq (2) is valid for a lossless system

= …………….eq2

Where,

= maximum speed of the flywheel

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= minimum speed of the flywheel

• The
  effective energy amount can also be found by incorporating the
round-trip efficiency ( n) in the equations

==

 The system round-trip efficiency between any two time instants can
be rewritten as follows by using the fact that energy is the time-
integral of power, and power is equal to torque times the speed.
therefore,
n= = …………. Eq3

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•   Machine losses in the system

 Mechanical friction losses[4]

 Windage losses[4]
 Electrical losses[4]

= = …….EQ.4
=+

Net energy consumed for electrical load

and electrical losses.
  mechanical
friction losses
where,
B = Viscous friction coefficient (Nm)
= mechanical Friction power loss
= windage power loss 7
 Mechanical friction losses
•= 2]+
  2

Friction losses due to the viscosity

mechanical friction losses
of the liquid used in the bearings

In the system the forces on the bearing are the force due to the wheel weight ( FG) and
forces
. due to unbalances( FB) [5]

Thus, the total force is given by  𝑭 = 𝑭 𝑮 + 𝑭 𝑩

 Unbalance force is defined as =

 Therefore the total force become= = mg+

*where ‘me’ is multiplication of residual mass and its distance from shaft (specified in 8
bearing parameters)
 Windage losses


• For
  the disk-shaped flywheels windage losses are defined as follows[1]:

*where is the torque coefficient

 For a flywheel radius Re, the torque coefficient is found to be [1]:

= 0.121

Therefore combing all the factors equation (4) can be written by as:

+
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•  Speed variation is assumed to be linear in the design therefore the variation of angular
speed can be defined with , the energy balance equation can be rewritten as[4]

= + 2*

integrating the above equation between time instant to we get the form[4] :

= )+ 2* (mg)
+
+0.542*0.121 …….. eq 5

*Where 0.542 is a error compensation factor incorporated in the equation

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 PARAMETER VALUES
(load-dependent friction
0.00028
coefficient)
(15 + 32) / 2 = 23.5 mm
(Average diameter of Bearing
(mm)
(15 + 32) / 2 = 23.5 mm
m*e 5 g mm
M
m*e 52gkgmm
5000 rpm
M
(assumed) 2 kg
1.93e-5
(Dynamic viscosity of air (kg/m
s) 5000 rpm
0.0056
(Air density (kg/m3)
1.93e-5

0.0056

*Bearing parameters belong to the low-friction FAG bearings at 5mbar pressure and at 40 °C [2] 11
 The only unknown in Eq. (5) is the maximum speed(). By solving the equation its
•  
value is found to be 4243 rad/s (∼40,500 rpm)

 Depth of discharge (DD) can be obtained from this speed value now
𝑤1
 
1−
DD = 𝑤2

 By placing the maximum and minimum speed values in Eq (2) the

energy difference is found as 19.7 Wh , of which only 11.5 Wh is
converted to electrical energy.

As a result, the round-trip efficiency under these conditions is

 𝐸 0
𝐸 diff
n=
=  58.4%
=
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 Mechanical friction and winding losses can be found from above EQ.2
•  
therefore,
 the maximum instantaneous value of torque that should be generated during motor operation can be
found from Equation below

= ……………………………..EQ.6
ⅆ𝝎
𝑰 
Where, = ⅆ𝒕

= 0.121

*Using w= i.e = 40,500 rpm

Solving the equations we get the following results

 = 8.26 mNm
 = 1.31 mNm ( max)
 = 17.53mNm ( max)

Therefore = 27.10mNm
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•   Results

 If the torque component corresponding to windage losses is subtracted in Eq.(6), the maximum
torque that the machine needs to generate = is found as 9.34 mNm.

 This shows that the highest component is the windage torque, and if it does not exist, efficiency
increases and a smaller motor would be sufficient for the application

 If the design is carried out for vacuum , the windage losses as zero and the maximum speed is found to
be 3450 rad/s (32,900 rpm). This yields a difference in energy of 12.92 Wh, of which 11.5 Wh is
converted to electrical energy, and a round-trip efficiency of 89% is achieved.

  n=

= 89%

 To achieve further high energy efficiencies in these systems magnetic suspension of rotor using
magnetic bearings which will decrease friction component thereby enhancing the efficiency beyond
90% 14
 flywheel design

o The inertia of the flywheel has been taken as 0.008 kgm2 .

o The weight of the system now depends on this value as well as the
material selection and mechanical design.
o Aluminium material will be used as the material to build the
flywheel.

A disk-shaped flywheel of 20 cm in diameter and 2 kg

in weight is to be used in project with shaping factor
of k= 0.8

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 Switch
control
3- phase
supply Driver
f
l
Motor/ y
Generator w
h
e
3- phase e
Power Magnetic
load l
conditioner bearing

Vacuum
chamber

Functional block diagram of the experimental setup

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 Flywheel dissipating energy

Flywheel storing energy

Energy vs time
*A
*A rough
rough estimation
estimation plot
plot
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 Speed falling linearly during
Speed rising linearly during Generating operation
motoring operation

  positive
  negative

  Energy/ / speed vs time 18

*A rough estimation plot
 REFERENCE

[1] Pyrhonen J, Jokinen T, Hrabovcova V. Design of Rotating Electrical Machines.

West Sussex, UK: John Wiley &Sons, 2008.

[2] FAG. Super Precision Bearings. Schweinfurt, Germany: Schaeffler Group

Industrial, 2010

[3] Kenny BH, Kascak PE, Jansen R, Dever TP, Santiago, W. Control of a high-speed
flywheel system for energy storage in space applications. IEEE T Ind Appl 2005; 41:
1029-1038

[4] Zhang C, Tseng KJ, Nguyen TD, Zhang S. Design and loss analysis of a high
speed
flywheel energy storage system based on axial- flywheel-rotor electric machines.
In: 9th International Power and Energy Conference; 2010; Singapore. pp. 886-891
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THANK YOU

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