Efficient topology system and method for flywheel rotor

Abstract

The invention relates to the technical field of flywheel rotor structure optimization, in particular to an efficient topological system and method for a flywheel rotor, and the system comprises an energy storage unit which comprises an energy storage module, a suspension module connected with the energy storage module, and an energy conversion module connected with the energy storage module; and the control unit comprises an adjusting module connected with the energy conversion module. The method has the beneficial effects that the geometric structure of the flywheel rotor is designed through topological optimization, the mass energy storage density of a flywheel energy storage system is improved, and the energy storage efficiency is optimized by reducing the mass of the rotor; the design rotating speed is enhanced, the stress distribution is optimized, the material failure risk is reduced, and the instantaneous energy storage and release capability of the system is improved; the load pressure of the magnetic suspension bearing is reduced, the maintenance cost is reduced, and the service life of the system is prolonged; the mechanical stability and safety are improved, and the failure probability is reduced due to more uniform stress distribution; the use efficiency of the materials is improved, and the structural strength is enhanced by reasonably distributing the materials.

Description

Technical Field

[0001] The present invention relates to the technical field of flywheel rotor structure optimization, and particularly to an efficient topology system and method for a flywheel rotor. Background Art

[0002] Flywheel energy storage systems play an important role in modern power systems due to their fast response, long cycle life, and environmental friendliness. The system has been widely used in scenarios such as power grid frequency modulation, energy balance of new energy power generation, UPS uninterruptible power supply, and industrial load regulation, and is an important part of new power systems and energy storage technologies. Flywheel energy storage systems store kinetic energy through the rotation of flywheel rotors and provide bearing or unloading forces for large-mass rotors through magnetic levitation bearings. However, under limited system space and the bearing capacity of magnetic levitation bearings, there are dual challenges in further improving the mass energy storage density and maximum design speed of the system. First, under the constraints of limited system space and the bearing capacity of magnetic levitation bearings, the improvement of the mass energy storage density and maximum design speed of existing flywheel energy storage systems is limited. Second, the rotors in existing flywheel energy storage systems usually adopt a uniform disk design. Although this design has mature technology and simple processes, the uniformity of its structure results in a relatively large rotor mass, increasing the inertial burden of the system and limiting the energy storage density. In addition, this design also increases the bearing pressure on magnetic levitation bearings, requires higher bearing performance, and increases the complexity of system design and maintenance. Moreover, the uniform disk design will cause stress concentration in specific areas of the rotor during high-speed rotation, increasing the risk of failure and limiting the maximum speed of the system. Finally, there are also limitations in material selection in the prior art. Although high-strength steel materials are widely used due to their mature technology and low cost, the limitations of their density and yield strength result in the maximum linear speed of the rotor generally not exceeding 300 - 500 m / s, thus limiting the improvement of energy storage density. In addition, the internal stress of this material is relatively large and the mass is relatively high, making it difficult to meet the more efficient energy storage requirements. Summary of the Invention

[0003] In view of the above or existing problems in the art, the present invention is proposed.

[0004] Therefore, the purpose of the present invention is to provide an efficient topology system and method for a flywheel rotor, which can improve its ultimate speed and energy storage density and reduce the load pressure on magnetic levitation bearings by optimizing the mass distribution of the flywheel rotor.

[0005] To solve the above technical problems, the present invention provides the following technical solution: An efficient topology system for a flywheel rotor, which includes an energy storage unit, including an energy storage module, a suspension module connected to the energy storage module, and an energy conversion module connected to the energy storage module;

[0006] The control unit includes a regulation module connected to the energy conversion module.

[0007] As a preferred embodiment of the high-efficiency topology system of the flywheel rotor of the present invention, wherein: the energy storage module includes a flywheel rotor for storing energy and is the core component for storing kinetic energy.

[0008] As a preferred embodiment of the high-efficiency topology system of the flywheel rotor of the present invention, wherein: the suspension module includes a magnetic suspension bearing for suspending the flywheel rotor to reduce the friction between the existing bearing and the flywheel rotor.

[0009] As a preferred embodiment of the high-efficiency topology system of the flywheel rotor of the present invention, wherein: the energy conversion module includes a generator for bidirectional conversion between kinetic energy and electrical energy.

[0010] As a preferred embodiment of the high-efficiency topology system of the flywheel rotor of the present invention, wherein: the regulation module includes a regulation control program for regulating the designed speed, energy input and output to make the system operate safely and stably.

[0011] To solve the above technical problems, the present invention also provides the following technical solution: a high-efficiency topology method for a flywheel rotor, which includes improving the geometric structure of the flywheel rotor through topology optimization design to increase the energy storage density and designed speed of the flywheel rotor;

[0012] By adjusting the material concentration area and opening holes for weight reduction according to the stress situation, the mass distribution is optimized and the stress concentration is reduced;

[0013] By reducing the mass of the rotor, the bearing pressure of the magnetic suspension bearing is reduced.

[0014] As a preferred embodiment of the high-efficiency topology method for a flywheel rotor of the present invention, wherein: the improvement of the geometric structure of the flywheel rotor refers to creating a hollow structure similar to an automobile wheel hub through topology optimization design to reduce the mass of the wheel body and the von Mises stress.

[0015] As a preferred embodiment of the high-efficiency topology method for a flywheel rotor of the present invention, wherein: adjusting the material concentration area includes concentrating the material in the key stress areas of the rotor and opening holes for weight reduction in the non-key stress areas.

[0016] As a preferred embodiment of the high-efficiency topology method for a flywheel rotor of the present invention, wherein: opening holes for weight reduction includes arranging holes in the low-stress areas of the rotor to reduce unnecessary materials, reduce the mass of the rotor, optimize its mass distribution, reduce the centrifugal force of the system, and thus reduce the stress concentration.

[0017] As a preferred solution of the efficient topology method for the flywheel rotor of the present invention, wherein: reducing the bearing pressure of the magnetic levitation bearing includes reducing the pressure by reducing the mass of the rotor, making the stress distribution more uniform during the high-speed operation of the magnetic levitation bearing, reducing the occurrence probability of stress concentration areas, and ultimately improving the mechanical stability of the rotor.

[0018] Advantages of the present invention: By topologically optimizing the geometric structure of the flywheel rotor, the present invention improves the mass energy storage density of the flywheel energy storage system. By reducing the mass of the rotor, the energy storage efficiency is optimized; the designed rotational speed is enhanced, the stress distribution is optimized, the risk of material failure is reduced, and the instantaneous energy storage and release capabilities of the system are improved; the load pressure on the magnetic levitation bearing is reduced, the maintenance cost is lowered, and the service life of the system is extended; the mechanical stability and safety are improved, and the more uniform stress distribution reduces the failure probability; the material utilization efficiency is improved. By reasonably distributing the materials, redundancy is reduced and the structural strength is enhanced. Description of the Drawings

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings. Among them:

[0020] Figure 1 Schematic diagram of the stress distribution of the flywheel rotor of the efficient topology system for the flywheel rotor.

[0021] Figure 2 Top view schematic diagram of the structure of the flywheel rotor of the efficient topology system for the flywheel rotor.

[0022] Figure 3 The first implementation manner of the efficient topology system for the flywheel rotor.

[0023] Figure 4 The second implementation manner of the efficient topology system for the flywheel rotor. Detailed Implementation Manner

[0024] To make the above objects, features, and advantages of the present invention more obvious and understandable, the following will give a detailed description of the specific implementation manner of the present invention with reference to the drawings in the specification.

[0025] Many specific details are set forth in the following description to facilitate a thorough understanding of the present invention. However, the present invention can also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0026] Second, the "one embodiment" or "embodiment" referred to herein means a specific feature, structure, or characteristic that may be included in at least one implementation manner of the present invention. The "in one embodiment" that appears in different places in this specification does not all refer to the same embodiment, nor is it an embodiment that is separate or selectively exclusive to other embodiments.

[0027] Embodiment 1

[0028] Referring to Figures 1 to 4 , which is the first embodiment of the present invention. This embodiment provides an efficient topology system for the flywheel rotor 101a, which can improve its ultimate rotational speed and energy storage density by optimizing the mass distribution of the flywheel rotor 101a and reduce the load pressure on the magnetic levitation bearing 102a.

[0029] Specifically, the energy storage unit 100 includes an energy storage module 101, a suspension module 102 connected to the energy storage module 101, and an energy conversion module 103 connected to the energy storage module 101;

[0030] The control unit 200 includes an adjustment module 201 connected to the energy conversion module 103.

[0031] It should be noted that the function of the energy storage unit 100 includes storing and releasing energy, and it is mainly applied to primary frequency modulation, secondary frequency modulation of the power system, and UPS uninterruptible power supply, etc.

[0032] Furthermore, the energy storage module 101 includes a flywheel rotor 101a, which is used to store energy and is the core component for storing kinetic energy.

[0033] Furthermore, the suspension module 102 includes a magnetic levitation bearing 102a, which is used to levitate the flywheel rotor 101a and reduce the friction between the existing bearing and the flywheel rotor 101a.

[0034] Furthermore, the energy conversion module 103 includes a generator 103a, which is used for the bidirectional conversion between kinetic energy and electrical energy.

[0035] Furthermore, the adjustment module 201 includes an adjustment control program 201a, which is used to regulate the designed rotational speed, energy input and output to make the system operate safely and stably.

[0036] It should be noted that the adjustment module 201 continuously monitors the state of the flywheel rotor 101a, including rotational speed, temperature, and stress distribution, to ensure the stability and safety of the system.

[0037] The operating principle of the system circuit is as follows: When there is surplus electrical energy in the power grid or the system that needs energy storage, this electrical energy is first transmitted to the generator 103a. The generator 103a converts the electrical energy into kinetic energy, driving the flywheel rotor 101a to rotate. As the electrical energy is input, the rotational speed of the flywheel rotor 101a gradually increases. During the rotation process, the flywheel rotor 101a stores kinetic energy through its geometric structure and material properties. At the same time, the magnetic levitation bearing 102a provides a levitation force for the flywheel rotor 101a, reducing friction and wear during the rotation of the flywheel rotor 101a and improving the energy conversion efficiency. At this time, the adjustment module 201 monitors and adjusts the input power of the generator 103a and the rotational speed of the flywheel rotor 101a to ensure that the flywheel rotor 101a accelerates to the designed rotational speed within a safe operating range. When the flywheel rotor 101a reaches the required energy storage state, that is, the designed rotational speed, the system is in a standby state, ready to release energy when needed.

[0038] When the power grid or the connected system needs additional electrical energy, the flywheel rotor 101a starts to decelerate. The kinetic energy stored in it is converted back into electrical energy through the generator 103a and transmitted back to the power grid or the equipment that needs energy. At this time, the magnetic levitation bearing 102a continues to provide levitation for the flywheel rotor 101a to ensure efficient energy conversion during the energy release process. At the same time, the adjustment module 201 adjusts the deceleration process of the flywheel rotor 101a, manages the energy output, ensures that the output energy matches the demand, and maintains the safe operation of the system.

[0039] In summary, through the topology optimization design of the geometric structure of the flywheel rotor 101a, the present invention improves the mass energy storage density of the flywheel energy storage system, optimizes the energy storage efficiency by reducing the mass of the flywheel rotor 101a; enhances the designed rotational speed, optimizes the stress distribution, reduces the risk of material failure, and improves the instantaneous energy storage and release capacity of the system; reduces the load pressure on the magnetic levitation bearing 102a, reduces the maintenance cost, and extends the service life of the system; improves the mechanical stability and safety, and the more uniform stress distribution reduces the failure probability; improves the material utilization efficiency, reduces redundancy by reasonably distributing materials, and enhances the structural strength.

[0040] Embodiment 2

[0041] This embodiment is the second embodiment of the present invention. This embodiment provides an efficient topology method for the flywheel rotor 101a, which can improve its ultimate rotational speed and energy storage density and reduce the load pressure on the magnetic levitation bearing 102a by optimizing the mass distribution of the flywheel rotor 101a.

[0042] Specifically, through the topology optimization design, the geometric structure of the flywheel rotor 101a is improved to increase the energy storage density and the designed rotational speed of the flywheel rotor 101a;

[0043] By adjusting the material concentration area and opening holes for weight reduction according to the stress situation, the mass distribution is optimized and the stress concentration is reduced;

[0044] By reducing the mass of the flywheel rotor 101a, the bearing pressure on the magnetic levitation bearing 102a is reduced.

[0045] Furthermore, the geometric structure improvement of the flywheel rotor 101a refers to creating a cavity structure similar to an automobile wheel hub through topology optimization design to reduce the wheel body mass and the von Mises stress.

[0046] It should be noted that, as Figure 1 (a) shows, the stress distribution of the flywheel rotor 101a designed with a traditional uniform disk at the krpm level of rotational speed. As Figure 1 (b) shows, the stress distribution of the flywheel rotor 101a after topology optimization of the present invention at the krpm level of rotational speed. Through Figure 1 the comparison of the stress distributions in (a) and (b), it can be seen that the stress distribution of the flywheel rotor 101a is more uniform, the maximum stress is significantly reduced, the mass is greatly reduced, and it shows a greater limiting rotational speed and energy storage density. This design reduces the stress by reducing the centrifugal force, enabling the flywheel rotor 101a to achieve higher safety and efficiency under the same material and rotational speed.

[0047] The von Mises stress is usually used to judge the stress distribution of the flywheel rotor 101a. The von Mises stress is a scalar value used to describe the yield criterion of a material under a multi-axial stress state. It includes three normal stresses (σx, σy, σz) and three shear stresses (τxy, τyz, τzx). These stress components together constitute the stress state inside the material, and its calculation formula is as follows:

[0048]

[0049] Since the von Mises stress provides a single index to measure the stress state inside the material and is used to predict when the material starts to undergo plastic deformation, that is, when the von Mises stress reaches the yield strength of the material, the material will change from the elastic state to the plastic state. Therefore, by calculating the von Mises stress, engineers can determine the weak links of the structure and optimize the design to improve the load-bearing capacity and durability of the structure.

[0050] Furthermore, adjusting the material concentration area includes concentrating the material in the key stress-bearing areas of the flywheel rotor 101a and at the same time opening holes for weight reduction in the non-key stress-bearing areas.

[0051] Furthermore, hole opening and weight reduction includes arranging holes in low stress areas of the flywheel rotor 101a to reduce unnecessary materials, lighten the mass of the flywheel rotor 101a, and optimize its mass distribution to reduce the centrifugal force of the system, thereby reducing stress concentration.

[0052] Furthermore, reducing the bearing pressure of the magnetic bearing 102a includes reducing the pressure by reducing the mass of the flywheel rotor 101a, so that the stress distribution of the magnetic bearing 102a is more uniform when running at high speed, reducing the probability of occurrence of stress concentration areas, and ultimately improving the mechanical stability of the flywheel rotor 101a.

[0053] Specifically, topology optimization is a mathematical method used to improve the performance of a structure by optimizing the material distribution under given load and constraint conditions. In this solution, this method is used to identify areas with less stress inside the flywheel rotor 101a and reduce the use of material in these areas to reduce the mass of the flywheel rotor 101a and optimize its mass distribution.

[0054] During the design process, a stress analysis of the flywheel rotor 101a is first performed to determine the stress distribution inside the flywheel rotor 101a under different working conditions. Through this analysis, it is possible to identify which areas are subject to higher stress and which areas are subject to lower stress. Based on the results of the stress analysis, cavities are designed in areas with lower stress. These cavities are similar to the structure of a car wheel hub and can significantly reduce the mass of the flywheel rotor 101a while maintaining the overall strength of the structure. The design of the cavities not only reduces the mass of the flywheel rotor 101a, but also optimizes the mass distribution, reduces the centrifugal force of the system, and thus reduces stress concentration. Through topological optimization, materials are concentrated in the key stress-bearing areas of the flywheel rotor 101a, which are subject to higher stress when rotating at high speeds. This optimization of material distribution helps to improve the limit speed and energy storage density of the flywheel rotor 101a. Due to the reduction in the mass of the flywheel rotor 101a and the optimization of the stress distribution, the flywheel rotor 101a can reach a higher speed without increasing stress concentration. After reducing the mass of the flywheel rotor 101a, the bearing pressure of the magnetic bearing 102a is also reduced, which helps to improve the stability and life of the energy storage module 101 and reduce maintenance costs. When the preliminary design is completed, it will undergo multiple iterations and verifications to ensure that the final structure meets the strength and stiffness requirements while achieving the optimal mass distribution and performance. After the design is completed, the optimized flywheel rotor 101a prototype is manufactured and actual tests are carried out to verify whether its performance meets the design expectations, including speed, energy storage density, durability and safety.

[0055] The specific process of topology design includes:

[0056] Determine the design space of the flywheel rotor 101a, i.e., the geometric boundaries and shape of the flywheel rotor 101a, and define physical and engineering constraints for the flywheel rotor 101a, such as material properties, maximum mass, maximum size, operating temperature range, stress limits, etc.;

[0057] Create an initial geometric model of the flywheel rotor 101a according to the defined physical and engineering constraints. At the same time, assume material properties and load conditions to provide a starting point for the iterative process;

[0058] Further use finite element analysis software to simulate the initial design, calculate the stress, strain and other key performance indicators under the given load, and analyze the results to evaluate the feasibility and performance of the initial design;

[0059] Further apply topology optimization algorithms, such as evolutionary algorithms, gradient-based methods or level set methods, to optimize the material distribution. Set the goal of the algorithm to maximize the performance index (such as stiffness or strength) while minimizing the mass or cost. According to the results of the algorithm, generate an optimized design, where the material is concentrated in the high-stress areas, and voids or thinning areas are formed in the low-stress areas, and post-process the optimization results to ensure that the generated design is manufacturable and meets all engineering and physical constraints.

[0060] Further perform finite element analysis on the optimized design again to evaluate whether its performance meets the design goals, compare the performance of the new design with that of the previous iteration, and determine whether further optimization is needed. After multiple rounds of iteration and testing, when the design meets all performance requirements and the optimization results are stable, confirm the final design.

[0061] In summary, the present invention optimizes the geometric structure of the flywheel rotor 101a through topology optimization, improves the mass energy storage density of the flywheel energy storage system, optimizes the energy storage efficiency by reducing the mass of the flywheel rotor 101a; enhances the design speed, optimizes the stress distribution, reduces the risk of material failure, and improves the instantaneous energy storage and release capacity of the system; reduces the load pressure on the magnetic levitation bearing 102a, reduces the maintenance cost, and extends the service life of the system; improves the mechanical stability and safety, and the more uniform stress distribution reduces the failure probability; improves the material utilization efficiency, reduces redundancy by reasonably distributing the material, and enhances the structural strength.

[0062] Importantly, it should be noted that the construction and arrangement of the present application shown in multiple different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who refer to this disclosure should easily understand that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter described in this application (such as installation arrangements, use of materials, color, orientation changes, etc.). For example, elements shown as integrally formed may be composed of multiple parts or elements, the positions of the elements may be inverted or otherwise changed, and the nature, number, or position of discrete elements may be altered or changed. Accordingly, all such modifications are intended to be included within the scope of the present invention. The order or sequence of any process or method steps may be changed or reordered according to alternative embodiments. In the claims, any "means-plus-function" clauses are intended to cover the structures that perform the functions described herein, and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the exemplary embodiments without departing from the scope of the present invention. Therefore, the present invention is not limited to a particular embodiment, but extends to various modifications that still fall within the scope of the appended claims.

[0063] In addition, in order to provide a concise description of the exemplary embodiments, all features of the actual embodiments may not be described.

[0064] It should be understood that in the development of any actual implementation, as in any engineering or design project, numerous specific implementation decisions may be made. Such development efforts may be complex and time-consuming, but for those of ordinary skill in the art who benefit from this disclosure, the development efforts will be a routine task of design, manufacture, and production without excessive experimentation.

[0065] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention may be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered within the scope of the claims of the present invention.

Claims

1. An efficient topology system for a flywheel rotor, characterized in that: Comprising, An energy storage unit (100), comprising an energy storage module (101), a suspension module (102) connected to the energy storage module (101), and an energy conversion module (103) connected to the energy storage module (101); A control unit (200), comprising an adjustment module (201) connected to the energy conversion module (103).

2. The high-efficiency topology system of the flywheel rotor (101a) as described in claim 1, characterized in that: The energy storage module (101) includes a flywheel rotor (101a), which is used to store energy and is the core component for storing kinetic energy.

3. The high-efficiency topology system of the flywheel rotor (101a) according to claim 2, characterized in that: The suspension module (102) includes a magnetic levitation bearing (102a), which is used to levitate the flywheel rotor (101a) and reduce the friction between the existing bearing and the flywheel rotor (101a).

4. The high-efficiency topology system of the flywheel rotor (101a) according to claim 3, characterized in that: The energy conversion module (103) includes a generator (103a), which is used for the bidirectional conversion between kinetic energy and electric energy.

5. The high-efficiency topology system of the flywheel rotor (101a) according to any one of claims 1 to 4, characterized in that: The adjustment module (201) includes an adjustment control program (201a), which is used to regulate the designed rotational speed, energy input and output, so that the system operates safely and stably.

6. An efficient topology method for a flywheel rotor (101a), applicable to an efficient topology system of the flywheel rotor (101a), characterized in that: Comprising, Through topology optimization design, improve the geometric structure of the flywheel rotor (101a) to increase the energy storage density and designed rotational speed of the flywheel rotor (101a); By adjusting the material concentration area and opening holes for weight reduction according to the stress situation, realize the optimization of mass distribution and reduce stress concentration; By reducing the mass of the rotor, reduce the bearing pressure of the magnetic levitation bearing (102a).

7. The efficient topology method of the flywheel rotor (101a) as claimed in claim 6, wherein: The improvement of the geometric structure of the flywheel rotor (101a) refers to creating a cavity structure similar to an automobile wheel hub through topology optimization design to reduce the mass of the wheel body and reduce the von Mises stress.

8. The efficient topology method of the flywheel rotor (101a) according to claim 7, characterized in that: The adjustment of the material concentration area includes concentrating the material in the key stress-bearing areas of the rotor, and at the same time opening holes for weight reduction in the non-key stress-bearing areas.

9. The efficient topology method of the flywheel rotor (101a) according to any one of claims 1 to 8, characterized in that: The opening of holes for weight reduction includes arranging holes in the low-stress areas of the rotor to reduce unnecessary materials, reduce the mass of the rotor, optimize its mass distribution, so as to reduce the centrifugal force of the system, thereby reducing stress concentration.

10. The efficient topology method of the flywheel rotor (101a) as described in claim 9, characterized in that: The reduction of the bearing pressure of the magnetic levitation bearing (102a) includes reducing the pressure by reducing the mass of the rotor, making the stress distribution of the magnetic levitation bearing (102a) more uniform during high-speed operation, reducing the occurrence probability of the stress concentration area, and finally improving the mechanical stability of the rotor.

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