Flywheel energy storage (FES) works by spinning a rotor (flywheel) 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. While some systems use low mass/high speed rotors, other use very massive rotors (e.g., 200 tonnes) and correspondingly much lower rotational speeds, referred to as grid-scale flywheel energy storage. Other designs employ high-speed rotors that operate at tens of thousands of revolutions per minute.
Most FES systems use electricity to accelerate and decelerate the flywheel, but devices that directly use mechanical energy are being developed.Torotrak Toroidal variable drive CVT , retrieved June 7, 2007.
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. 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.
Main components
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.
To reduce friction, magnetic bearings are sometimes used instead of mechanical bearings.
Possible future use of superconducting bearings The expense of refrigeration led to the early dismissal of low-temperature superconductors for use in magnetic bearings. However, high-temperature superconductor (HTSC) bearings may be economical and could possibly extend the time energy could be stored economically. Hybrid bearing systems are most likely to see use first. High-temperature superconductor bearings have historically had problems providing the lifting forces necessary for the larger designs but can easily provide a stabilizing force. Therefore, in hybrid bearings, permanent magnets support the load and high-temperature superconductors are used to stabilize it. The reason superconductors can work well stabilizing the load is because they are perfect diamagnets. If the rotor tries to drift off-center, a restoring force due to flux pinning restores it. This is known as the magnetic stiffness of the bearing. Rotational axis vibration can occur due to low stiffness and damping, which are inherent problems of superconducting magnets, preventing the use of completely superconducting magnetic bearings for flywheel applications.
Since flux pinning is an important factor for providing the stabilizing and lifting force, the HTSC can be made much more easily for flywheel energy storage 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.
Physical characteristics
General Compared with other ways to store electricity, FES systems have long lifetimes (lasting decades with little or no maintenance; full-cycle lifetimes quoted for flywheels range from in excess of 105, up to 107, cycles of use), high specific energy (100–130 W·h/kg, or 360–500 kJ/kg), and large maximum power output. The energy efficiency (ratio of energy out per energy in) of flywheels, also known as round-trip efficiency, can be as high as 90%. Typical capacities range from 3 kWh to 133 kWh. Rapid charging of a system occurs in less than 15 minutes. The high specific energies often cited with flywheels can be a little misleading as commercial systems built have much lower specific energy, for example 11 W·h/kg, or 40 kJ/kg.rosseta Technik GmbH, Flywheel Energy Storage Model T4, retrieved February 4, 2010.
Form of energy storage
| Moment of inertia: || |- | Angular velocity: || |- | Stored rotational energy: || |} Here is the integral of the flywheel's mass, and is the rotational speed (number of revolutions per second).
Specific energy 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
where is kinetic energy of the rotor [J], is the rotor's mass [kg], is the rotor's geometric shape factor [dimensionless], is the tensile strength of the material [Pa], is the material's density [kg/m3].
Geometry (shape factor) The highest possible value for the shape factor of a flywheel rotor, is , which can be achieved only by the theoretical constant-stress disc geometry. A constant-thickness disc geometry has a shape factor of , while for a rod of constant thickness the value is . A thin cylinder has a shape factor of . For most flywheels with a shaft, the shape factor is below or about . A shaft-less design has a shape factor similar to a constant-thickness disc (), which enables a doubled energy density.
Material properties 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.
Rotor materials Several modern flywheel rotors are made from composite materials. Examples include the carbon-fiber composite flywheel from Beacon Power Corporation and the PowerThru flywheel from Phillips Service Industries. Alternatively, Calnetix utilizes aerospace-grade high-performance steel in their flywheel construction.
For these rotors, the relationship between material properties, geometry and energy density can be expressed by using a weighed-average approach.
Tensile strength and failure modes 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.
Energy storage efficiency Flywheel energy storage systems using mechanical bearings can lose 20% to 50% of their energy in two hours.rosseta Technik GmbH, Flywheel Energy Storage, German, retrieved February 4, 2010. 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.
Conversely, flywheels with magnetic bearings and high vacuum can maintain 97% mechanical efficiency, and 85% round trip efficiency.Beacon Power Corp, Frequency Regulation and Flywheels fact sheet, retrieved July 11, 2011.
Effects of angular momentum in vehicles 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.Study on Rollover prevention of heavy-duty vehicles by using flywheel energy storage systems, Suda Yoshihiro, Huh Junhoi, Aki Masahiko, Shihpin Lin, Ryoichi Takahata, Naomasa Mukaide, Proceedings of the FISITA 2012 World Automotive Congress, Lecture Notes in Electrical Engineering Volume 197, 2013, pp 693-701, doi:10.1007/978-3-642-33805-2 57
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.
Full-motion gimbals 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.