Flywheel-based energy storage methods and apparatus

• US 5,124,605 A
• Filed: 01/11/1991
• Issued: 06/23/1992
• Est. Priority Date: 01/11/1991
• Status: Expired due to Term

• Current Assignee: Trinity Flywheel Power (American Flywheel Systems, Inc.)
• Original Assignee: American Flywheel Systems, Inc.
• Inventors: Bitterly, Jack G., Bitterly, Steven E.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): REBSCH, DONALD
• Application Number:
  US07/640,282
• Time in Patent Office: 529 Days
• Field of Search: 74/572, 29/894, 29/895, 29/895.2, 152/1, 152/17, 152/43, 152/73, 301/6 WB, 301/63 PW, 301/74, 310/90.5, 310/114, 310/261
• US Class Current: 310/74
• CPC Class Codes: F16C 2361/55 Flywheel systems
• CPC Class Codes: F16C 32/044 Active magnetic bearings
• CPC Class Codes: F16C 39/06 using magnetic means
• CPC Class Codes: F16F 15/30 Flywheels F16F15/16, F16F15/28 take precedence; suppression of vibrations in rotating systems using elastic members or friction-damping members moving with the system, i.e. split flywheels or single masses connected to a hub by elastic members or friction-damping members F16F15/12; rotary-body aspects in general F16C13/00, F16C15/00
• CPC Class Codes: F16F 15/305 made of plastics, e.g. fibre reinforced plastics [FRP] , i.e. characterised by their special construction from such materials
• CPC Class Codes: F16F 15/3156 Arrangement of the bearings
• CPC Class Codes: H02K 5/165 radially supporting the rotor around a fixed spindle; radially supporting the rotor directly H02K5/167, H02K5/173 take precedence
• CPC Class Codes: H02K 7/025 for power storage
• CPC Class Codes: H02K 7/09 with magnetic bearings
• CPC Class Codes: Y02E 60/16 Mechanical energy storage, e.g. flywheels or pressurised fluids
• CPC Class Codes: Y10T 74/212 Containing fiber or filament

Abstract

Flywheel-based energy storage devices, with methods for their use and fabrication. The devices have the capacity to store electric energy as kinetic energy and to generate electric energy from the stored kinetic energy. Preferred devices comprise a pair of counter-rotating anisotropic flywheels which are designed to rotate rapidly within an evacuated housing. The flywheels comprise a lightweight hub and a circumferentially-wound fiber rim. The hub and rim are fabricated from materials having high tensile strength and are connected with systems of novel tube assemblies positioned around the hub parallel to the axis of rotation. The flywheels are principally supported by magnetic bearings and are further stabilized during rotation by a self-restoring liquid bearing system.

Claims

1. An energy storage device, comprising:

a housing;

a shaft assembly comprising a shaft which defines an axis, contained within the housing and attached thereto;

a first flywheel adapted to rotate around said axis, comprising a plurality of tube assemblies substantially parallel to said axis; and

a second flywheel adapted to rotate around said axis in a direction counter to the direction of the first flywheel, comprising a plurality of tube assemblies substantially parallel to said axis;

wherein the shaft of the shaft assembly comprises a substantially radial portion and two substantially cylindrical axial portions and the shaft assembly further comprises;

at least one magnetic shaft bearing adjacent the radial portion of the shaft; and

at least one magnetic shaft sleeve substantially surrounding the axial portions of the shaft.

2. The energy storage device of claim 1 wherein the interior of the housing is at a pressure below atmospheric pressure.

3. The energy storage device of claim 1 wherein the first flywheel and the second flywheel are each substantially anisotropic.

4. The energy storage device of claim 1 wherein the first flywheel and the second flywheel each comprise at least one permanent magnet.

5. The energy storage device of claim 1 wherein the first flywheel and the second flywheel individually comprise a plurality of faces and are positioned such that a first face of the first flywheel is proximate a first face of he second flywheel and a second face of the first flywheel is remote from a second face of the second flywheel.

15. The energy storage device of claim 1 wherein each tube assembly contacts at least one other tube assembly.

16. The energy storage device of claim 1 wherein each tube assembly is substantially arcuate.

6. An energy storage device, comprising:

a housing;

a shaft assembly comprising a shaft which defines an axis, contained within the housing and attached thereto;

a first flywheel adapted to rotate around said axis, comprising a plurality of tube assemblies substantially parallel to said axis; and

a second flywheel adapted to rotate around said axis in a direction counter to the direction of the first flywheel, comprising a plurality of tube assemblies substantially parallel to said axis;

wherein the first flywheel and the second flywheel individually comprise;

a hub including;

a magnetic bearing sleeve;

a core material substantially surrounding the outer periphery of the bearing sleeve, a portion of the core material forming a portion of the first face and the second face of the flywheel;

a first magnetic ring contained within the portion of the core material which forms the first face of the flywheel; and

a second magnetic ring contained within the portion of the core material which forms the second face of the flywheel; and

a collar substantially surrounding the outer periphery of the core material;

a plurality of tube assemblies positioned around the outer periphery of the hub; and

a first rim positioned around the outer periphery of the tube assemblies.

7. The energy storage device of claim 6 further comprising:

a plurality of tube assemblies positioned around the outer periphery of the first rim; and

a second rim positioned around the tube assemblies and the first rim.

8. The energy storage device of claim 6 wherein the shaft assembly comprises a magnetic shaft sleeve opposite the bearing sleeve.

9. The energy storage device of claim 6 wherein the shaft assembly comprises a shaft bearing opposite the first magnetic ring.

10. The energy storage device of claim 6 wherein the housing comprises a housing ring opposite the second magnetic ring.

11. The energy storage device of claim 6 wherein a portion of the core material defines a circumferential channel at the second face of the flywheel.

12. The energy storage device of claim 11 wherein the channel contains a liquid.

13. The energy storage device of claim 11 wherein the housing comprises one or more cams which extend into the channel.

14. The energy storage device of claim 13 wherein:

the shaft assembly is separated from the flywheel by a predetermined distance; and

the cam and the second face of the flywheel are separated by a distance which is less than the distance between the shaft assembly and the flywheel.

17. The energy storage device of claim 6 wherein a portion of each tube assembly is substantially concave.

18. The energy storage device of claim 7 wherein a proton of each tube assembly is substantially convex.

19. An energy storage device, comprising:

a housing;

a shaft assembly comprising a shaft which defines an axis, contained within the housing and attached thereto;

a first flywheel adapted to rotate around said axis, comprising a plurality of tube assemblies substantially parallel to said axis;

a second flywheel adapted to rotate around said axis in a direction counter to the direction of the first flywheel, comprising a plurality of tube assemblies substantially parallel to said axis; and

permanent magnets contained within the tube assemblies.

20. The energy storage device of claim 19 wherein an electromagnet is attached to the housing.

21. The energy storage device of claim 19 further comprising a core material within the tube assemblies.

22. An energy storage device, comprising:

a housing;

a shaft assembly comprising a shaft which defines an axis, contained within the housing and attached thereto;

a first flywheel adapted to rotate around said axis, comprising;

a hub;

a plurality of tube assemblies positioned substantially parallel to said axis around the outer periphery of the hub; and

a first rim comprising wound fiber positioned around the outer periphery of the tube assemblies;

a second flywheel adapted to rotate around said axis in a direction counter to the direction of the first flywheel, comprising;

a hub;

a plurality of tube assemblies positioned substantially parallel to said axis around the outer periphery of the hub; and

a first rim comprising wound fiber positioned around the outer periphery of the tube assemblies;

a plurality of tube assemblies positioned around the outer periphery of the first rim; and

a second rim comprising wound fiber positioned around the tube assemblies and the first rim.

23. The energy storage device of claim 22 wherein the fiber comprises a plurality of generally parallel oriented filaments.

24. The energy storage device of claim 22 wherein the fiber comprises aromatic polyamide.

25. The energy storage device of claim 22 wherein the fiber comprises fused silica.

26. The energy storage device of claim 22 wherein the wound fiber defines a plurality of interstices.

27. The energy storage device of claim 26 wherein the interstices contain material for binding the fiber to itself.

28. A process for generating electric energy, comprising the steps of:

providing an energy storage device which comprises;

a housing;

a shaft assembly comprising a shaft which defines an axis, contained within the housing and attached thereto;

a first flywheel adapted to rotate around said axis, comprising a plurality of tube assemblies substantially parallel to said axis;

a second flywheel adapted to rotate around said axis in a direction counter to the direction of the first flywheel, comprising a plurality of tube assemblies substantially parallel to said axis; and

transfer means for transferring energy into and out of the energy storage device, comprising;

at least one permanent magnet within each of the first flywheel and the second flywheel; and

at least one electromagnet in electromagnetic communication with the permanent magnet; and

rotating the first flywheel and the second flywheel, thereby generating an electric potential between the permanent magnet and the electromagnet;

wherein the permanent magnet is within at least one of the tube assemblies.

29. A system for connecting a hub with a first rim of wound fiber wherein the hub and first rim are adapted to rotate around a shaft which defines an axis, comprising a plurality of tube assemblies substantially parallel to said axis and in contact with both the outer periphery of the hub and the inner diameter of the first rim, wherein the tube assemblies individually comprise:

a tube; and

a permanent magnet contained within the tube.

30. The system of claim 29 wherein the tubes are positioned around the outer periphery of the first rim;

and a second rim is positioned around the tube assemblies and the first rim.

31. The system of claim 29 which comprises at least five tube assemblies.

32. The system of claim 29 wherein each tube assembly is substantially arcuate.

33. The system of claim 29 wherein a first portion of each tube assembly is substantially concave and a second portion of each tube assembly is substantially convex.

34. A process for constructing a substantially anisotropic flywheel, comprising the steps of:

providing a rim having a predetermined inner diameter;

positioning within the rim a hub having a predetermined outer diameter;

providing a plurality of tubes which each have a diameter greater than one-half the difference between the rim inner diameter and the hub outer diameter;

compressing at least one tube; and

placing each tube between the rim and the hub;

wherein the hub comprises;

a magnetic bearing sleeve;

a core material substantially surrounding the outer periphery of the magnetic bearing sleeve, a portion of the core material forming a portion of a first face and a second face of the flywheel;

a first magnetic ring contained within the portion of the core material which forms the first face of the flywheel; and

a second magnetic ring contained within the portion of the core material which forms the second face of the flywheel; and

a collar substantially surrounding the outer periphery of the core material.

35. The process of claim 34 wherein each tube is substantially arcuate.

36. The process of claim 34 wherein a first portion of each tube is substantially concave and a second portion of each tube is substantially convex.

37. The process of claim 34 wherein the rim comprises wound fiber.

38. The process of claim 37 wherein the fiber comprises a plurality of generally parallel-oriented filaments.

39. The process of claim 37 wherein the fiber comprises aromatic polyamide.

40. The process of claim 37 wherein the fiber is wound in a generally parallel configuration.

41. The process of claim 34 further comprising winding fiber around a substrate to produce the rim.

42. The process of claim 40 further comprising contacting the fiber with an adhesive before winding.

43. The process of claim 40 wherein the fiber is wound at a pressure below atmospheric pressure.

44. The process of claim 34 further comprising:

filling at least one compressed tube with water and freezing the water before placing the tube between the hub and rim.

45. A flywheel adapted to rotate around an axis, which comprises:

a hub;

a plurality of tube assemblies positioned around the outer periphery of the hub substantially parallel to said axis; and

a rim positioned around the outer periphery of the tube assemblies;

wherein the hub comprises;

a magnetic bearing sleeve;

a core material substantially surrounding the outer periphery of the bearing sleeve, a portion of the core material forming a portion of a first face and a second face of the flywheel; and

a first magnetic ring contained within the portion of the core material which forms the first face of the flywheel; and

a second magnetic ring contained within the portion of the core material which forms the second face of the flywheel; and

a collar substantially surrounding the outer periphery of the core material.

46. The flywheel of claim 45 wherein a portion of the core material defines a circumferential channel at the second face of the flywheel.

47. A flywheel adapted to rotate around an axis, which comprises:

a hub;

a plurality of tube assemblies positioned around the outer periphery of the hub substantially parallel to said axis; and

a rim positioned around the outer periphery of the tube assemblies;

wherein the tube assemblies individually comprise;

a tube; and

a permanent magnet contained within the tube.

48. The flywheel of claim 47 wherein the magnet is at the second face of the flywheel.

49. The flywheel of claim 47 further comprising a core material within the tube.

50. A process for storing energy, comprising the steps of:

providing an energy storage device which comprises;

a housing;

a shaft assembly comprising a shaft which defines an axis, contained within the housing and attached thereto;

a first flywheel adapted to rotate around said axis, comprising a plurality of tube assemblies substantially parallel to said axis;

a second flywheel adapted to rotate around said axis in a direction counter to the direction of the first flywheel, comprising a plurality of tube assemblies substantially parallel to said axis; and

means for transferring energy into and out of the energy storage device, comprising;

at least one permanent magnet within at least one of the tube assemblies of each of the first flywheel and the second flywheel, and

an electromagnet in electromagnetic communication with the permanent magnet; and

providing electromagnetic energy to the transfer means to rotate the first flywheel and the second flywheel.

51. A flywheel adapted to rotate around an axis, which comprises:

a hub;

a plurality of tube assemblies positioned around the outer periphery of the hub substantially parallel to said axis;

a rim positioned around the outer periphery of the tube assemblies; and

at least one permanent magnet positioned between the hub and the rim.