Flywheel energy storage system

Group 8 : Presentation
Introduction Internal Combustion Engine

A flywheel is a simple form of mechanical storing device by

converting kinetic energy to electrical energy

Cross compound steam engine

• The working principle of the flywheel

is based on Law of Inertia

• The flywheel is used to harmonize

irregular rotational power and ensure
smooth running

2
DEFINITION OF PROBLEM
Problem statement Requirements
1 • Flywheel energy storage system is used to 2 • It must be able to power light for
solve energy problems at a lower cost households

• Has a high life-cycle compared to the • The input speed of the Generator
chemical batteries should accommodate the speed of
the flywheel
• High efficiency for electrical systems
• Rotor should produce a minimum
of 264KJ
Constraints
Criteria
3 • The design is bound by the motor- 4 • User friendly
generator maximum speed limit
• Store energy
• Purchase of the flywheel
• Discharge energy
• The design has a limited budget

3
DESIGN DEVELOPMENT
Flywheel concepts Concept 1 Concept 2 Concept 3 CONCEPT 4
 

SPECIFICATIONS

EASE TO MANUFACTURE 1 2 2 4

SAFETY 3 4 2 3
COST OF THE PRODUCTION 1 3 3 4

USER FRIENDLY 2 4 3 4
POWER 2 2 3 4
WEIGHT 3 3 2 4
LOSSES 3 1 2 2
ENERGY STORAGE 2 3 2 4

SPEED 3 2 3 4

Discharge 1 3 2 4
TOTAL 24 27 24 37
FINAL CONCEPT
Flywheel working principle

Stage 1: Powering
• External power source required (220/230 V)

• Motor is powered through the source

• Motion is transmitted through a V-belt to rotor

Stage 2: Charging

• Rotor/flywheel rotates due to transmitted motion

by motor

• Energy is stored in the form of kinetic energy

• Transferred for discharge through the V-belt

connection
Flywheel working principle
Stage 3: Discharge

• Kinetic energy is converted to electrical energy

• Energy circulates through the system

• It is connected and used as a power source to other

appliances and the system itself
Calculations

Assumptions:

• Specifications of a motor are known to be (P = 0.37KW, N = 2900rpm)

• Diameter of the pulleys are known as: Da = 46.05mm, Db =51.2mm

• Shaft material: steel, and allowable shear stress of 84MPa

• Pulley belt does not slip

• The dimensions or specifications are bound to change depending on the

development made during the design or manufacturing
Calculations
Frame analysis
Calculations
 

• The ideal amount of energy we wanted to achieve is 264 kJ

• From the above equation the necessary rotational speed of both the shaft and flywheel
to produce that amount of is:

• Based on the required speed above an analysis for size, material and shape thus the
found stresses on the system, deflections on the system and specifications for the
main part are as follow:
• Natural frequency of 117,73 Hz, a maximum deflection of 0.018mm, , Vmax = 245,1 N

• Max Bending stress = , Max shear stress =

• Flywheel shaft length of 530 mm, Flywheel mass, radius and thickness of 50kg, 200
mm and 51,2 mm respectively , motor speed of rpm, pulleys are Da = 46.05mm, Db
=51.2mm in diameter, Generator of rated speed of 2800 rpm and power output of 500
W, Frame dimensions 600mm bredth by 1m length
Working Drawings with dimensions
Safety considerations

Motor Shaft
• Motor

• operating in high speed and has low electric losses,
high power density, high efficiency, and low rotor
losses.
• Check current flow, voltage and resistance (using
digital multimeter)
• ensure that maximum deflection due to bending,
and maximum twist due to torsion of the shaft is
within the allowable limits.

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Safety considerations cont…

Pillow block Bearing Generator

• Check for strength & rigidity • Check external strap from the generator
• Heat dissipation • Check plus connection to the electrical
• Alignments • Check the tightness of the v-belt and pulley
• lubrication • Operating temperature

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Required Safety tests
 Pulley misalignment test
 Motor test (dynamic testing & static testing)
 Bending moments test
 Fatigue test (rotordynamic modeling using mesh)
 Stress analysis test
 Generator testing (High voltage test, partial discharge test and pulse
test)
Maintenance and repair
Motor Maintenance
• Check if it has been making odd noise.
• Check if no harm has been done due to its vibrations by vibration inspection.
• Look into the commuter and brushes to see if they are in working order.
• Do a winding test.

Belt drive maintenance

• Check belt guard, bust build up, cracks/worn
• Check wear on pulleys, pulley misalignment and angular

Generator
• Thermal test
• Pulse testing
• voltage test (under load)

Bearing maintenance
• Check if the bearings are lubricated.
Impact of design

Safety and Environmental

• environmentally friendly
• Indirect environmental impact (renewable energy)

Economical
• High cost
• Unclear application value
• Unhealty market mechanism

Health

zero affection
• The only health impact (is in case of an accident)
The main initial triggers for Rotor failures
Triggers Initial Failure mode

1.Rotor cracks, because of the Rotor fragments break out and fly off in
circumferential stresses. radial and tangential direction

2. Rotor shaft or hub breaks, because of Entire rotor flies – off in a radial direction
torsional or other stresses' blocked
breaking bearing or radial vibration.

3.On composite flywheels overheating Rotor fragments break out and fly off in
can create rotor cracking or softening . radial and tangential direction
 Specific failure modes for composite rotor

Failure mode Description of consequences

1.Rotor disintegration 1.Rotor disintegrates into multiple small

particles creating an abrasive and high
hydro dynamic pressure.

2. Rotor burst in presence of oxygen 1.Explosion risk caused by high

temperature cracking of the composite resin
and creating radicals which react
exothermically with oxygen
SWOT ANALYSES
Strengths Threats

• Produces minimum required power • Not 100% safe

• Operates for longer periods • Not to be operated by kids
• Low maintenance cost • Shock hazards

• Operated at enclosed space

• Needs an external power • Suitable for domestic use
source
• Affordable
• Energy dissipates over time
• Environmentally friendly

Weaknesses Opportunities

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Cost analysis
Part Specification Material Length Unit Unit Price Total Price Shop Contact details

Vevor 1/3HP DC Speed 1750rpm Aluminum   1 R3000 R3000 Want-it All (wantitall.co.za) 087 231 0202
Motor
Glass Filled Pc 6mm-width x Glass Filled PC Out Dia. 2 R181.69 R363.38 RS online 086 000 7772
Timing Belt Pulley 2.032mm Pitch, 8mm 46.05mm (za.rs-online.co.za)
Día Bore

Glass Filled Pc 6mm-width x Glass Filled PC Out Dia. 2 R172.16 R344.32 RS online 086 000 7772
Timing Belt Pulley 2.032mm Pitch, 8mm 51.23mm (za.rs-online.co.za)
Dia. Bore

Timing belt 6mm width Rubber 304.8mm 2 R77.51 R155.02 RS online 086 000 7772
(za.rs-online.co.za)

Pillow Block Bore Dia. 15.87mm Cast iron - 2 R274.34 R548.68 RS online 086 000 7772
Bearing (za.rs-online.co.za)

Stainless steel Rod 1m x 18mm Dia. 303S31 Stainless 1m 1 R2399.26 R2399.26 RS online 086 000 7772
steel (za.rs-online.co.za)

Angle Iron 25mm x 25mm x Mild steel 6m 2 R84 R168.00 Leroy Merlin 010 4983 8000
2mm x 6m (leroymerlin.co.za)

Brushless Engine 500W 36/48/60V - - 1 R2031.58 R2031.58 Bang-Good  

motor (banggood.com)

Bright Zinc Plated M14 x 50mm steel 50 mm 1 R 886.70 1 Bag R886.70 RS online 086 000 7772
Steel Hex Bolt (za.rs-online.co.za)

4 Hexagon Nut M14 steel - 1 R19.90 R19.90 Leroy Merlin 010 4983 8000
(leroymerlin.co.za)
Total Cost R9916.84    
GANT CHART
17-Feb 7-Apr 27-May 16-Jul 4-Sep 24-Oct 13-Dec

GROUPING

TOPIC SELECTION

MEETING

BRAIN STORM

PROPOSAL PRESNTATION

CONCEPTS

CONCEPTS ANALYSES

PROPOSAL REPORT

CONSULTING

FREE HAND DRAWINGS

DRAWING ADJUSTMENTS

CONSULTING

3D-DRAWINGS

PROGRESS PRESENTATION

PROGRESS REPORT

MATERIAL SELECTION

QUATATION

MEETING

FINAL PRESENTATION

MEETING

FINAL REPORT
Thank you