messib-electrical energy storage using flywheels-website
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Electrical energy storage using flywheels
A new lightweight and high strength orthotropic composite wheel for FW system in buildings with
improved kinetically storage capabilities and electrical performance
The objective was to design and build a kinetic energy storage device for use in office buildings,
homes, residences and other buildings, where could be used, with the aim of better management of
energy produced and consumed.
Flywheels are well suited for short time storage (seconds to minutes) and high number of load-
unload cycles. In this regard there are several clear objectives to achieve:
Bioclimatic buildings that have their own renewable power generation systems,
available storage capacity of the energy generated when it is not consumed in order
to take advantage, and also to provide the energy needed when there is not
sufficient power generated.
Figure 1: Energy storage and management
The implementation of this technology for renewable energy allows energy management more
efficient and consume fewer resources. Currently, large amounts of resources are wasting by not
being able to store unused energy at production time.
The current barrier when applied to buildings is to achieve an enough amount of energy and safety
risk.
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The composite rotor allows higher speed and enable the storage of greater amounts of energy
(50.000rpm 2,5MJ 100Kw), in comparison with other materials. An important consideration is
that fibre reinforced composite rotors fail in a less destructive manner than metallic rotors, and is
thus intrinsically safer.
Employing active magnetic bearings allows the reduction of losses and noise and a more efficient
control at high speeds. In the same objective, integrates the vacuum generating system.
The mechanical design has been revised and focused on obtaining an efficient machine but from the
perspective of an economic and safety product.
The bidirectional AC/DC converter and the STS (static transfer switch), are integrated to process and
control the energy flows so as to optimize the energy consumption.
Activities within the MESSIB project:
Development of a composite flywheel.
Development of flywheel with magnetic bearings and high vacuum.
Development of a power conversion architecture
Integration, additional elements and laboratory test
Manufacturing techniques for adaptable solutions for buildings and districts
Achievements and progress during the MESSIB project:
Definition of specifications and calculations for flywheel solution
Design and manufacturing development for the flywheel and converter solution
Setup and fine tune for standard and limit work conditions:
Adjustment of levitation system (current loops, position, thermal, ...)
Rotodynamic conditions adjustment
System tested in industrial environment.
High power and short time cycles flattened
The most important milestones of the design and manufacture of flywheel:
The various figures below show the most important milestones of the design and manufacture offlywheel. The designs and manufacturing processes have been carefully analyzed and defined in
order to achieve a prototype machine with industrial specifications and tuning has been done
considering working conditions for maximum performance and safety critical conditions.
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Wheel
Fiber IM7 and resin 8552
Interior diameter 204mm,
exterior diameter 314mm,
fiber volume 55%, and fiber
angle 80.
Figure 2: Wheel grinding and polished process
Figure 3: Campbell diagram natural frequency
versus Rotationial frequency
Mechanical design and manufacture
Resistant structural
calculation
Rotodynamic calculations
Union fiber wheel and
preloaded titanium hub
Figure 4: Shaft and wheel tight-fitting process
0 1 2 3 4 5 6 7 8 9 10
x 104
0
200
400
600
800
1000
1200
1400
1600
1800
Spinning Speed [RPM]
NarutalFrequency[Hz]
External Diameter 314[mm]/Length 225[mm]
External Diameter 264.6[mm]/Length 310[mm]
Spinning Speed
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Figure 5: Top magnetic bearing configuration
Levitation & control
Upper and lower radial
bearings
1 axial bearing
High resolution position
sensors
Dedicated electronic control
(DSP+FPGA+NETBURNER)
Figure 6: Radial bearingmagnetic simulation
Figure 7: Real time control board
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Converter
Commutation module
(MCm);
Frequency variation device
(MCD)
Smart bidirectional converter
AC/DC (F&B Gen)
Figure 8: Bidirectional converter
Main Result: COMPLETE FLYWHEEL SYSTEM
TheMESSIB flywheel storage system is a fully integrated line interactive system that uses a flywheel
to store mechanical energy in a rotating mass. When utility power is interrupted, the ESF (Energy
Storage Flywheel) will convert the mechanical energy stored in the flywheel into electrical energy.
Kinetic energy storage energy suits well for applications with high power, low energy and high
number of load-unload cycles. Said energy is supplied to the external load until one of the following
conditions
occurs:
The standby generator assumes the load
The utility power is available again
The flywheel runs out of energy
The ESF can be used in a wide range of commercial power applications and provides voltage
regulation, protection and well regulated power to cover critical loads, sags, surges or outages.
Figure x: Line regulation
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Configuration
The mechanical design has been optimized towards a safe product, yet efficient and cost-effective. The following picture shows the current machine configuration.
Figure 9: Flywheel configuration Figure 10: Flywheel connection
System features
High reliability
Harmonic cancellation
Transient protection
High-speed voltage protection
Power factor improvement
Remote control & monitoring
Low maintenance
Specifications Energy: 2.5 MJ Power: 100kW Rotational speed: 50,000 rpm Voltage interface: 240 a.c . 3 ph, 400V dc Working temp: -20C - 50C Storage temp: -20C - 80C Rotor: CFRP with titanium hub Active magnetic bearings. Axial bearing only
counteracts gravity 10-2 mbar
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Technology
The solution integrates various technologies developed byTekniker
Active magnetic bearings Real time control electronics Power amplifiers High-reliability position sensors CFRP Rotors and wheels
Energy management
The system presents several operation modes which allow that the ESF automatically functions to
supply AC electrical power to the critical load. The ESF continually monitors itself and the incoming
utility power, and automatically switches between these modes as-requested, with no interventionfrom an operator. The detection and switching logic inside the ESF ensures that changes in the
operation mode are automatic and transparent to the critical load. The figures that follow hereunder
identify the main components in the systems and the location of the Input, Output and Converter
nodes.
Figure 11: Block diagram of a working configuration
Paralleling power stages
In order to handle high power capabilities and because the cost of developing large items raises
production costs appreciably, is more efficient and easier to control the use of flywheel battery
configurations.
The figure shows a typical configuration of a flywheels battery used in powerline quality
improvement.
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Figure 12: Flywheel battery configuration
Renewable energy management
The implementation of this technology for renewable energy storage permits a more efficient energy
management and ensures the consumption of fewer resources. At present, large amounts of
resources are being wasted due to the inability of existing systems to store unused energy during
production.
(see Figure 1)
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Figure 13: Wheel surface grinding
Figure 14: Electrical connection
Figure 15: Vacuum power connectors
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Figure 16: Wheel surface coating
Figure 17: Insertion of the wheel intohousing
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Figure 18: Flywheel connection
Figure 19: Axial bearing development
Figure 18: Tekniker bunker facilities:
general view
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Figure 19: Tekniker bunker facilities:
Top loading area
Figure 20: Tekniker bunker facilities:
Closing system of the upper cover
Figure 21: Tekniker bunker facilities:
Closing system of the upper cover
Figure 22: Tekniker bunker facilities:
Access area
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Figure 23: Tekniker bunker facilities:
Internal view
Figure 24: Wheel grinding
Figure 25: Shaft and hub tight-fitting
process
Figure 26: Initial setup
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Figure 27: Winding process
Figure 28: Winding process