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An Integrated Flywheel Energy Storage System with a Homopolar Inductor Motor/Generator and High-Frequency Drive

An Integrated Flywheel Energy Storage System with a Homopolar Inductor Motor/Generator and High-Frequency Drive

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Published by iMiklae
This thesis presents the design, construction, and test of a high-speed integrated flywheel energy storage system. This flywheel system integrates a homopolar inductor motor/alternator and a steel energy storage rotor to achieve high power density energy storage using low-cost materials. A sixstep inverter drive strategy that minimizes inverter VA-rating and enables high frequency operation is also implemented. Lumped parameter design equations are developed, and used to optimize the flywheel system. Analytical expressions for rotor and stator losses from harmonics in the six-step drive are also developed. A prototype flywheel energy storage was built. A novel method for constructing the slotless stator was developed and implemented. The prototype flywheel was designed for 30kW of power, 140W · hr of energy storage, and an operating speed range of 50, 000rpm - 100, 000rpm. Experiments were conducted for speeds up to 60, 000rpmand power levels up to 10kW. System efficiencies of 83%, which includes losses in the power electronics and the motor, were achieved. Most experimental results were in line with designed values. Experimental measurements of the harmonic losses showed very good agreement with the analytical calculations, and demonstrated that low rotor losses had been achieved.
This thesis presents the design, construction, and test of a high-speed integrated flywheel energy storage system. This flywheel system integrates a homopolar inductor motor/alternator and a steel energy storage rotor to achieve high power density energy storage using low-cost materials. A sixstep inverter drive strategy that minimizes inverter VA-rating and enables high frequency operation is also implemented. Lumped parameter design equations are developed, and used to optimize the flywheel system. Analytical expressions for rotor and stator losses from harmonics in the six-step drive are also developed. A prototype flywheel energy storage was built. A novel method for constructing the slotless stator was developed and implemented. The prototype flywheel was designed for 30kW of power, 140W · hr of energy storage, and an operating speed range of 50, 000rpm - 100, 000rpm. Experiments were conducted for speeds up to 60, 000rpmand power levels up to 10kW. System efficiencies of 83%, which includes losses in the power electronics and the motor, were achieved. Most experimental results were in line with designed values. Experimental measurements of the harmonic losses showed very good agreement with the analytical calculations, and demonstrated that low rotor losses had been achieved.

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Categories:Types, Research
Published by: iMiklae on May 08, 2013
Copyright:Attribution Non-commercial

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10/05/2013

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Most of the mechanical drawings made for the flywheel system have been included in

this appendix. The computer file for each drawing is indicated on the drawing and included on

the CD-ROM described in Appendix B. The drawings were made in Autosketch 6.0, which is

available from the Autodesk company.

Please note that the drawing scales indicated are not accurate because the drawings have

been scaled to 75% of the original size to fit the format of the thesis. The dimensions indicated

are still accurate.

117

Figure A.1: Cutaway view of assembled flywheel system.

118

Figure A.2: Drawing of endcap.

119

Figure A.3: Drawing of endplate #1.

120

Figure A.4: Drawing of modifications made to endplate #1. These modifications were made to
allow the mounting of a retainer for the tolerance ring.

121

Figure A.5: Drawing of endplate #2.

122

Figure A.6: Drawing of modifications made to endplate #2. These modifications were made to
allow the mounting of a retainer for the tolerance ring.

123

Figure A.7: Drawing of housing ring.

124

Figure A.8: Top view of main housing.

125

Figure A.9: Section view of main housing at AA’ (as labeled in Fig. A.8).

126

Figure A.10: Section view of main housing at BB’ (as labeled in Fig. A.8).

127

Figure A.11: Pattern for stator laminations.

128

Figure A.12: Drawing of winding bobbin.

129

Figure A.13: Bottom view of winding ring.

130

Figure A.14: Side view of winding ring. Note that this part was later modified, and the radially
oriented holes were removed when the vertical portion of the inner lip was cut off.

131

Figure A.15: Top view of winding ring. Note that this part was later modified, and the ring of 72
holes was removed when the vertical portion of the inner lip was cut off.

132

Figure A.16: View of endcap with thermocouple mount.

133

Figure A.17: Drawings of sinusoidal rotor.

134

Figure A.18: Side view of sinusoidal rotor.

135

Figure A.19: View of sinusoidal rotor profile.

136

Figure A.20: Drawings of square-cut rotor.

137

Figure A.21: Side-view of square-cut rotor.

138

Figure A.22: Detail of bearing mount system. The tolerance ring retainer was added later and is
not shown.

139

Figure A.23: Drawing of bearing washer.

140

Figure A.24: Drawing of tolerance ring retainer.

141

Figure A.25: Side view of assembled flywheel mounted on its baseplate.

142

Wires

Top view

(middle and top plate removed)

Top plate

Middle Plate

Bottom Plate

Threaded rods

24" long, 1"-8 thread

Pipe

Side cutaway view

Wire Access

Motor Containment Pit

Side Plate

Figure A.26: Assembled view of flywheel system in the containment system.

143

Appendix B

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