Flywheel energy storage (FES) works by accelerating a rotor (flywheel) to a very high speed and maintaining the energy in the system as rotational energy. When energy is extracted from the system, the flywheel's rotational speed is reduced as a consequence of the principle of conservation of energy; Contact online >>
Flywheel energy storage (FES) works by accelerating a rotor (flywheel) to a very high speed and maintaining the energy in the system as rotational energy. When energy is extracted from the system, the flywheel''s rotational speed is reduced as a consequence of the principle of conservation of energy; adding energy to the system correspondingly results in an increase in the speed of the flywheel.
Most FES systems use electricity to accelerate and decelerate the flywheel, but devices that directly use mechanical energy are being developed.[1]
Advanced FES systems have rotors made of high strength carbon-fiber composites, suspended by magnetic bearings, and spinning at speeds from 20,000 to over 50,000 rpm in a vacuum enclosure.[2] Such flywheels can come up to speed in a matter of minutes – reaching their energy capacity much more quickly than some other forms of storage.[2]
A typical system consists of a flywheel supported by rolling-element bearing connected to a motor–generator. The flywheel and sometimes motor–generator may be enclosed in a vacuum chamber to reduce friction and energy loss.
First-generation flywheel energy-storage systems use a large steel flywheel rotating on mechanical bearings. Newer systems use carbon-fiber composite rotors that have a higher tensile strength than steel and can store much more energy for the same mass.[3]
To reduce friction, magnetic bearings are sometimes used instead of mechanical bearings.
Since flux pinning is an important factor for providing the stabilizing and lifting force, the HTSC can be made much more easily for FES than for other uses. HTSC powders can be formed into arbitrary shapes so long as flux pinning is strong. An ongoing challenge that has to be overcome before superconductors can provide the full lifting force for an FES system is finding a way to suppress the decrease of levitation force and the gradual fall of rotor during operation caused by the flux creep of the superconducting material.
The maximal specific energy of a flywheel rotor is mainly dependent on two factors: the first being the rotor''s geometry, and the second being the properties of the material being used. For single-material, isotropic rotors this relationship can be expressed as[9]
For energy storage, materials with high strength and low density are desirable. For this reason, composite materials are frequently used in advanced flywheels. The strength-to-density ratio of a material can be expressed in Wh/kg (or Nm/kg); values greater than 400 Wh/kg can be achieved by certain composite materials.
Several modern flywheel rotors are made from composite materials. Examples include the carbon-fiber composite flywheel from Beacon Power Corporation[13] and the PowerThru flywheel from Phillips Service Industries.[14] Alternatively, Calnetix utilizes aerospace-grade high-performance steel in their flywheel construction.[15]
For these rotors, the relationship between material properties, geometry and energy density can be expressed by using a weighed-average approach.[16]
One of the primary limits to flywheel design is the tensile strength of the rotor. Generally speaking, the stronger the disc, the faster it may be spun, and the more energy the system can store. (Making the flywheel heavier without a corresponding increase in strength will slow the maximum speed the flywheel can spin without rupturing, hence will not increase the total amount of energy the flywheel can store.)
When the tensile strength of a composite flywheel''s outer binding cover is exceeded, the binding cover will fracture, and the wheel will shatter as the outer wheel compression is lost around the entire circumference, releasing all of its stored energy at once; this is commonly referred to as "flywheel explosion" since wheel fragments can reach kinetic energy comparable to that of a bullet. Composite materials that are wound and glued in layers tend to disintegrate quickly, first into small-diameter filaments that entangle and slow each other, and then into red-hot powder; a cast metal flywheel throws off large chunks of high-speed shrapnel.
For a cast metal flywheel, the failure limit is the binding strength of the grain boundaries of the polycrystalline molded metal. Aluminum in particular suffers from fatigue and can develop microfractures from repeated low-energy stretching. Angular forces may cause portions of a metal flywheel to bend outward and begin dragging on the outer containment vessel, or to separate completely and bounce randomly around the interior. The rest of the flywheel is now severely unbalanced, which may lead to rapid bearing failure from vibration, and sudden shock fracturing of large segments of the flywheel.
Traditional flywheel systems require strong containment vessels as a safety precaution, which increases the total mass of the device. The energy release from failure can be dampened with a gelatinous or encapsulated liquid inner housing lining, which will boil and absorb the energy of destruction. Still, many customers of large-scale flywheel energy-storage systems prefer to have them embedded in the ground to halt any material that might escape the containment vessel.
Flywheel energy storage systems using mechanical bearings can lose 20% to 50% of their energy in two hours.[17] Much of the friction responsible for this energy loss results from the flywheel changing orientation due to the rotation of the earth (an effect similar to that shown by a Foucault pendulum). This change in orientation is resisted by the gyroscopic forces exerted by the flywheel''s angular momentum, thus exerting a force against the mechanical bearings. This force increases friction. This can be avoided by aligning the flywheel''s axis of rotation parallel to that of the earth''s axis of rotation.[citation needed]
Conversely, flywheels with magnetic bearings and high vacuum can maintain 97% mechanical efficiency, and 85% round trip efficiency.[18]
When used in vehicles, flywheels also act as gyroscopes, since their angular momentum is typically of a similar order of magnitude as the forces acting on the moving vehicle. This property may be detrimental to the vehicle''s handling characteristics while turning or driving on rough ground; driving onto the side of a sloped embankment may cause wheels to partially lift off the ground as the flywheel opposes sideways tilting forces. On the other hand, this property could be utilized to keep the car balanced so as to keep it from rolling over during sharp turns.[19]
When a flywheel is used entirely for its effects on the attitude of a vehicle, rather than for energy storage, it is called a reaction wheel or a control moment gyroscope.
The resistance of angular tilting can be almost completely removed by mounting the flywheel within an appropriately applied set of gimbals, allowing the flywheel to retain its original orientation without affecting the vehicle (see Properties of a gyroscope). This does not avoid the complication of gimbal lock, and so a compromise between the number of gimbals and the angular freedom is needed.
The center axle of the flywheel acts as a single gimbal, and if aligned vertically, allows for the 360 degrees of yaw in a horizontal plane. However, for instance driving up-hill requires a second pitch gimbal, and driving on the side of a sloped embankment requires a third roll gimbal.
Although the flywheel itself may be of a flat ring shape, a free-movement gimbal mounting inside a vehicle requires a spherical volume for the flywheel to freely rotate within. Left to its own, a spinning flywheel in a vehicle would slowly precess following the Earth''s rotation, and precess further yet in vehicles that travel long distances over the Earth''s curved spherical surface.
A full-motion gimbal has additional problems of how to communicate power into and out of the flywheel, since the flywheel could potentially flip completely over once a day, precessing as the Earth rotates. Full free rotation would require slip rings around each gimbal axis for power conductors, further adding to the design complexity.
To reduce space usage, the gimbal system may be of a limited-movement design, using shock absorbers to cushion sudden rapid motions within a certain number of degrees of out-of-plane angular rotation, and then gradually forcing the flywheel to adopt the vehicle''s current orientation. This reduces the gimbal movement space around a ring-shaped flywheel from a full sphere, to a short thickened cylinder, encompassing for example ± 30 degrees of pitch and ± 30 degrees of roll in all directions around the flywheel.
An alternative solution to the problem is to have two joined flywheels spinning synchronously in opposite directions. They would have a total angular momentum of zero and no gyroscopic effect. A problem with this solution is that when the difference between the momentum of each flywheel is anything other than zero the housing of the two flywheels would exhibit torque. Both wheels must be maintained at the same speed to keep the angular velocity at zero. Strictly speaking, the two flywheels would exert a huge torqueing moment at the central point, trying to bend the axle. However, if the axle were sufficiently strong, no gyroscopic forces would have a net effect on the sealed container, so no torque would be noticed.
To further balance the forces and spread out strain, a single large flywheel can be balanced by two half-size flywheels on each side, or the flywheels can be reduced in size to be a series of alternating layers spinning in opposite directions. However this increases housing and bearing complexity.
In the 1950s, flywheel-powered buses, known as gyrobuses, were used in Yverdon (Switzerland) and Ghent (Belgium) and there is ongoing research to make flywheel systems that are smaller, lighter, cheaper and have a greater capacity. It is hoped that flywheel systems can replace conventional chemical batteries for mobile applications, such as for electric vehicles. Proposed flywheel systems would eliminate many of the disadvantages of existing battery power systems, such as low capacity, long charge times, heavy weight and short usable lifetimes. Flywheels may have been used in the experimental Chrysler Patriot, though that has been disputed.[20]
Flywheels have also been proposed for use in continuously variable transmissions. Punch Powertrain is currently working on such a device.[21]
During the 1990s, Rosen Motors developed a gas turbine powered series hybrid automotive powertrain using a 55,000 rpm flywheel to provide bursts of acceleration which the small gas turbine engine could not provide. The flywheel also stored energy through regenerative braking. The flywheel was composed of a titanium hub with a carbon fiber cylinder and was gimbal-mounted to minimize adverse gyroscopic effects on vehicle handling. The prototype vehicle was successfully road tested in 1997 but was never mass-produced.[22]
In July 2014 GKN acquired Williams Hybrid Power (WHP) division and intends to supply 500 carbon fiber Gyrodrive electric flywheel systems to urban bus operators over the next two years[24] As the former developer name implies, these were originally designed for Formula one motor racing applications. In September 2014, Oxford Bus Company announced that it is introducing 14 Gyrodrive hybrid buses by Alexander Dennis on its Brookes Bus operation.[25][26]
Flywheel systems have been used experimentally in small electric locomotives for shunting or switching, e.g. the Sentinel-Oerlikon Gyro Locomotive. Larger electric locomotives, e.g. British Rail Class 70, have sometimes been fitted with flywheel boosters to carry them over gaps in the third rail. Advanced flywheels, such as the 133 kWh pack of the University of Texas at Austin, can take a train from a standing start up to cruising speed.[2]
The Parry People Mover is a railcar which is powered by a flywheel. It was trialled on Sundays for 12 months on the Stourbridge Town Branch Line in the West Midlands, England during 2006 and 2007 and was intended to be introduced as a full service by the train operator London Midland in December 2008 once two units had been ordered. In January 2010, both units are in operation.[27]
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