This is related to U.S. Provisional Application No. 60/316,559 filed on Aug. 30, 2001 and entitled “Axially Free Flywheel System”.

This invention pertains to a flywheel energy storage system and more particularly to a flywheel system having a flywheel supported by a combination of an axial magnetic bearing and compliant radial rolling element mechanical bearings, with the flywheel being mechanically unrestrained in the axial direction. The unrestrained axial support allows for Poisson Effect contraction and thermal expansions during operation and simultaneously greatly extends the mechanical bearing life by reducing or eliminating axial loading. The radial compliance in the mechanical bearing support permits high-speed supercritical operation and reduced radial bearing loads.

BACKGROUND OF THE INVENTION

Flywheel power supplies have emerged as an alternative to electrochemical batteries for storing energy, with many advantages including higher reliability, longer life, lower or no maintenance, higher power capability and environmental friendliness. Flywheel power supplies store energy in a rotating flywheel that is supported by a low friction bearing system inside a chamber. The chamber is usually evacuated to reduce losses from aerodynamic drag. A motor/generator accelerates the flywheel for storing energy, and decelerates the flywheel for retrieving energy. Power electronics maintain the flow of energy in and out of the system and can instantaneously prevent power interruptions, or alternatively can manage peak loads.

One way to support a flywheel for rotation at high speeds is with rolling element mechanical bearings such as ball bearings. The life of mechanical bearings is strongly influenced by the loads that these bearings must carry. To extend the life of flywheel systems using mechanical bearings, a magnetic bearing can effectively be used in combination with the mechanical bearings for the purpose of reducing the load on the mechanical bearings. In this arrangement, the flywheel typically rotates about a vertical axis and the mechanical bearings provide radial support while the magnetic bearing carries much of the flywheel's weight axially. One such flywheel energy storage system is shown in FIG.

1

. The flywheel system

30

includes a steel flywheel

31

that rotates inside an evacuated vessel

32

. The interior of the vessel

32

is a chamber

41

maintained at a vacuum for reduction of aerodynamic drag. The flywheel

31

, in this design, has an integrated motor/generator

33

that accelerates and decelerates the flywheel through cooperation with the outer diameter of the flywheel

31

. The motor/generator

33

includes an outer laminated stator portion

34

, motor/generator coils

42

, stator flux return path

35

and a field coil

36

for operation. The flywheel

31

is supported for rotation on upper and lower rolling element mechanical bearings

37

and

39

. These bearings

37

,

39

are mounted in fixed upper and lower mounts

38

and

40

. Load on the bearings

37

,

39

is reduced through the use of an axial magnetic bearing

43

, shown as an annular electromagnet with electromagnetic coil

44

. The magnetic bearing

43

supports a majority of the weight of the flywheel

31

while allowing some desired amount of loading on the bearings

37

,

39

. The electromagnet is controlled either by using strain gauges, not shown, on the support structure that sense and control the bearing loading through use of a closed loop controller, or simply by use of a constant current power supply.

Unfortunately, this configuration of mechanical and magnetic bearing system is not optimal for allowing rotation to very high-speeds for efficiently storing large amounts of energy. There are several drawbacks. The rigid radial support provided by the mechanical bearings would cause the rigid body critical speeds to be encountered at a relatively high speed if the flywheel were operated to high speeds. Encountering these resonances at a high speed would impart severe loading on the bearings that would reduce their life and potentially be dangerous. Operation at high speeds, but below the rigid body critical speeds, causes high bearing loading from any flywheel imbalances because the flywheel is being forced to spin about a geometric center rather than the mass center.

Another major problem with operating a flywheel system to high speeds is that the loads on the bearings can significantly increase due to dimensional changes in the flywheel. The effect of high speed rotation is illustrated in FIG.

2

. The dimensions of a flywheel

50

are shown at

52

for zero speed and at

51

for high speed rotation. The effect of the centrifugal stress is that the outer diameter expectedly grows by a radial increment

53

from the radial and hoop stresses. This growth does not change the bearing loading. The secondary result from this growth is that the flywheel shrinks by an axial increment

54

from Poisson ratio contraction. For axially thick flywheels, the shrinkage can be as much as 0.050 inches. Such a large length change will not only drastically load the mechanical bearings against each other but can also cause them to fail before achieving full speed. The flywheel can also expand and contract axially from temperature changes in the flywheel or surrounding structure. Heating from high power motor/generators is one potential cause for added bearing loads.

The increased bearing loading drastically affects the life of mechanical bearings. Bearing life is generally a cubic function of the load, so that a doubling of the load will decrease the life by a factor of eight. Further compounding the shortening of life from the increased axial loading is that for angular contact bearings, axial loading can be as much as 35 times more fatiguing to the bearing than an equivalent size radial load. This sensitivity varies based on the contact angle, number of balls, ball diameter and the axial thrust load applied.

Besides problems of axial bearing loading that occurs between the bearings during operation, use of a mechanical strain gauges to measure axial loading at a single bearing is not as sensitive as desirable for removing almost the entire bearing axial load, especially if the flywheel support structure is rigid. Likewise, applying a constant current to the coil cannot provide sufficiently accurate axial load removal for maximum reliable operating life.

The construction of flywheel systems that support a flywheel with mechanical bearings can also suffer significant damage from shipping and handling. The system shown in

FIG. 1

has no power during shipping and hence the ball bearings must carry the full flywheel weight. The strain gage and load cell can become damaged and plastically deformed from impact loadings, especially if they were designed to be sensitive enough to maintain very low axial bearing loading. The bearings of this as well as other design systems could be easily damaged from impact loads such as simply setting the system down during transportation handling. The force generated from an impact can be several times the weight of the flywheel and can cause the balls to Brinnell indent the bearing races or cause the bearings to shift in position.

SUMMARY OF THE INVENTION

This invention provides a flywheel energy storage system that allows high-speed operation with use of mechanical rolling element bearings for flywheel support. The mechanical bearings provide radial support for a vertical axis flywheel but they allow it to be mechanically free or unrestrained in the axial direction. One or more magnetic bearings are used to carry the flywheel weight axially. The axial unconstraint by the mechanical bearings allows the flywheel to freely grow or shrink in axial length from Poisson Effect contraction that occurs when rotating to very high speeds and stress levels as well as from thermal expansions from motor/generator heating or other sources. Excessive axial loads applied from the bearings on each other are thereby prevented. The axial mechanical freedom also insures that the magnetic bearing carries all of the flywheel weight, thus dramatically extending the mechanical bearing lives. The life of rolling element bearings is generally a cubic function of the applied loads and axial loading on commonly used angular contact bearings is many times more fatiguing to the bearings than radially applied loads. Eliminating the axial loading from the flywheel greatly extends the bearing lives. Tandem multiple preloaded angular contact bearings can be used for the mechanical bearings. These bearing sets share the loads between several bearings, extending life, and are manufactured with the desirable minimum axial preload for longest term reliable operation. The axial preload is accurately built-in and does not change as the flywheel is rotated. Alternatively, the bearings can each be single bearing pairs that are preloaded using springs with a stiffness that is lower than the magnetic bearing. Therefore, the bearings maintain their near designed preload despite the axial position of the flywheel from the magnetic bearing support or changes in the flywheel dimensions.

The axial magnetic bearings can use permanent magnets, attached to the flywheel, that are arranged to be in vertical repulsion with stationary cooperating permanent magnets. This provides a completely passive axial magnetic bearing system. In another embodiment of the invention, the axial magnetic bearing uses an actively controlled electromagnetic coil. The coil is controlled using either flywheel axial acceleration or, more preferably, a position sensor. The coil can be used in a simple electromagnet or in a permanent magnet biased thrust actuator for higher lift force and/or lower power consumption. The use of an active magnetic bearing does not require magnets on the flywheel and has the potential for higher speed rotation. It also can be lower in cost, and not suffer from any demagnetization effects.

The high speed capability of flywheels in accordance with the invention is further facilitated by using radially compliant elements mechanically in series with the mechanical bearings. Providing for a lower radial stiffness allows the flywheel to traverse its rigid body resonance at a low speed. Above that speed, the flywheel spins about its mass center instead of the geometric center and radial loading on the bearing becomes much lower. The power loss from rotation can also be reduced. The flywheel can then smoothly and easily operate to higher speeds. Balance requirements for the flywheel can be significantly reduced, reducing costs and extending mechanical bearing life. In one embodiment, the radial support allows the flywheel to traverse its cylindrical rigid body critical resonance at a speed that is less than 25% of the normal fully charged operation speed.

The use of the radially compliant elements or springs with the mechanical bearings also has the effect of helping the flywheel to rotate stably while having axially free sliding connections to the bearings. Although not completely free, due to friction, the flywheel is essentially mechanically unrestrained by the mechanical bearings, so that it can move axially. Use of sliding joints where energy can be lost from frictional damping in the rotating object is well known in the field of high speed machinery to potentially cause problems with nonsynchronous rotordynamic whirl and is usually avoided. However, rotor whirl can be avoided if the foundation stiffness is made sufficiently low for the mass of the rotating object. In this case, the radially compliant elements or springs that allow the flywheel to spin above the rigid body resonance also help keep the system stable with the reduced stiffness.

In one aspect of the invention, the radially compliant elements are placed between the mechanical bearings and the flywheel such that they rotate with the flywheel. The result is that above the rigid body resonance, the radial springs simply deflect and the flywheel rotates about its mass center Because the springs rotate with the flywheel, the springs do not cycle with each revolution. The life of the springs in the flywheel systems are thus increased for longer-term reliable operation. The radially compliant element can be a radial spring such as a tolerance ring or alternatively a quill shaft.

In another embodiment, the radial springs do not rotate with the flywheel but have a fatigue life of greater than 5 billion cycles of radial deflection equal to the radial distance between the mass center and the geometric center of said flywheel. This provides for at least 1 year of continual rotation at 10,000 rpm. An even higher cycle life such as ten to twenty times higher is even more preferable to preferably last the life of the system. Besides reducing the rigid body resonances, the low radial stiffness can potentially allow the flywheel to spin smoothly through other vibration modes that may exist depending on the system construction.

The invention also makes the flywheel system significantly less prone to damage during shipping, handling and installation. The axially unrestrained condition of the flywheel in the mechanical bearings prevents the flywheel from axially impact loading the bearings with the weight of the flywheel when the system is set down. The radial compliant elements in series with the mechanical bearings prevent damage from radial impact loading. The result of the invention is a much more robust flywheel system employing mechanical bearings, a system that accounts for the axial flywheel dimension changes, a system that can rotate to higher speeds for storing more energy and a system that maximizes the life of the mechanical bearings by elimination of axial loading from the flywheel simultaneously with greatly reduced radial loading.

The invention provides for greatly increased mechanical bearing life of the flywheel system. To extend the bearing life even further, the flywheel can be designed to operate with a slower rotational speed, reducing the bearing fatigue cycles incurred. In one aspect of the invention, the flywheel is constructed primarily from steel instead of composite materials to provide a lower operating speed. The flywheel can also preferably be constructed with an increased diameter so its normal fill speed operation is at less than 25 krpm. Implementing a motor/generator that has an air core armature can also further reduce bearing loads. The air core armature provides high efficiency while reducing or eliminating non-circumferential force generation during operation. dr

DESCRIPTION OF THE DRAWINGS

The invention and its many attendant advantages will become more clear upon reading the following description of the preferred embodiments in conjunction with the following drawings, wherein:

FIG. 1

is a schematic elevation of a prior art flywheel energy storage system with a mechanical and magnetic bearing system;

FIG. 2

is a sectional elevation of a solid cylindrical flywheel illustrating the dimensional effects on the flywheel when rotated to high speed;

FIG. 3

is a schematic elevation of a flywheel energy storage system in accordance with the invention;

FIG. 4

is a schematic elevation of another configuration of flywheel energy storage system in accordance with the invention;

FIG. 5

is a bar chart comparing the mechanical bearing life versus flywheel diameter for use with the invention;

FIG. 6

is a schematic elevation of another flywheel energy storage system in accordance with the: invention;

FIG. 7

is a schematic elevation of another flywheel energy storage system in accordance with the invention;

FIG. 8

is a schematic drawing of another flywheel energy storage system in accordance with the invention;

FIG. 9

is a schematic elevation of another flywheel energy storage system in accordance with the invention;

FIG. 10

is a schematic elevation of another flywheel energy storage system in accordance with the invention;

FIG. 11

is a schematic elevation of another flywheel energy storage system in accordance with the invention; and

FIG. 12

is a schematic elevation of another flywheel energy storage system in accordance with the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Turning to the drawings, wherein like reference characters designate identical or corresponding parts,: and more particularly to

FIG. 3

thereof, a flywheel energy storage system

60

in accordance with the invention is shown having a flywheel

61

supported for rotation about a substantially vertical axis of rotation inside a sealed container

62

. The inside of the container

62

is a chamber

63

preferably maintained at a vacuum or other low-drag atmosphere for reduction of aerodynamic drag. In systems where drag is less of a concern, the low drag atmosphere can be a small molecule gas such as helium instead of a vacuum, with the result of potentially lower costs but higher drag loss.

The flywheel

61

is radially supported with upper and lower mechanical bearing supports

64

and

68

engaging upper and lower flywheel shafts

67

and

71

. The bearing supports

64

,

68

use rolling element bearings

65

and

69

to allow low loss rotation. The bearings can be individual ball bearing sets or tandem multiple preloaded angular contact bearing sets to share the radial loading and insure adequate and accurate preload for long term operation, as shown. The bearings preferably use the minimum preloading amount, which is a function of the bearing size. Ceramic hybrid bearing sets, ceramic balls in metal or steel races, are preferred for highest speed and longest life operation. They can be lubricated with grease, oil or more preferably a dry lubricant such as molybdenum disulfide to prevent contamination of the vacuum in the chamber

63

. The rolling element bearings

65

,

69

are mechanically in series with radial compliant elements

66

,

70

for reducing the radial stiffness of the bearing supports

64

,

68

. In this configuration, the compliant elements, which can be radial springs, are located between the mechanical bearing sets

65

,

69

and the support housings

72

,

73

and thus are stationary. The radial compliant elements are preferably constructed from metal for long life in vacuum, and for high thermal conductivity. They can be made from numerous constructions including metal mesh, or tolerance rings such as those sold by USA Tolerance Rings Inc.

The weight of the flywheel is borne axially by upper and lower magnetic bearings

74

and

75

. The upper and lower flywheel shafts

67

and

71

slide axially freely (with some friction) inside the rolling element bearings

65

,

69

such that the mechanical bearings do not carry appreciable axial loading from the flywheel. Some very small loading is transferred to the bearings from axial friction with the flywheel shafts

67

,

71

, however this amount would be negligible compared to the weight due to the sliding interface. Because the axial loading is removed from the mechanical bearings, their lives can be greatly extended. The life of rolling element bearings is generally a cubic function of the applied loading such that a reduction of the bearing loads by half results in an increase in life by a factor of eight. Further adding to the benefits of axial load elimination of the invention is that axial loads are typically many times more fatiguing to common angular contact bearings than radial loads. In some cases, depending on the bearing size and configuration, axial loads can be as much as

35

times more fatiguing to the bearing than an equivalent value radial load.

In the flywheel system shown in

FIG. 3

, the magnetic bearings

74

,

75

are passive. They have permanent ring magnets

76

and

79

, or an annular array of magnets, attached to or rotating with the flywheel

61

, arranged in axial repulsion with stationary ring magnets

78

and

80

in close axial proximity. The magnetic bearings can be employed at either the top or bottom of the flywheel, or at both ends. As shown, the top magnetic bearing

74

includes a thrust disk

77

attached to and rotating with the top flywheel shaft

67

for attachment of the rotating ring magnet

76

. Because high power magnets such as NdFeB are mechanically weak in tensile strength, difficulty may be encountered in reinforcing the magnets for rotation to high speed, especially if the flywheel is very heavy and requires ring magnets of very large diameter and surface area to generate sufficient axial force. The magnet ring attached to the flywheel may be an annular array made from an assembly of individual magnet pieces around the circumference. The use of pieces prevents development of excessive hoop stresses that could otherwise cause the magnet to fail mechanically. Gaps between magnet pieces that develop when rotated to high speed are very small and thus are not magnetically problematic.

Magnets with axial magnetization are generally easier to manufacture and are lower in cost than radially magnetized magnets. Several designs of axial repulsion magnetic bearings can be constructed and used with the invention The magnetic bearings generate axial repulsive forces between the flywheel and the rest of the system. They can also generate some radial destabilizing forces that tend to push the flywheel radially off center and radially load the bearings. Care should be taken in the exact system design (magnet dimensions) to insure that these forces remain small for the entire allowable radial deflection of the upper and lower bearing supports

64

,

68

.

The mechanical rolling element bearings

65

and

69

provide radial support for the flywheel while the magnetic bearings carry the axial weight of the flywheel. The connection between the flywheel shafts and the mechanical bearings is unconstrained axially such that thelmagnetic bearings essentially carry all of the flywheel weight. This greatly extends the lives of the mechanical bearings by eliminating detrimental axial loading. The sliding connection also serves a second significant purpose by preventing dimensional changes in the flywheel from adding loading to the mechanical bearings. As a flywheel is rotated to very high speeds and stress levels, the outer diameter grows radailly. However, the large radial and hoop direction stresses cause the flywheel to shrink axially due to Poission Ratio contradiction of the flywheel material. If the bearings were rigidly connected to the flywheel, excessive bearing loading and possible bearing failure could result. The amount of contraction depends on the axial thickness of the flywheel and the operating stress levels, however contractions on the order of 0.050 inches are possible. The axial loading from dimensional changes can also result from temperature changes in the flywheel from motor/generator heating and or from temperature changes to the surrounding flywheel container.

The radial bearings are in series with compliant elements

66

and

70

such that the upper and lower radial support each have a low stiffness. The low radial stifffness allows the flywheel to operate above the rigid body resonance at a relatively low speed. Above the resonance, the flywheel spins about its mass center instead of geometric center and thus radial loads are significantly reduced, extending the bearing life. Having the transition through the resonance at low speed, such as less than 1000 rpm for some high speed systems, prevents encountering the resonance at a high speed which would cause extreme bearing loading and can possibly fail the bearings. Operating supercritically can also lower the bearing drag. In one embodiment, the radial support preferably allows the flywheel to traverse its cylindrical rigid body critical resonance at a speed that is less than 25% of the normal fully charged operation speed. Because the radial compliant elements are stationery, they are cycled as the flywheel rotates due to the offset between the mass center and geometric center of the flywheel. This distance is typically small at less than a few thousandths of an inch, especially for a balanced flywheel. In one embodiment of the invention, radial springs have a fatigue life of greater than 5-75 billion cycles of radial deflection equal to the radial distance between the mass center and the geometric center of said flywheel. This allows the flywheel system to last 1-15 years while rotating at 10 krpm. A longer fatigue life is preferable and can be attained by careful design and manufacturing. Small radial spring deflections resulting from a smaller offset between the mass center and geometric center of the flywheel, and from radial spring design improvements, can result in significantly longer fatigue lives. A thin metal spring or metal mesh that does not undergo significant bending stress can accomplish this.

The lower radial stiffness from the compliant elements also facilitates stable rotation to high speed. Sliding joints on rotating objects, which can dissipate energy through friction, are thought to be best avoided in rotating machinery design as they can lead to nonsynchronous rotordynamic whirl problems. However, rotor whirl is a function of the foundation flexibility. The lower radial stiffness imparted from having radial compliant elements in series with the bearings also helps the stability of the flywheel system despite having sliding connections.

During shipping, handling and installation of the flywheel system, the invention is much more robust and resistant to damage than prior art flywheel systems that use mechanical bearings. The axial unrestrained connection between the flywheel and mechanical bearings prevents impact damage to the bearings from the weight of the flywheel, especially when the system is set down hard. The radial compliant elements in series with the mechanical bearings also prevent damage from radial impact loading. The passive axial magnetic thrust bearings increase in repulsive force as the axial gap between ring magnets decreases, and will prevent contact in most shipping situations. In the event that the unit is dropped during shipment, the end of the shaft can be designed to contact the bottom of the housing or an impact absorbing bumper before the magnets make contact, to prevent damage to the magnets.

In operation, the flywheel

61

is accelerated and decelerated for storing and retrieving energy through an attached motor/generator

81

. Many designs of motors and generators exist and could be used with the invention. The motor/generator is preferably a brushless design for long life. The motor/generator

81

shown is a brushless permanent magnet synchronous motor/generator type. The motor/generator

81

uses magnets

82

attached to the lower flywheel shaft

71

. The magnets

82

cooperate with a surrounding laminated stator

83

for electrical/mechanical energy conversion.

Another flywheel system

90

, shown in

FIG. 4

, includes a flywheel

91

mounted on radial bearings

94

and

98

, and an axial magnetic bearing

102

for rotation about a vertical axis inside a container

92

having an evacuated internal chamber

93

. The flywheel is accelerated using a motor/generator

109

using magnets

110

attached to the flywheel shaft

108

that magnetically interact with a surrounding stator

111

to accelerate the flywheel

91

to store energy, and decelerate the flywheel to recover energy. The flywheel

91

is radially supported by the upper and lower mechanical bearing supports

94

and

98

. The bearing supports

94

,

98

use preloaded tandem pair angular contact bearings

95

,

99

. Radial compliant elements

97

and

101

may be used in tandem with the bearings

95

and

99

such that the compliant elements rotate with the flywheel

91

. The result of having the compliant elements rotate with the bearings is that, above the rigid body resonance speed, they do not continue to be cycled and just simply deflect to a stable deflected position to allow rotation about the mass center. This provides a much longer life for the compliant elements. If the compliant elements

97

,

101

are low cost tolerance rings, the rings may be selected to minimize the axial friction between the flywheel shafts

107

,

108

and the tolerance rings to reduce the potential for any axial loading from the flywheel

91

being transferred to the bearings

95

,

99

. However, some friction is required to overcome the drag torque in rotating the mechanical rolling element bearings. Placing the radial compliant elements such that they make up the sliding connection provides the benefit of rotational friction in the axial unrestraint.

The magnetic bearing

102

for axial levitation of the flywheel

91

uses an electromagnetic coil

104

to provide stable axial levitation. The coil in this case is part of a simple stationary electromagnet

103

located at the top of the flywheel

91

. The flywheel

91

is constructed of steel and thus the electromagnet

103

exerts an upward force on the flywheel

91

. Control for the coil power is provided by an controller (not shown) using feedback from an axial sensor

106

that senses the flywheel axial acceleration or more preferably simply the flywheel axial position. Other magnetic bearing control schemes using the electromagnetic coil

104

for also sensing the flywheel position are known and could alternatively be employed.

Because attractive magnetic bearings inherently generate unstable tilting moments that would tend to tilt the flywheel, the electromagnet

103

and the axial end of the flywheel

105

can be curved step-wise to reduced generation of such moments. A tilting moment exerted on the flywheel

91

by the magnetic bearing would cause extra radial loading on the radial mechanical bearings

95

,

99

and thus would be undesirable. The use of an active magnetic bearing as shown in this configuration can reduce costs by not requiring permanent magnets although the costs of a control system is required, and it can potentially allow higher rotational speeds by not having rotating magnet loading. The life of rolling element bearings, such as ball bearings, is greatly influenced by the loads that the bearings must carry. Larger bearings can carry larger loads, however they can be rotated only at lower speeds. They also have inherently higher losses, which may or may not be problematic depending on the application and system design. The stress and hence material utilization of the material in a flywheel is related to the square of the peripheral speed and not the rotational speed. Because it is desirable to most effectively utilize a flywheel and also to have the longest bearing life, it is preferable to have a high peripheral speed with a low rotational speed. This is made possible by using flywheels that have a large diameter. It is further facilitated by using metal or steel flywheels that have lower tip speed capabilities than composite material flywheels. A comparison of mechanical bearing life versus flywheel diameter for solid steel flywheels used with the invention is shown in FIG.

5

. All of the flywheels are operating with the same stress level and tip speed, 500 m/sec. All bearings are subject to 40 lbs radial loading and zero added axial loading using tandem preloaded angular contact bearing pairs all preloaded with the minimum axial preloads. The bearings are ceramic hybrids using dry lubricant. As shown, an 8 inch diameter flywheel rotates at 47 krpm, a 16 inch diameter flywheel rotates at 23.5 krpm and a 24 inch diameter flywheel rotates at 15.7 krpm. The bearing life for a slower rotating flywheel is longer than for a faster rotating flywheel due to a lower number of cycles per interval of time as expected. This is a linear relationship. However, a secondary effect has also been found to take effect. The slower rotational speed of a larger flywheel also allows a larger bearing set to be used. The larger bearing for the same radial load dramatically increases the life of the mechanical bearing as shown. An L

1

life corresponds to 99% survival rate of the bearings for that loading and life. The life of the 24 inch diameter bearing is shown to be a smaller increment higher than the 16 inch diameter flywheel as compared to the difference between the 16 inch and 8 inch flywheels. This is because the 16 inch and 24 inch flywheels are both shown using the same size bearings and the extended life is merely the result of the slower rotational speed. Other effects such as maintaining bearing lubrication must also be considered in the bearing life and other types of bearings and lubrication methods can be applied. However, larger diameter and steel flywheels can dramatically increase the mechanical bearing life with the invention. In another embodiment of the invention a flywheel constructed of steel is used with diameter greater than length for longer mechanical bearing life. Preferably, the flywheel rotates at 25 krpm or less in normal operation. Solid steel disks allow maximum energy storage by having equivalent radial and hoop stresses, however steel ring flywheels rotate with even lower tip speeds and could also be employed with the invention.

Another flywheel system

110

, shown in

FIG. 6

, has a steel flywheel

111

with diameter greater than length, used for storing energy. The flywheel

111

rotates about a substantially vertical axis inside a container

112

having an internal evacuated chamber

113

. The flywheel is accelerated and decelerated using a brushless motor/generator

128

, in this case, of the reluctance type. The flywheel shaft

115

contains a radial gear rotor

129

that cooperates with a surrounding stator

130

to form the motor/generator

128

. A separate motor and generator could also be employed. The flywheel

111

is radially supported using upper and lower ball bearing sets

116

and

117

. Series connected radially compliant elements

118

and

119

are attached between the inner race of the bearings

116

,

117

and the flywheel shafts

114

and

115

such that they rotate with the flywheel

111

. In this case, another aspect of the invention is also illustrated. The axial unrestrained connection between the flywheel

111

and mechanical bearings

116

,

117

is provided not through sliding connections but through low axial stiffness springs which in this case are also the radial compliant elements

118

and

119

. A magnetic bearing

122

carries the axial weight of the flywheel, and illustrates yet a further aspect of the invention. The magnetic bearing

122

is a permanent magnet biased thrust bearing having an electromagnetic coil

125

for axial force generation and is controlled using a position sensor

127

. A thrust disk

126

attached to the upper flywheel shaft

114

provides a target for axial force generation. A steel yoke

123

provides a path for the flux from the electromagnetic coil

125

, and permanent magnets

124

amplify the force. The benefits of using permanent magnet bias include higher lifting force capability and lower power consumption as well as more linearized response.

Another flywheel energy storage system

140

, illustrated in

FIG. 7

, uses a steel disk flywheel

141

that rotates inside a container

142

having an internal chamber

143

maintained at a vacuum The flywheel is accelerated and decelerated using a brushless motor/generator

162

having permanent magnets

163

attached to an upper shaft

144

and cooperating with a surrounding fixed stator

164

for energy conversion. The flywheel

141

is radially supported using upper and lower bearing supports

146

and

150

. The bearing supports use tandem preloaded angular contact bearing pair sets

147

and

151

for rotation. Radially compliant elements

149

and

153

reduce the radial stiffness. Liner tubes

165

and

166

can be used to allow free axial sliding between the flywheel shafts

144

,

145

and the compliant elements

149

,

153

.

In this configuration, the magnetic bearing uses a permanent magnetic bearing

154

to carry the weight of the flywheel

141

. The permanent magnetic bearing

154

drives flux through the flywheel

141

and returns through a yoke

157

to be magnetically efficient. A lower magnetic bearing

155

, which is active, controls the flywheel axial position. The active magnetic bearing

155

uses an electromagnetic coil

160

and steel poles

159

to provide a downward force that balances the force from the upper magnetic bearing

154

. A position sensor

167

provides feedback and an upper axial stop

166

prevents damage to the sensor when the system

140

is inoperative. The magnetic bearings in this configuration illustrate another aspect of the invention. The magnetic bearings

154

,

155

provide radial centering stiffness or support as well as axial support. As explained previously, axial magnetic bearings tend to generate unstable tilting moments that try to tilt the flywheel. However in this case, the magnetic bearings

154

,

155

generate some stable radial centering stiffness along with the axial force and unstable tilting moments. The radial centering stiffness of the upper magnetic bearing

154

works against the unstable tilt moment from the lower magnetic bearing and vice-versa. The passive radial centering stiffnesses are the result of putting annular grooves

158

and

161

in the faces of the flywheel

141

. The annular poles

157

,

159

and a ring magnet

156

tend to line up radially with the rotor poles created by the grooves

158

,

161

and hence generate a positive radial stiffness. Other designs of passive radial magnetic bearings exist and could also be used. The passive radial stiffness reduces radial mechanical bearing loads that would otherwise result from the tilting moments of the upper and lower magnetic bearings

154

,

155

. They can also reduce loads imparted from external sources that would be carried by the mechanical bearings

154

,

155

. However, the mechanical rolling element bearings

146

,

150

primarily carry the radial loading. Sources of radial loading include system tilt, earthquakes, unbalance, etc.

Another flywheel energy storage system

170

, shown in

FIG. 8

, has a steel flywheel

171

with diameter greater than length. The flywheel

171

rotates inside an evacuated chamber

173

within a container

172

. In this configuration, the flywheel is supported by upper and lower mechanical bearing supports

174

and

175

having mechanical bearing sets

176

and

179

with outer races that rotate with the flywheel

171

. The mechanical bearings

176

,

179

are attached to the flywheel

171

through the radial compliant elements

177

and

180

that also rotate with the flywheel. Upper and lower shafts

178

and

181

are stationary. The axial position of the flywheel

171

is maintained by upper and lower active magnetic bearings

182

and

185

. The magnetic bearings use annular electromagnetic coils

184

and

187

along with yokes

183

and

186

to generate axial force, and an axial position sensor

188

provides feedback. During shipping and handling, the active electromagnetic bearings

182

,

185

would not be operable. The flywheel bearing

179

could rest on a stop, not shown, on the shaft

181

or alternatively the flywheel could be mechanically axially supported, not through the lower bearing

179

, to prevent damage. The flywheel

171

could be made to rest on the lower shaft

181

or yoke

186

. Passive axial permanent magnet repulsion bearings on the other hand provide the benefit of axial support and free rotation without the use of power. A motor/generator

189

uses a laminated stator ring

190

, motor/generator coils

193

, a flux return ring

191

and an annular field coil

192

to provide energy conversion and voltage regulation.

The invention is applicable not only for flywheel systems employing steel flywheels, but could also be used with higher speed composite flywheels, as shown in

FIG. 9

, wherein another flywheel energy storage system

200

is shown having a high speed composite flywheel

201

that rotates inside an evacuated chamber

203

within a container

202

. The composite flywheel

201

is made of a hoop wound glass fiber/epoxy ring

204

inside a hoop wound carbon fiber/epoxy ring

205

. Other configurations of composite flywheels could also be used with the invention. The flywheel is attached to a central tube

207

by a high elongation hub

206

that allows the flywheel

201

to grow radially with speed. Upper and lower mechanical bearing supports

209

and

212

support the flywheel radially. The supports include rolling element bearings

210

and

213

attached to radial compliant elements

211

and

214

for reduced radial stiffness. The mechanical bearings

210

,

213

rotate about a stationary central shaft

208

. The axial weight of the flywheel is supported by a combination of active and passive magnetic bearings

216

and

226

. The active magnetic bearing

216

provides control through use of an electromagnetic coil

218

and yoke

217

that act upon a ferromagnetic target

219

attached to the hub

206

. A position sensor

220

provides feedback. A passive magnetic bearing

226

using a permanent magnet ring

215

that acts on the central tube

207

reduces the force requirements of the active magnetic bearing

216

but cannot lift the entire weight of the flywheel

201

.

The rolling element bearings in this configuration illustrate another aspect of the invention. Because the axial loading is essentially eliminated from the mechanical bearings, the mechanical bearings

210

,

213

can be roller bearings. Roller bearings offer even higher radial load capability and life for a given radial load. They are also available in ceramic hybrid form for maximum speed capability.

The motor/generator

221

illustrates another aspect of the invention by using an air core design to reduce the radial destabilizing forces generated. The motor/generator

221

uses permanent magnets

223

on the bore of an outer tube

222

to create a radial magnetic field in cooperation with the central tube

207

. Air core stator coils

224

attached to a support

225

provide for power conversion. Other designs or air core motor/generators could also be used. Likewise, an axial gap motor/generator could also be used to prevent generation of radial motor/generator destabilizing forces that would add to the radial loads carried by the mechanical bearings.

Another flywheel energy storage system

230

in accordance with the invention, shown in

FIG. 10

, has a steel disk flywheel

231

supported for rotation about a vertical axis in an evacuated chamber

233

inside a container

232

to reduce aerodynamic drag. The flywheel

23

1

is supported radially by upper and lower rolling element bearings

234

,

235

. An axial magnetic bearing

244

supports the weight of the flywheel

231

by using a rotating permanent ring magnet

245

or annular array of magnets that axially repels a stationery permanent ring magnet

246

. The radial support for the flywheel

231

uses tandem preloaded angular contact bearing pairs

236

,

239

that are mounted to the container

232

. The radial compliant elements or springs in this configuration comprise upper and lower quill shafts

238

,

241

. The quill shafts

238

,

241

are connected to inner ends of shafts

237

,

240

that are radially supported in the bearings

236

,

239

, but are axially unrestrained and can slide inside the bearings

236

,

239

. To prevent potentially excessive radial displacement, limit tubes

242

,

243

are provided. The limit tubes

242

,

243

limit displacement by contacting the bearings or the housing.

The axial unrestraint by the radial support

234

,

235

along with the use of a permanent magnet repulsive bearing

244

is that the temperature effects do not effect the loads or life of the bearings

236

,

239

. Permanent magnets have a temperature coefficient whereby they tend to have reduced flux density with elevated temperature. The repulsive axial magnetic bearing

244

results in a levitation height that changes with temperature and the mechanical bearings are unaffected due to the unrestraint or free sliding connection.

The flywheel

231

is accelerated and decelerated using an attached motor/generator

247

. The motor/generator

247

uses an air core armature

250

, which reduces or eliminates generation of destabilizing forces that must be carried by bearings

234

,

235

,

244

. The motor/generator

247

uses a steel disk

247

′ having an annular array of multiple circumferentially spaced protrusions

248

around the circumference that act as poles and form an air gap

249

, in which the air core armature

250

is supported by a support tube

252

. A concentric annular field coil

251

, supported on in inner circumference of the air core armature

249

, generates flux that travels in a flux path through the flywheel

231

and steel disc

247

′, is focused into axial rays by the protrusions

248

, and jumps the air gap

249

through the air core armature

250

, inducing an alternating current in the air core armature

250

as the flywheel

231

rotates. The field coil

251

provides a simple and effective method for power regulation. Raising or lowering the current to the field coil

251

for a given speed of the flywheel

231

can control the back emf of the motor/generator

247

.

Another flywheel energy storage system

290

, shown in

FIG. 11

, includes a flywheel

291

having multiple piece construction, and supported for rotation about a vertical axis in an evacuated chamber

253

inside a sealed container

292

. The flywheel

291

is constructed from two steel rotor portions

254

,

255

that are connected together by a stainless steel magnetic insulator

256

. The rotor portions

254

,

255

have multiple, circumferentially spaced protrusions

273

,

274

around the outer circumference that face an armature airgap

275

that is created between the two rotor portions

254

,

255

. An annular air core armature

276

is located in the armature air gap

275

. Field coils

277

,

278

generate flux that travels in a flux path

281

to and from the flywheel

291

through steel poles

279

,

280

, across the air gap

275

and through the air core armature

276

. The flux induces alternating current voltage in the armature

276

as the flywheel

251

rotates. Wires

282

for the armature

275

and the field coils

277

,

278

exit the sealed container

292

through a vacuum tight feedthrough

285

and connect to power electronics

283

and a power buss

284

. The vacuum in the chamber

253

is maintained by a vacuum connection

286

to an external vacuum pump

287

.

The flywheel

291

is supported radially by upper and lower mechanical bearings

257

,

258

and an axial magnetic bearing

269

supports the weight of the flywheel

291

. The axial magnetic bearing

269

uses rotating permanent magnets

270

that axially repel stationery permanent magnets

271

. The radial supports

257

,

258

comprise single rolling element mechanical bearing sets

259

,

264

that are attached to stationery mounts

261

,

265

. Radially compliant elements or tolerance rings

260

,

266

connect the bearings

259

,

264

to the flywheel shafts

263

,

268

and allow for axial sliding. Because rolling element bearings typically require some small amount of preload to prevent ball skidding and bearing damage, axial springs

262

,

267

provide axial preload against the flywheel

291

and essentially against each other. To maintain proper preload despite changes in the potential axial position of the flywheel, the preload springs

262

,

267

preferably have a lower stiffness than the axial magnetic bearing

269

. The stiffness is preferably much lower so that axial displacement of the flywheel

291

from temperature changes to the magnetic bearing

269

do not change the bearing preload by more than a pound or so. Typical required preloads can be as low as 5 pounds for bearings that radially support a flywheel weighing several hundred pounds, but they vary depending on the many factors of the system design. Other arrangements of preload springs and bearing locations could also be utilized in accordance with the invention. For instance, the preload springs could be mounted stationery and the mechanical bearings could be made to slide axially in the stationery mounts. The benefit of using single bearing pairs is reduced costs and lower drag losses, however they provide lower radial load capacity.

Another flywheel energy storage system

300

, shown in

FIG. 12

, has a steel flywheel rim

301

that rotates in an evacuated chamber

303

inside a sealed container

302

. The flywheel rim

301

is comprised of two rim pieces

304

,

305

that are assembled to create an armature airgap

308

. The rim

301

has an annular array of multiple circumferentially spaced protrusions

307

that face the armature air gap

308

and form poles of a motor/generator

309

. A field coil

310

generates flux that travels in a flux path

312

through the rim pieces and across the air gap

308

, inducing alternating current voltage in an air core armature

311

located in the armature air gap

308

, as the flywheel

301

rotates. Wires

325

from the motor/generator

309

exit the container

302

through a sealed connection

326

. A field controller

327

controls the current to the field coil

310

to control the induced voltage in the armature

311

. A rectifier

328

rectifies power from the armature

311

to a DC buss

330

when generating power and an inverter

329

produces synchronous alternating current to drive the motor/generator

309

as a motor for storing energy.

The rim

301

is connected to a central tube

313

through the use of a hub

306

. The flywheel

301

is supported radially by upper and lower mechanical bearings

314

,

315

, and the weight of the flywheel

301

is supported by an axial magnetic bearing

322

. The flywheel

301

rotates about a stationery central shaft

318

. Single ball bearing sets

316

,

319

slide on the central shaft

318

and connect to the central tube

313

through radial springs

317

,

320

. The bearings

316

,

319

are axially preloaded by a single central spring

321

on the center shaft

318

.

A vacuum pumping port

311

allows for pulling of an initial vacuum

303

and for sealing the container

302

. An internal getter pump

332

maintains the vacuum

303

for the life of the flywheel system

300

.

Obviously, numerous modifications and variations of the preferred embodiment described above are possible and will become apparent to those skilled in the art in light of this specification. Different attributes of all of the different disclosed configurations can be interchanged and are not intended to be exclusive for use with the other elements and attributes of a particular system configuration. Many functions and advantages are described for the disclosed preferred embodiments, but in many uses of the invention, not all of these functions and advantages would be needed. Therefore, I contemplate the use of the invention using alternate or fewer than the complete set of noted components, features, benefits, functions and advantages. Moreover, several species and embodiments of the invention are disclosed herein, but not all are specifically claimed, although it is intended that all be covered by generic claims. Therefore, it is my intention that each and every one of these species and embodiments, and the equivalents thereof, be encompassed and protected within the scope of the following claims, and no dedication to the public is intended by virtue of the lack of claims specific to any individual species.