Dual stiffness bearing damping system

• US 6,747,378 B2
• Filed: 08/20/2001
• Issued: 06/08/2004
• Est. Priority Date: 08/20/2001
• Status: Expired due to Term

• Current Assignee: Beacon Power (RGA Labs, Inc.)
• Original Assignee: Beacon Power Corporation (RGA Labs, Inc.)
• Inventors: Brackett, Norman C.
• Primary Examiner(s): LE, DANG D
• Application Number:
  US09/933,496
• Publication Number:
  US 20030034700A1
• Time in Patent Office: 1,023 Days
• Field of Search: 310/74, 310/51, 310/90, 384/581, 384/582, 384/618, 384/620, 745/72, 745/74
• US Class Current: 310/51
• CPC Class Codes: F16C 2361/55 Flywheel systems
• CPC Class Codes: F16C 27/04 Ball or roller bearings, e.g. with resilient rolling bodies
• CPC Class Codes: F16F 15/04 using elastic means single elements or their attachment F16F1/00 - F16F13/00; F16F15/023, F16F15/03 take precedence
• CPC Class Codes: H02K 5/24 specially adapted for suppression or reduction of noise or vibrations
• CPC Class Codes: H02K 7/025 for power storage
• CPC Class Codes: H02K 7/08 Structural association with bearings
• CPC Class Codes: Y02E 60/16 Mechanical energy storage, e.g. flywheels or pressurised fluids
• CPC Class Codes: Y10T 74/2119 Structural detail, e.g., material, configuration, superconductor, discs, laminated, etc.

Abstract

In one aspect of the present invention discloses a dual-stiffness damping system for an evacuated energy storage system, the damping system comprising one or more flexible dampers and a plurality of more rigid bumpers, and a method of damping an evacuated energy storage system using dual-stiffness damping. Indeed, under normal operating conditions, a flexible damper, having a stiffness of about 500 lb/in to about 4000 lb/in, minimizes the rigid body critical speed of the rotor assembly of the energy storage system, allowing relative displacement between the stator assembly and rotor assembly but preventing the assemblies from physically contacting each other. Under more extreme external loading conditions, e.g., during an earthquake, the plurality of more rigid bumpers, having a stiffness of about 50,000 to 250,000 lb/in, engages the outer race of the bearing assembly to arrest further relative displacement substantially. In another aspect of the present invention, the dual stiffness damping system is combined with a bearing assembly and a mounting unit to produce a self-contained damping system that can be quickly and easily installed and replaced.

Claims

1. A damping system for an evacuated energy storage device, said device having a rotor assembly that is rotatably supported and guided by a bearing assembly, comprising a rolling element substantially confined between an inner and an outer race, and a stator assembly, the system comprising:

one or more flexible dampers, each having a first stiffness; and

a plurality of rigid bumpers, each of said plurality of rigid bumpers having a second stiffness, wherein said second stiffness is greater than said first stiffness, and wherein said bumpers frictionally engage the outer race during extreme loading.

2. The damping system as recited in claim 1, wherein the one or more flexible dampers comprises a mesh damper.

3. The damping system as recited in claim 1, wherein the one or more flexible dampers comprises an elastomeric damper.

4. The damping system as recited in claim 3, wherein the elastomeric damper is made of silicon rubber.

5. The damping system as recited in claim 1, wherein said rotor assembly and said stator assembly are configured and arranged so as to be separated by a first clearance at substantially all locations except in proximity of the outer race of the bearing assembly, whereat said outer race of said bearing assembly is configured and arranged to be separated from one of said plurality of rigid bumpers by a second clearance, to allow relative displacement of said stator assembly with respect to said rotor assembly.

6. The damping system as recited in claim 5, wherein the first clearance is about 13 to about 17 mils.

7. The damping system as recited in claim 6, wherein the first clearance is about 15 mils.

8. The damping system as recited in claim 5, wherein the second clearance is about 8 to about 12 mils.

9. The damping system as recited in claim 8, wherein the second clearance is about 10 mils.

10. The damping system as recited in claim 1, wherein said plurality of more rigid bumpers is fabricated from at least one of aluminum, metal, alloys, carbon, carbon-carbon composites, and carbon fiber composite materials.

11. The damping system as recited in claim 1, wherein said plurality of more rigid bumpers is configured and arranged so as to substantially limit further relative displacement between the rotor assembly and stator assembly by frictionally engaging the outer race of the bearing assembly after an initial, first relative displacement equal in magnitude to a second clearance that separates said outer race of said bearing assembly from said plurality of more rigid bumpers.

12. The damping system as recited in claim 11, wherein said second clearance has a magnitude of about 8 to about 12 mils.

13. The damping system as recited in claim 12, wherein said second clearance has a magnitude of about 10 mils.

14. The damping system as recited in claim 1, wherein the first stiffness of the one or more flexible dampers is about 500 lb/in to about 4000 lb/in.

15. The damping system as recited in claim 14, wherein the first stiffness of the one or more flexible dampers is about 1200 lb/in.

16. The damping system as recited in claim 1, wherein the second stiffness of the plurality of more rigid bumpers is about 50,000 lb/in to about 250,000 lb/in.

17. The damping system as recited in claim 16, wherein the second stiffness of the plurality of more rigid bumpers is about 200,000 lb/in.

18. A self-contained bearing assembly system for an evacuated energy storage device, said device further having a rotor assembly and a stator assembly, which assemblies are separated by a first clearance and a second clearance, the system comprising:

a bearing assembly for rotatably supporting and guiding said rotor assembly, the bearing assembly further comprising;

an inner race,

an outer race, and

a rolling element that is rollably disposed and confined between said inner and outer races;

a mounting assembly, the mounting assembly further comprising;

an upper damper grounding plate,

a lower damper grounding plate, and

a circumferential mounting plate;

one or more flexible dampers, wherein an inner periphery of said one or more flexible dampers is in tight interference fit with said outer race of said bearing assembly and an outer periphery of said one or more flexible dampers is securely and removably attached to said circumferential mounting plate; and

a plurality of more rigid bumpers, wherein at least one of said plurality of more rigid bumpers is configured and arranged on said upper damper grounding plate so as to be disposed in proximity of said outer race of said bearing assembly and one or more of said plurality of more rigid bumpers is configured and arranged on said lower damper grounding plate so as to be disposed in proximity of said outer race of said bearing assembly.

19. The bearing assembly system as recited in claim 18, wherein the one or more flexible damper comprises a mesh damper.

20. The bearing assembly system as recited in claim 18, wherein the one or more flexible damper comprises an elastomeric damper.

21. The bearing assembly system as recited in claim 20, wherein the elastomeric damper is made of silicon rubber.

22. The bearing assembly system as recited in claim 18, wherein the plurality of more rigid bumpers are configured and arranged so as to be separated from the outer race of the bearing assembly by a second clearance and elsewhere, the rotor assembly and the stator assembly are configured and arranged so as to be separated by a first clearance to allow relative displacement between said rotor and stator assemblies.

23. The bearing assembly system as recited in claim 22, wherein the first clearance is about 13 to about 17 mils.

24. The bearing assembly system as recited in claim 23, wherein the first clearance is about 15 mils.

25. The bearing assembly system as recited in claim 22, wherein the second clearance is about 8 to about 12 mils.

26. The bearing assembly system as recited in claim 25, wherein the second clearance is about 10 mils.

27. The bearing assembly system as recited in claim 18, wherein said upper and lower grounding plates and said plurality of more rigid bumpers are fabricated from at least one of aluminum, metal, alloys, carbon, carbon-carbon composites and carbon fiber composite materials.

28. The bearing assembly system as recited in claim 18, wherein said plurality of more rigid bumpers is configured and arranged so as to substantially limit further relative displacement between the rotor and stator assemblies by frictionally engaging the outer race of the bearing assembly after an initial relative displacement equal in magnitude to a second clearance that separates said outer race of said bearing assembly from said plurality of more rigid bumpers.

29. The bearing assembly system as recited in claim 28, wherein said second clearance has a magnitude of about 8 to about 12 mils.

30. The bearing assembly system as recited in claim 29, wherein said second clearance has a magnitude of about 10 mils.

31. The bearing assembly system as recited in claim 18, wherein the first stiffness of the one or more flexible dampers is about 500 lb/in to about 4000 lb/in.

32. The bearing assembly system as recited in claim 31, wherein the first stiffness of the one or more flexible dampers is about 1200 lb/in.

33. The bearing assembly system as recited in claim 18, wherein the second stiffness of the plurality of more rigid bumpers is about 50,000 lb/in to about 250,000 lb/in.

34. The bearing assembly system as recited in claim 33, wherein the second stiffness of the plurality of more rigid bumpers is about 200,000 lb/in.

35. The bearing assembly system as recited in claim 18, wherein the system further comprises a gasket that is fixedly attached to the plurality of more rigid bumpers, wherein said gasket is less rigid than said plurality of more rigid bumpers.

36. An evacuated energy storage device, said device comprising:

a bearing assembly;

said bearing assembly further comprising;

an inner race,

an outer race,

a rolling element, wherein said rolling element is substantially confined between said inner and said outer race;

a rotor assembly that is rotatably supported and guided by said bearing assembly;

a stator assembly; and

a dual stiffness damping system, the system comprising;

one or more flexible dampers, each having a first stiffness; and

a

plurality of rigid bumpers, each of said plurality of rigid bumpers having a second stiffness, wherein said stiffness is greater than first stiffness, and wherein said bumpers frictionally engage the outer race during extreme loading.

37. The evacuated energy storage device as recited in claim 36, wherein the one or more flexible dampers of the dual stiffness damping system comprise a mesh damper.

38. The evacuated energy storage device as recited in claim 36, wherein the one or more flexible dampers of the dual stiffness damping system comprise an elastomeric damper.

39. The evacuated energy storage device as recited in claim 38, wherein the elastomeric damper is made of silicon rubber.

40. The evacuated energy storage device as recited in claim 36, wherein said rotor assembly and said stator assembly are configured and arranged so as to be separated by a first clearance at substantially all locations except in proximity of the outer race of the bearing assembly, whereat said outer race of said bearing assembly is configured and arranged so as to be separated from one of said plurality of rigid bumpers by a second clearance, to allow relative displacement of said stator assembly with respect to said rotor assembly.

41. The evacuated energy storage device as recited in claim 40, wherein the first clearance is about 13 to about 17 mils.

42. The evacuated energy storage device as recited in claim 41, wherein the second clearance device is about 8 to about 12 mils.

43. The evacuated energy storage device as recited in claim 36, wherein said plurality of more rigid bumpers is fabricated from at least one of aluminum, metal, alloys, carbon, carbon-carbon composites, and carbon fiber composite materials.

44. The evacuated energy storage device as recited in claim 36, wherein the first stiffness of the one or more flexible dampers is about 500 lb/in to about 4000 lb/in.

45. The evacuated energy storage device as recited in claim 36, wherein the second stiffness of the plurality of more rigid bumpers is about 50,000 lb/in to about 250,000 lb/in.

46. An evacuated energy storage device, said device comprising:

a self-contained bearing assembly system, said system comprising;

a bearing assembly for rotatably supporting and guiding said rotor assembly, the bearing assembly further comprising;

an inner race,

an outer race, and

a rolling element that is rollably disposed and confined between said inner and outer races;

a mounting assembly, the mounting assembly further comprising;

an upper damper grounding plate,

a lower damper grounding plate, and

a circumferential mounting plate;

one or more flexible dampers, wherein an inner periphery of said one or more flexible dampers is in tight interference fit with said outer race of said bearing assembly and an outer periphery of said one or more flexible dampers is securely and removably attached to said circumferential mounting plate; and

a plurality of more rigid bumpers, wherein at least one of said plurality of more rigid bumpers is configured and arranged on said upper damper grounding plate so as to be disposed in proximity of said outer race of said bearing assembly and one or more of said plurality of more rigid bumpers is configured and arranged on said lower damper grounding plate so as to be disposed in proximity of said outer race of said bearing assembly;

a rotor assembly that is rotatably supported and guided by said bearing assembly; and

a stator assembly.

47. The evacuated energy storage device as recited in claim 46, wherein the one or more flexible damper comprises a mesh damper.

48. The evacuated energy storage device as recited in claim 46, wherein the one or more flexible damper comprises an elastomeric damper.

49. The evacuated energy storage device as recited in claim 48, wherein the elastomeric damper is made of silicon rubber.

50. The evacuated energy storage device as recited in claim 46, wherein the plurality of more rigid bumpers are configured and arranged so as to be separated from the outer race of the bearing assembly by a second clearance and elsewhere, the rotor assembly and the stator assembly are configured and arranged so as to be separated by a first clearance to allow relative displacement between said rotor and stator assemblies.

51. The evacuated energy storage device as recited in claim 50, wherein the first clearance is about 13 to about 17 mils.

52. The evacuated energy storage device as recited in claim 51, wherein the first clearance is about 15 mils.

53. The evacuated energy storage device as recited in claim 50, wherein the second clearance is about 8 to about 12 mils.

54. The evacuated energy storage device as recited in claim 53, wherein the second clearance is about 10 mils.

55. The evacuated energy storage device as recited in claim 46, wherein said upper and lower grounding plates and said plurality of more rigid bumpers are fabricated from at least one of aluminum, metal, alloys, carbon, carbon-carbon composites, and carbon fiber composite materials.

56. The evacuated energy storage device as recited in claim 46, wherein said plurality of more rigid bumpers is configured and arranged so as to substantially limit further relative displacement between the rotor and stator assemblies by frictionally engaging the outer race of the bearing assembly after an initial relative displacement equal in magnitude to a second clearance that separates said outer race of said bearing assembly from said plurality of more rigid bumpers.

57. The evacuated energy storage device as recited in claim 56, wherein said second clearance has a magnitude of about 8 to about 12 mils.

58. The evacuated energy storage device as recited in claim 57, wherein second clearance has a magnitude of about 10 mils.

59. The evacuated energy storage device as recited in claim 46, wherein the first stiffness of the one or more flexible dampers is about 500 lb/in to about 4000 lb/in.

60. The evacuated energy storage device as recited in claim 46, wherein the second stiffness of the plurality of more rigid bumpers is about 50,000 lb/in to about 250,000 lb/in.

61. The evacuated energy storage device as recited in claim 46, wherein the self-contained bearing assembly system further comprises a gasket that is fixedly attached to the plurality of more rigid bumpers, wherein said gasket is less rigid than said plurality of more rigid bumpers.