Flywheel support system for mobile energy storage

• US 5,559,381 A
• Filed: 11/08/1993
• Issued: 09/24/1996
• Est. Priority Date: 11/08/1993
• Status: Expired due to Term

• Current Assignee: Beaver Aerospace And Defense, Inc.
• Original Assignee: Rosen Motors, L.P.
• Inventors: Rosen, Harold A., Bosley, Robert W.
• Primary Examiner(s): LaBalle, Clayton E.
• Application Number:
  US08/148,361
• Time in Patent Office: 1,051 Days
• Field of Search: 310/74, 310/90.5, 310/112, 310/113, 322/4, 244/165, 74/572, 280/217, 180/165, 318/161, 318/150
• US Class Current: 310/74
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B62M 1/10 involving devices which enable the mechanical storing and releasing of energy occasionally, e.g. arrangement of flywheels
• CPC Class Codes: F16F 15/302 comprising arrangements for cooling or thermal insulation
• 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 15/315 characterised by their supporting arrangement, e.g. mountings, cages, securing inertia member to shaft F16F15/31 takes precedence
• CPC Class Codes: H02K 5/173 using bearings with rolling contact, e.g. ball bearings
• CPC Class Codes: H02K 7/025 for power storage
• CPC Class Codes: H02K 7/083 radially supporting the rotary shaft at both ends of the rotor H02K7/086, H02K7/09 take precedence
• CPC Class Codes: H02K 7/09 with magnetic bearings
• CPC Class Codes: H02K 9/197 in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator
• CPC Class Codes: Y02E 60/16 Mechanical energy storage, e.g. flywheels or pressurised fluids
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10S 903/96 having chargeable mechanical accumulator

Abstract

A flywheel support system isolates the flywheel and its motor-generator from the driving environment of an electrically powered motor vehicle. A suitable liquid, placed between the outer and vacuum housings of the flywheel assembly, provides buoyancy and damping to the vacuum housing, cooling of the motor-generator, and serves as one of the barriers to rotor energy and angular momentum transfer in the event of an accident or failure. During normal operation, a shearable mechanical gimbal system keeps the vacuum housing centered in the outer housing, reacts the spin moments generated by the motor-generator, and provides a path for the electrical leads into the vacuum housing. In the event of bearing seizure or rotor failure, the mechanical gimbal will shear and allow the vacuum housing to gradually spin down against the fluid. A system of both active and passive axial and radial magnetic bearings supports the rotating assembly including the rotor of the motor-generator. Rotor-stator gap proximity sensors, strategically placed along the axis, permit a minimum gap to be used in the motor-generator. The placement of the center of gravity of the vacuum housing and its contents below the center of buoyancy produces a vertical orientation of the housing in the absence of accelerations, thus minimizing the power consumed by the magnetic support system when the vehicle is parked.

Claims

1. A flywheel support system for a flywheel-motor-generator assembly providing mobile energy storage, said support system including a liquid suspension system comprising:

an outer housing;

a vacuum housing disposed within said outer housing, wherein said vacuum housing and said outer housing define a cavity;

a radiator operatively attached to said outer housing; and

a pump disposed within said cavity for circulating a liquid in a predetermined portion of said cavity so as to transfer waste heat to said radiator.

2. The flywheel support system as recited in claim 1, wherein a stator of said flywheel-motor-generator is disposed proximate to said predetermined portion of said cavity.

3. The flywheel support system as recited in claim 1, further comprising a plurality of shearable support members operatively disposed between said outer housing and said vacuum housing.

4. The flywheel support system as recited in claim 1, wherein the flywheel-motor-generator assembly has a respective center of mass, wherein said vacuum housing has an associated center of buoyancy and wherein said center of buoyancy is disposed with respect to said center of mass so as to produce a righting moment applied to the flywheel-motor-generator assembly.

5. The flywheel support system as recited in claim 4, wherein said righting moment is applied to a rotor axis of the flywheel-motor-generator assembly so as to permit alignment of the rotor axis along a vertical when an associated vehicle is parked irrespective of orientation of the vehicle.

6. The flywheel support system as recited in claim 1, wherein said liquid outside of said portion is circulated by convection so as to maintain said vacuum housing wetted by said liquid outside of said portion at ambient temperature.

7. A flywheel support system for a flywheel-motor-generator assembly providing mobile energy storage, said support system including a bearing support system comprising:

a magnetic active radial bearing disposed in a predetermined plane about an axial shaft of the flywheel-motor-generator assembly;

a plurality of magnetic passive radial bearings;

a plurality of magnetic active axial bearings, wherein at least one of said active axial bearings is disposed proximate to an end of said shaft

a magnetic passive axial bearing;

plurality of proximity sensors located equidistant from said shaft for determining a position of said shaft within a cylinder defined by said proximity sensors; and

a control system for controlling said active radial bearing and said active axial bearings in response to signals produced by said proximity sensors.

8. The flywheel support system as recited in claims 7, wherein said control system controls said active radial bearing and said active axial bearings so as to enable reduction of a gap between said shaft and said cylinder.

9. The flywheel support system as recited in claim 7, wherein said active radial bearing is disposed proximate to a center of mass of the flywheel-motor-generator assembly.

10. The flywheel support system as recited in claim 7, wherein force generated by said active radial bearing is adjusted in response to said signals so as to maintain a predetermined clearance between said shaft and said cylinder in response to vehicle accelerations.

11. The flywheel support system as recited in claim 7, wherein said passive radial bearings counteract torques produced during vehicle acceleration resulting from axial displacement of a center of mass of a stator in the flywheel-motor-generator assembly and by hydrodynamic forces on a mechanical gimbal during vehicle rotations.

12. The flywheel support system as recited in claim 7, wherein said active axial bearings support the weight of the flywheel-motor-generator assembly against gravity and during vertical accelerations.

13. The flywheel support system as recited in claim 7, wherein said cylinder is located coincident with a stator of the flywheel-motor-generator.

14. The flywheel support system as recited in claim 13, wherein said cylinder is located coincident with the stator of the flywheel-motor-generator so as to minimize loss of clearance between said shaft and said stator.

15. The flywheel support system as recited in claim 7, wherein said passive axial bearing supports the weight a rotor of the flywheel-motor-generator assembly when said control system is turned OFF.

16. The flywheel support system as recited in claim 7, said proximity sensors further comprising:

a plurality of first proximity sensors located in a first plane equidistant from centerline of said shaft; and

a plurality of second proximity sensors located in a second plane equidistant from said centerline of said shaft;

wherein said first proximity sensors and said second proximity sensors define said cylinder,

wherein said cylinder is substantially coincident with a motor-generator of the flywheel-motor-generator assembly,

wherein said first plane is disposed substantially parallel to said second plane, and

wherein said control system controls said active radial bearing and said active axial bearings in response to respective signals produced by said proximity sensors, said control signals being combined in said control system to approximate at least one virtual proximity sensor located equidistant between said first plane and said second plane.

17. The flywheel support system as recited in claim 7, wherein said proximity sensors are disposed about first and second circles of intersection between said cylinder and respective first and second planes, said first plane being disposed orthogonal to said second plane, wherein said cylinder is substantially coincident with a motor-generator of the flywheel-motor-generator assembly, and wherein said control system controls said active radial bearing and said active axial bearings in response to respective signals produced by said proximity sensors, said control signals being combined in said control system to approximate at least one virtual proximity sensor located a predetermined distance from said first plane.

18. The flywheel support system as recited in claim 7, wherein said cylinder is a right circular cylinder.

19. A safety system for a high energy density flywheel assembly, comprising:

a vacuum housing;

an energy absorbing suspension fluid;

an outer housing;

a mechanical gimbal operatively coupling said vacuum housing to said outer housing; and

a reinforcing wrapping,

arranged to form a multiple barrier and energy dissipation means for protecting a vehicle and associated passengers from accidental release of energy from the flywheel assembly.

20. The safety system as recited in claim 19, wherein said mechanical gimbol includes shearable gimbal pins protecting the passengers and the vehicle from sudden transfer of angular momentum resulting from bearing seizure of at least one of a plurality of bearing or contact between said vacuum housing and said flywheel assembly, wherein gimbal pins in respective said gimbal pins shear and permit said vacuum housing to gradually spin down against the fluid disposed between said vacuum housing and said outer housing.