Composite flywheel for energy storage, phase 3
The prupose of the project was twofold: to verify a novel rotordesign as studied in previous projects and to manufacture and test a 1 kWh prototype flywheel storage unit with this rotordesign.
The project aims at the exploration of the performance of a new flywheel design when applied as an energy storage unit. The project is the first step towards a development of flywheel-based energy storage systems for load levelling in weak electrical grids, industrial processes and for transport purposes. The project consists of three separate Tasks: 1: Prototype design, manufacturing and preliminary testing. 2: Integration in systems. 3: Upgrading in size and identification of related problems. The aim of Task 1 is to design and manufacture a flywheel rotor according to the new design principles (patented) and through a series of tests and experiments to verify the function. The prototype rotor will have an outer diameter of 400 mm, mechanical bearings and energy transmission through a shaft and gearbox. 4 wheels will be manufactured as well as separate components in order to solve specific problems arising. Task 2 consists of system analysis, where operating conditions for a flywheel storage unit will be analysed. Task 3 investigates the problems involved in an upscaling of the flywheel to 4-600 kWh, including new bearing principles (magnetic levitation) and principles for energy transmission. The Task involves recommendations for a possible continuation of the project for larger storage systems.
The present report covers phase 1 of the project, in which the design of the unit as well as the manufacturing og the polymeric composite parts are performed. The generic design of the flywheel unit is outlined. The flywheel and the motor/generator are separate, and the flywheel rotor is contained in a vacuum house (steel) and supported in squeeze film damped ball bearings. Two designs of the critical connection element - the hub - between the steel shaft and the carbon/epoxy flywheel rim is designed and manufactured. Trial manufacturing of the 400 mm outside diamter, 55-mm thick rim is performed prior to the final manufacturing of two carbon/epoxy rims. Mechanical components testing have been performed to virify the behaviour of the composite parts as well as the strength capacity of the assembled rotor
Key figures
Category
Participants
| Partner | Subsidy | Auto financing |
|---|---|---|
| Demex A/S | ||
| NESA A/S | ||
| Udsen (P) Aircraft Industry A/S |
Contact
Postboks 49
DK-4000 Roskilde, Denmark
Andersen, Svend Ib (seniorforsker), 46775700, materials@risoe.dk
Øvr. Partnere: DEMEX Rådgivende Ingeniører A/S; NESA A/S; Udsen (P) Aircraft Industry A/S; NESA A/S
