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The flywheel hybrid primarily consists of a rotating flywheel, a continuously variable transmission
system (CVT), a step up gearing (along with a clutch) between the flywheel and the CVT and clutch which
connects this system to the primary shaft of the transmission. When the brakes are applied or the vehicle
decelerates, the clutch connecting the flywheel system to the driveline/ transmission is engaged, causing energy
to be transferred to the flywheel via the CVT. The flywheel stores this energy as rotational energy and can
rotate up to a maximum speed of 60000 rpm. When the vehicle stops, or the flywheel reaches its maximum
speed, the clutch disengages the flywheel unit from the transmission allowing the flywheel to rotate
independently. Whenever this stored energy is required, the clutch is engaged and the flywheel transmits this
energy back to the wheels, via the CVT. Generally the flywheel can deliver up to 60 kW of power or about 80
HP. Fig.1 shows Volvo’s flywheel KERS system Layout and Fig. 2 shows a schematic layout of general
flywheel hybrid.
Fig.1 Volvo’s flywheel KERS system Layout [3] Fig.2 Schematic Layout of the Hybrid [2]
The important parts of the flywheel hybrid will now be discussed in detail.
2.1. The flywheel
The flywheel is the component which harvests kinetic energy, when the vehicle brakes, by increasing its
rotational speed. The ability of flywheels to store energy is explained by the relation between the flywheel’s
inertia, angular velocity and kinetic energy.
The equation for the energy stored in a flywheel reads as follows:
ଵ
ܧൌ ߱ܫଶ (1) [2]
ଶ
Where E is the energy (Joules); I is the inertia of the flywheel (kgm2), and ω is the angular velocity (rad/sec) of
the flywheel.
The equation for the inertia of a flywheel is:
ଵ
ܫൌ ݉ሺݎଵଶ െ ݎଶଶ ሻ (2) [2]
ଶ
Where ݉ is the mass of the flywheel; ݎଵ and ݎଶ are the inner and outer radius of the flywheel respectively.
Combining equation 1 and 2 we get:
ଵ
Eൌ ݉ሺݎଵଶ െ ݎଶଶ ሻ߱ଶ (3)
ଶ
From equation 3, a flywheel's energy is proportional to its mass, and proportional to the square of its
rotational speed or angular velocity. In other words, by doubling the mass, the energy stored is also doubled, and
by doubling the speed, the energy stored is quadrupled. Thus by increasing the speed of the flywheel it will be
possible to reduce the mass and size of it, to a level where its weight is insignificant while analysing fuel
efficiency. In order to make the system more efficient it is necessary enclose the flywheel in a vacuum chamber,
and in order to eliminate the resistance due to air and reduce friction it is mounted on magnetic bearings.
The amount of energy that can safely be stored in the rotor depends on the point at which the rotor will warp or
shatter. The hoop stress on the rotor is given by:
ߪ௧ ൌ ߩ ݎଶ ߱ଶ (4) [6]
Where ߪ௧ is the tensile stress on the rim of the flywheel; ߩ is the density, r is the outer radius of the flywheel and
߱ is the angular velocity of the rotating flywheel.
The flywheel can be fabricated using different materials based on the maximum rotational speed
requirements and other design constraints. High speed flywheels for speeds above 30000 rpm are usually
composed of high strength carbon fibre. A large mass is not desired for high speed flywheels because extra mass
means more energy will be needed to accelerate the vehicle. On the other hand, low speed flywheels with speed
values below 20000 rpm, are generally made of steel or other metals for low cost. The weight of the flywheel is a
very important factor in determining the efficiency of the system.
2.2. The flywheel vacuum chamber
The vacuum chamber is another very essential part of the flywheel hybrid system. The major function of the
vacuum chamber is to minimize the air resistance as the flywheel rotates. Without the vacuum chamber, the
friction caused by air resistance is enough to cause significant energy losses and heat the carbon fibre rim to its
glass transition temperature [10]. Vacuum chambers for KERS systems are frequently made of metals like
aluminium, stainless steel, or the like because these metals can provide adequate strength to withstand
differential pressure between an evacuated interior and the surrounding atmosphere, as well as to provide a
barrier to the passage of atmospheric gases through the chamber wall by diffusion or flow through structural
defects. Fig.3 shows the flywheel hybrid system designed by flybrid.
Fig.5 CVT in a lower gear [9] Fig.6 CVT in a higher gear [9]
CVT
EPICYCLIC GEARS
5. Future Scope
The simplicity of energy transfer in this mechanical KERS system makes it superior to the electrical
KERS system. Mechanical hybrids are more powerful, more efficient, and cheaper than electrical hybrids. In the
future, automobiles will be much more fuel efficient than the cars of today. Flywheel kinetic energy recovery
system technology is definitely practical because many car companies are looking into using the system in
average everyday cars. Volvo in partnership with Flybrid, officially announced that they intend to develop and
produce a vehicle that uses the flywheel based kinetic energy recovery system. With improvement in technology,
KERS will definitely become even more efficient and affordable. The main driving force which will launch
flywheel-based kinetic energy recovery systems into the automotive industry is the low cost in comparison with
fully hybrid vehicles. Any vehicle could be designed and fitted with a flywheel-based kinetic energy recovery
system, but the area most affected by this technology would be any vehicle with a start-stop cycle of driving.
This technology has already been tested in FLYBUS (a flywheel hybrid system developed for buses).
The Flywheel KERS is a technology of great importance and potential. With more advancements and
refinements, this system would increase the efficiency of hybrid vehicles. It can reduce fuel consumption and at
the same time increase power. Its lower CO2 emissions reduce air pollution. Probably the biggest advantage of
this system is its ability to be retrofitted. The flywheel KERS does not come without flaws, however,
developments still need to be made in reducing the forces that act upon the flywheel. With these forces
minimized, the system would have much higher efficiency and would be able to store energy longer. It would
rival hybrid electric vehicles in efficiency and range.
References:
[1] Bjorn Bolund et. Al. “Flywheel energy and power storage systems” (online)
<http://www.inference.phy.cam.ac.uk/sustainable/refs/storage/Flywheel.pdf>
[2] Brockbank, C., & Cross, D. (2008) (online) “Mechanical Hybrid system comprising a flywheel and CVT for Motorsport & mainstream
Automotive applications.” <http://www.torotrak.com/pdfs/tech_papers/2009/sae_wc_2009_09pfl-0922_kers.pdf>
[3] ”Flywheel hybrid systems (KERS)” (online) <http://www.racecar-engineering.com/articles/f1/flywheel-hybrid-systems-kers/>
[4] Hilton, J., Cross, D. “Flybrid systems: Breakthrough technology for greener driving.” The Royal Academy of Engineering. [Online].
Available: <http://innovationnow.raeng.org.uk/innovations/default.aspx?item=6>
[5] Home - Flybrid Systems, Web. 25 Jan. 2012 (online) <http://www.flybridsystems.com/index.html>.
[6] Micheal Mathew, “Design of flywheel for improved energy storage”, (online)
<http://ethesis.nitrkl.ac.in/1125/1/Design_of_flywheel_for_improved_energy_storage_using_computer_aided_analysis.pdf/>
[7] Lucas, Paul. "Volvo to Develop Kinetic Energy Recovery System." Green Cars: Cars with CO2 Emissions under 150g/km plus News,
Information, Articles and Press Releases. 27 May 2011. Web. 29 Feb. 2012.
[8] “Magnetic Bearing Systems” (online) <http://www.waukbearing.com/en/magnetic-bearing-systems/>
[9] “Toroidal CVT (Nissan Extroid)” (online) <http://www.carbibles.com/transmission_bible_pg3.html/>
[10] “Vacuum chambers for flywheels”, John Micheal Pinneo, Jonathan Forrest Garber <http://www.faqs.org/patents/app/201200>
[11] Volvo Cars’ tests of flywheel technology confirm fuel savings of up to 25% <http://www.greencarcongress.com/2013/04/kers-
20130425.html>