27

ADVANCED ENGINEERING
3(2009)1, ISSN 1846-5900
KINETIC ENERGY RECOVERY SYSTEM
BY MEANS OF FLYWHEEL ENERGY STORAGE

Cibulka, J.

Abstract: This paper deals with the design of Kinetic Energy Recovery Systems (KERS) by
means of Flywheel Energy Storages (FES). KERS by means of FES are currently under
development both for motor sport and road hybrid vehicles. The aim of the work is the
optimalization and implementation to the hybrid and electric road vehicles. Testing equipment
for the experimental analysis of the simplified FES was designed.

Keywords: Kinetic Energy Recovery System, Flywheel Energy Storage, Kinetic
Storage, Flywheel, Reluctance Motor, Electric Generator / Motor, Regenerative /
Recuperative Braking.

1 INTRODUCTION

1.1 Introduction to Regenerative Braking
A regenerative brake is a mechanism that reduces vehicle speed by converting some of
its kinetic energy into another useful form of energy - electric current, compressed air.
This captured energy is then stored for future use or fed back into a power system
for use by other vehicles. For example, electrical regenerative brakes in electric railway
vehicles feed the generated electricity back into the supply system.
In battery electric and hybrid electric vehicles, the energy is stored in a battery or
bank of twin layer capacitors for later use. Other forms of energy storage which may be
used include compressed air and flywheels.
Regenerative braking utilizes the fact that an electric motor can also act as a
generator.
The vehicle's electric traction motor is operated as a generator during braking and
its output is supplied to an electrical load [Fig. 1.].
It is the transfer of energy to the load which provides the braking effect.


Fig. 1. Regenerative braking kinetic energy stored in a battery

Regenerative braking should not be confused with dynamic braking, which
dissipates the electrical energy as heat and thus is less energy efficient.
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Fig. 2. Mechanism conceptual diagram Fig. 3. System control battery storage

Conceptual diagram of mechanism shows comparison characteristic curve between
hydraulic and regenerative braking, while driver intentionally brakes [Fig. 2.].
Regenerative braking reuse kinetic energy by using its electric motor to regenerate
electricity.
Normally, electric motors are turned by passing an electric current through it.
However, if some outside force is used to turn the electric motors, it functions as a
generator and produces electricity. This makes it possible to employ the rotational
force of the driving axle to turn the electric motors, thus regenerating electric energy
for storage (in the battery) and simultaneously slowing the car with the regenerative
resistance of the electric motors.
The system control coordinates regenerative braking and the braking operation of
the conventional hydraulic brakes [Fig. 3.], so that kinetic energy, which is normally
discarded as friction heat when braking, can be collected for later reuse in normal
driving mode.
Typically, driving in city traffic entails a cycle of acceleration followed by
deceleration. The energy recovery ratio under these driving conditions can therefore be
quite high. To take advantage of this situation, the system proactively uses regenerative
braking when running the car in the low speed range.
The regenerative braking effect rapidly reduces at lower speeds; therefore the
friction brake is still required in order to bring the vehicle to a complete halt. The
friction brake is a necessary back-up in the event of failure of the regenerative brake.
Most road vehicles with regenerative braking only have power on some wheels (as
in a 2WD car) and regenerative braking power only applies to such wheels, so in order
to provide controlled braking under difficult conditions (such as in wet roads) friction
based braking is necessary on the other wheels.

1.2 Introduction to Flywheel Energy Storage
Kinetic storages, also known as Flywheel Energy Storages (FES), are used in many
technical fields.
While using this technical approach, inertial mass is accelerating to a very high
rotational speed and maintaining the energy in the system as rotational energy. The
energy is converted back by slowing down the flywheel. Available performance comes
from moment of inertia effect and operating rotational speed.
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Flywheel mass is either mechanically driven by CVT (Continuously Variable
Transmission) gear unit [Fig. 4.] or electrically driven via electric motor / generator
unit [Fig. 5.].


Fig. 4. Mechanically driven composite flywheel Fig. 5. Electrically driven flywheels

Devices that directly use mechanical energy are being developed, but most FES
systems use electricity to accelerate and decelerate the flywheel.
In comparison with other conventional ways of storing electricity (batteries and
capacitors), electric FES systems combined with innovative concept offer essential
advantages. Especially considering full-cycle lifetime, operating temperature range and
steady voltage and power level, which is independent of load, temperature and state of
charge. Thus FES provides minimally much higher power output and energy
efficiency.

2 SYSTEM COMPONENTS

[Fig. 6.] refers to KERS components, respectively: Electric Propulsion Motor /
Generator, Power Electronics Inverter, and the Quad Flywheel Storage.


Fig. 6. KERS components Fig. 7. Motor / Generator

2.1 Electric Propulsion Motor/Generator
Electric Propulsion Motor and Generator in one, also known as a MGU - Motor
Generator Unit [Fig. 7.].
2.2 System Control
System communication is provided via CAN interface (ControllerArea Network).

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Fig. 8. Overview of KERS System control

2.2.1 Power Electronics
[Fig. 9.] refers to integrated power electronics liquid cooled Inverter.


Fig. 9. Liquid cooled Inverter

An inverter is an electrical or electro-mechanical device that reversely converts
direct current DC - from flywheel, to alternating current AC - to MGU. The resulting
AC can be at any required voltage and frequency with the use of appropriate
transformers, switching, and control circuits.

2.2.2 Control Electronics
[Fig. 10.] refers to flywheel storage subunits equipped with bonding pad for control
electronics.


Fig. 10. Control electronics ECU Fig.11. Microprocessor of Control unit

Design of bonding pad provides direct connection of control unit, which works
similar to ECU - Engine Control Unit.
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2.3 Flywheel Energy Storage


Fig. 12. Quad FES consists of 4 subunits

[Fig. 13.] refers to one of 4 subunits of Quad FES, which consists of water-cooled
housing and heat sink with contact surface for control electronics. Further we could see
an electrical configuration for direct connection of control unit.


Fig. 13. FES Subunit overview Fig. 14. Cross-section - coolant duct

2.3.1 Flywheel Rotor - Reluctance Motor
Rotor flywheel mass works as reluctance motor in contrast to common mechanical
flywheel. [Fig. 15.] refers to cross-section through storage subunit as reluctance motor.


Fig. 15. FES - Reluctance motor Fig.16. Hybrid-Bearing

Flywheel energy storage subunit consists of stator, incl. stator windings and
channel for coolant backflow. Further we could see flywheel rotor equipped with
Hybrid-Bearing [Fig. 16.].
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Hybrid-Bearing is combination of hydrodynamic and ball bearing, works in
dependence on RPM. Ball bearing acts during starting acceleration from low speed.
Hydrodynamic bearing starts working contactless at high revolutions.

2.3.2 Safety Concept
Safety concept concerning Control System is following:
Control unit limits rotational speed by a hardware lock in the output stage. Control
system monitors all security parameters. During idle operation is no voltage induced.
In case of error messages or breakdown, control system discharge KERS.
Controlled and safe discharge of the system is possible by converting rotational energy
in thermal energy. In the flywheel storage system, the critical energy is reduced by
using several small storages, coolant ducts and channels in stator [Fig. 14.], [Fig. 15.].
FES is designed as a reluctance motor and its resulting safety benefits are
following:
Inner flywheel rotor is designed as homogenous flywheel mass without any addi-
tional coil former, windings, magnets or rotor cage. Laminated rotor consists of sheet-
metal packet, incl. disc spring and rotor shaft equipped with hybrid bearing [Fig. 17.].

Fig. 17. Flywheel rotor of storage subunit

In case of breakdown, homogeneous flywheel rotor made only from sheet-metal
stock has no massive fragmental parts. The stator is also used as a crumple zone and
works as a safety bandage.
Laminated rotor consists of sheet-metal packet has very high bursting strength.
Highest stress of rotor sheets is approximately 70% of Proof stress R
p
0.2. (Offset Yield
Strength).

3 BASIC PRINCIPLES

3.1 Stored Energy
Basic principle of kinetic energy storage is made by rotational energy. While using this
technical approach, inertial mass is accelerating to a very high rotational speed and
maintaining the energy in the system as rotational energy.
Stored energy is proportional to inertia of rotor and is a quadratic function of
revolution speed:

2 2
2 R I E
S
= (1)
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3.2 Regenerative braking - charge mode
Car is decelerating during recuperative charge mode.



Electric motor works as generator and sending energy to flywheel storage.



Flywheel rotor is accelerated in recuperative charge mode.


Fig.18. KERS braking simulation - Recuperative charge braking mode

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3.3 Boost acceleration - discharge mode

Car is accelerating during boost discharge mode.


The Flywheel rotor is decelerated during boost discharge mode and the energy is
converted back.


Flywheel acts as a generator and sending energy back to electric motor, which
works as propulsion motor.


Fig.19. KERS boost simulation - Discharge generator boost mode

4 EXPERIMENT - FES MEASUREMENT

Testing equipment for the experimental analysis of the simplified FES was designed in
order to prove the basic principles of discharge generator mode.
Stored energy is proportional to inertia of rotor and is a quadratic function of
revolution speed (
2 2
2 R I E
S
= ).
During boost discharge mode the flywheel rotor acts as a generator and is
decelerated.
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Experimental facility consists of: Power Supply, Power Electronics, Electric
Motor, Flywheel, Amperemeter, Voltmeter and Shunt [Fig. 26.].

Fig. 20. Experimental facility


Fig. 21. Electromotor with elastic coupling

Fig. 22. Theoretical solution Discharging characteristics of unloaded FES
Stored energy E
ak
vs. RPM
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Fig. 23. FES on load Propeller


Fig. 24. Experiment Discharging characteristics of FES on load - Generated voltage

5 CONCLUSION

5.1 Comparison with other storage technologies
In comparison with other battery storage technologies, KERS offers:
Cycle durability [Fig. 25.] - 90% efficiency of flywheel (including power elec-
tronics) in both directions during KERS reference duty cycle.
Extensive operating temperature range [Fig. 26.].
Steady voltage and power level [Fig. 27.], which is independent of load, tem-
perature and state of charge.
High efficiency at whole working speed range.
No chemistry included, thus no environmental pollution and great recycling
capability.
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Fig. 25. Comparative chart in terms of cycle loading

Fig. 26. Comparative chart - Operating temperature range (at appr. 80% Performance)

Fig. 27. Comparative chart in terms of Voltage stability (full cycle)
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5.2 Vision for race and stock cars
In motor sports applications this extra boost energy is used to improve acceleration.


Fig. 28. Race vehicle from Le Mans - Chrysler Patriot equipped with FES

KERS by means of FES are currently under development both for F1 motor sport
and road hybrid vehicles.
F1 Teams have said they must respond in a responsible way to the world's
environmental challenges. The FIA allowed the use of 60 kW KERS in the regulations
for the 2009 Formula One season. Energy can either be stored as mechanical energy, as
in a flywheel [Fig. 29.], or can be stored as electrical energy, as in a battery or
supercapacitor).


Fig. 29. Williams Hybrid Power F1 KERS Fig. 30. Kinetic storage for hybrid car

Same technology can be applied to road hybrid cars to improve fuel efficiency,
especially in city traffic. [Fig. 30.].
Road vehicles with electric or hybrid drive utilizing regenerative braking.
Vision for stock car is in convenient hybrid system with high energetic efficiency
and dynamics.
Flywheel storage technology provides boost acceleration and braking force.
FES supports starting and guarantees light, silent and emissionfree starts of
combustion engine. KERS also supplies all electric appliances, stabilizes on-board
power supply and offers stable air-condition.
Kinetic recuperation based on braking energy stored in flywheel is without cycle
loading, unlike braking energy repeatedly stored in battery.