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Design, Fabrication, and Testing of 10 MJ Composite Flywheel Energy Storage Rotors
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Abstract
Flywheel energy storage systems employing high speed composite flywheels and advanced electric motor/generators are being evaluated by the Department of Defense (DoD), NASA [1], and firms [2,3] to replace electrochemical battery banks in satellites and manned space applications. Flywheel energy storage systems can provide extended operating life and significant reduction in weight and volume compared to conventional electrochemical systems. In addition, flywheels can provide momentum or reaction wheel functions for attitude control.
This paper describes the design, fabrication, and spin testing of two 10 MJ composite flywheel energy storage rotors. To achieve the demonstrated energy density of greater than 310 kJ/kg in a volume of less than 0.05 m3, the rotors utilize flexible composite arbors to connect a composite rim to a metallic shaft, resulting in compact, lightweight, high energy density structures.
The paper also describes the finite element stress and rotordynamics analyses, along with a description of the fabrication and assembly techniques used in the construction of the rotor. A description of the experimental setup and a discussion of spin testing of the rotors up to 45,000 rpm (965 m/s tip speed) are also presented. Accurate measurements of rotor centrifugal growth made with laser triangulation sensors confirmed predicted strains of greater than 1.2% in the composite rim.
Due to the weight penalty associated with flywheel designs requiring containment structures, there is a strong need to develop flywheel systems which operate safely in space, preferably without dedicated containment structures. A future paper will describe results of a 28,600 rpm composite rotor burst test performed in a containment structure as a step towards understanding composite rotor failure modes.
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Authors
- J.D. Herbst - Center for Electromechanics, The University of Texas at Austin
- S.M. Manifold - Center for Electromechanics, The University of Texas at Austin
- B.T. Murphy - Center for Electromechanics, The University of Texas at Austin
- J.H. Price - Center for Electromechanics, The University of Texas at Austin
- R.C. Thompson - Center for Electromechanics, The University of Texas at Austin
- W.A. Walls - Center for Electromechanics, The University of Texas at Austin
- A. Alexander - CAES
- K. Twigg - CAES
Topic
Citation
Herbst, J., Manifold, S., Murphy, B., Price, J. et al., "Design, Fabrication, and Testing of 10 MJ Composite Flywheel Energy Storage Rotors," SAE Technical Paper 981282, 1998, https://doi.org/10.4271/981282.Also In
References
- Christopher D.A. Beach R. “Flywheel Technology Development Program for Aerospace Applications,” 1997 IEEE
- Pieronek T.J. Decker D.K. Spector V.A. “Spacecraft Flywheel Systems -- Benefits and Issues,” 1997 IEEE
- Edwards J. Christopher D.A. Aldrich J.W. Beach R.F. Barton J.R. “Flight Test Demonstration of a Flywheel Energy Storage System on the International Space Station,” 1997 IEEE
- Tsai T. Price J. “Advanced Non-Electric Propulsion System for High Speed Rail.”
- Steele R.S. Babelay, E.F. Jr. “Data Analysis Techniques Used at the Oak Ridge Y-12 Plant Flywheel Evaluation Laboratory,” Proceedings of the 1980 Flywheel Technology Symposium Scottsdale, AZ 423 433
- Steele R.S. “Composite Flywheel Balance Experience,” Proceedings of the 16th Intersociety Energy Conversion Engineering Conference Atlanta GA August 1981