Flywheel magnetic lift and bearing system

Abstract

A system may include a large flywheel including a rotatable large mass member and one or more shafts coupled with the rotatable large mass member. A system may include a magnetic lift component having one or more magnets positioned about the central aperture, the one or more shafts passing through the central aperture in the magnetic lift component, the one or more magnets pulling the large flywheel toward the magnetic lift component. A system may include a support structure coupled with the magnetic lift member, the support structure holding the magnetic lift member in a rest position relative to the support structure. A system may include one or more bearings coupled with the support structure and the one or more shafts to hold the one or more shafts on the rotational axis.

Description

Background Technology

[0001] This disclosure relates to mechanical energy storage units. Embodiments relate to flywheel-based mechanical energy storage units.

[0002] Currently, residential electricity users and power companies utilize various energy storage sources to offset fluctuating electricity production and usage, such as the duck curve associated with solar or other renewable energy production. As renewable energy becomes increasingly prevalent, fluctuations in electricity production and usage are further exacerbated. These issues impose significant costs and other problems on utilities, causing power outages and other disruptions.

[0003] Typically, excess or backup power is stored in chemical storage devices, such as large chemical batteries. Unfortunately, chemical batteries have many problems that make them unsuitable for both residential and utility applications. For example, chemical batteries can be very expensive, structurally complex, and require extensive fire safety measures. They are also environmentally unfriendly because their production processes use toxic chemicals, generate significant amounts of greenhouse gases, and result in substantial material waste. Furthermore, chemical batteries have a short lifespan, as they have a limited lifespan and a limited number of charge-discharge cycles before needing to be disposed of.

[0004] Traditional mechanical energy storage solutions are too complex, too bulky to be implemented at the residential level, cannot meet the scalability requirements of power companies, or face other problems. Summary of the Invention

[0005] In some aspects, the technology described herein relates to a system comprising: a large flywheel including a rotatable mass component and one or more shafts coupled to the rotatable mass component; a magnetic lifting component having one or more magnets positioned around a central through-hole, the one or more shafts passing through the central through-hole in the magnetic lifting component, the one or more magnets pulling the large flywheel toward the magnetic lifting component; a support structure coupled to the magnetic lifting component, the support structure holding the magnetic lifting component in a stationary position relative to the support structure; and one or more bearings coupled to the support structure and the one or more shafts to hold the one or more shafts on a rotation axis.

[0006] In some respects, the technology described herein relates to a system in which the rotatable mass component includes: a top plate having a flat top surface that rotates about the axis of rotation, the flat top surface being positioned adjacent to one or more magnets of the magnetic lifting component, the top plate being attracted by the one or more magnets to reduce the downward force of the large flywheel acting on the one or more bearings.

[0007] In some respects, the technology described herein relates to a system in which the rotatable mass component comprises: a top plate; a plurality of stacked mass plates; and a bottom plate located between the top plate and the bottom plate.

[0008] In some respects, the technology described herein relates to a system in which a top plate and a bottom plate are coupled together by a plurality of fasteners, and the top plate and the bottom plate apply compressive forces to the plurality of large mass plates.

[0009] In some respects, the technology described herein relates to a system in which one or more shafts located on the axis of rotation include a top shaft and a bottom shaft, the top shaft being separate from the bottom shaft, the top shaft passing through the central perforation of the magnetic lifting member.

[0010] In some respects, the technology described herein relates to a system in which the one or more bearings comprise: one or more top bearings and one or more bottom bearings, the one or more top bearings interacting with the top of the large flywheel at the one or more shafts, and the one or more bottom bearings interacting with the bottom of the rotatable large mass component at the one or more shafts.

[0011] In some respects, the technology described herein relates to a system in which one or more magnets are configured to pull the large flywheel with a force greater than the weight of the large flywheel.

[0012] In some respects, the technology described herein relates to a system that further includes: one or more seals that form an airtight seal between the interior and exterior of a flywheel housing, the support structure including the flywheel housing, the large flywheel being located inside the flywheel housing.

[0013] In some respects, the technology described herein relates to a system in which the support structure includes a cover, a rotatable mass component is located within the support structure, one or more magnets are coupled to the bottom surface of the cover, and the one or more magnets are located within the support structure.

[0014] In some respects, the technology described herein relates to a system in which the support structure includes a sealed housing; a vacuum assembly coupled to the housing to establish an internal vacuum; and one or more magnets located within the internal vacuum.

[0015] In some respects, the technology described herein relates to a system in which the magnetic lifting component includes: a backing ring coupled to the support structure; one or more magnets disposed on the backing ring; and a magnet retainer surrounding the one or more magnets and coupled to the backing ring.

[0016] In some respects, the technology described herein relates to a system that further includes: a magnetic coupler having a first rotor and a second rotor, the first rotor including a first set of magnets and the second rotor including a second set of magnets, the first set of magnets and the second set of magnets interacting to cause the first rotor to be rotatably coupled to the second rotor.

[0017] In some respects, the technology described herein relates to a system in which a first rotor is located within at least a portion of a second rotor, the first rotor is coupled to one or more shafts, and the second rotor is coupled to a motor.

[0018] In some aspects, the technology described herein relates to a mechanical energy storage unit comprising: a large flywheel including a rotatable mass component and one or more shafts coupled to the rotatable mass component, the rotatable mass component including: a top clamping plate; a plurality of mass plates; a bottom clamping plate located between the top clamping plate and the bottom clamping plate; and a plurality of fasteners coupling the top clamping plate to the bottom clamping plate and applying compressive force to the plurality of mass plates; and a magnetic lifting component having one or more magnets positioned around a central perforation, the one or more... A shaft passes through the central perforation in the magnetic lifting component, and one or more magnets pull the large flywheel toward the magnetic lifting component. A top clamping plate is positioned adjacent to the one or more magnets of the magnetic lifting component. A support structure is coupled to the magnetic lifting component and holds the magnetic lifting component in a stationary position relative to the support structure. One or more bearings are coupled to the support structure and the one or more shafts to maintain the one or more shafts on the axis of rotation. The top clamping plate is attracted to the one or more magnets to reduce the downward force of the large flywheel on the one or more bearings.

[0019] In some respects, the technology described herein relates to a mechanical energy storage unit in which one or more magnets are configured to pull the large flywheel with a force greater than the weight of the large flywheel.

[0020] In some respects, the technology described herein relates to a mechanical energy storage unit, wherein the support structure includes a cover, a rotatable mass component is located within the support structure, and a magnetic lifting component is coupled to the cover.

[0021] In some respects, the technology described herein relates to a mechanical energy storage unit, wherein the magnetic lifting component includes: a backing ring coupled to the support structure; one or more magnets disposed on the backing ring; and a magnet holder surrounding the one or more magnets and coupled to the backing ring.

[0022] In some aspects, the technology described herein relates to an assembly for a flywheel, comprising: a magnetic lifting member having one or more magnets positioned around a central perforation, one or more shafts of the flywheel passing through the central perforation in the magnetic lifting member, the one or more magnets pulling the flywheel toward the magnetic lifting member, the magnetic lifting member being held by a support structure, wherein the magnetic lifting member includes: a backing ring coupled to the support structure; the one or more magnets disposed on the backing ring; and a magnet retainer coupled to the backing ring and providing support for the one or more magnets.

[0023] In some respects, the technology described herein relates to a component in which one or more magnets are configured to pull the flywheel with a force greater than the weight of the flywheel.

[0024] In some respects, the technology described herein relates to a component in which: the support structure includes a housing having a cover, the flywheel being located within the housing; one or more magnets are coupled to the bottom surface of the cover; and the one or more magnets are located within the housing.

[0025] Other embodiments of one or more of these aspects, or other aspects, include corresponding systems, apparatuses, and computer programs configured to perform various actions related to these aspects and / or store various data related to these aspects. These and other implementations, such as various data structures for controlling mechanical energy storage units, may be encoded on a physical computer storage device. In some cases, as discussed throughout this disclosure, these and various other embodiments may include numerous additional features. It should be understood that the language used in this disclosure has been chosen primarily for readability and edibility purposes and is not intended to limit the scope of the subject matter disclosed herein. Attached Figure Description

[0026] This disclosure is illustrated in the accompanying drawings by way of example rather than limitation, wherein the same reference numerals are used to refer to similar elements.

[0027] Figure 1A An exemplary mechanical energy storage unit or flywheel assembly is shown.

[0028] Figure 1B An exemplary cross-sectional view of the flywheel assembly is shown.

[0029] Figure 1C An exemplary flywheel assembly is shown.

[0030] Figure 1D An exemplary flywheel assembly is shown with the cover and other components omitted to show an exemplary flywheel inside the housing.

[0031] Figure 2A A side top view of an exemplary flywheel is shown.

[0032] Figure 2B A cross-sectional view of an exemplary flywheel is shown.

[0033] Figure 2C and 2D A side top view of an exemplary flywheel is shown.

[0034] Figure 3A An exemplary flywheel support structure is shown, including top and bottom clamping plates.

[0035] Figure 3B An exemplary clamping plate is shown.

[0036] Figure 3C An exemplary stacked board is shown.

[0037] Figure 3D An exemplary flywheel shaft is shown.

[0038] Figure 4A , 4B Views of an exemplary flywheel assembly are shown in Figures 4 and 4C, with various components omitted for illustrative purposes.

[0039] Figure 4D An exemplary housing cover with various components attached is shown.

[0040] Figure 5A A cross-sectional view of an exemplary upper shaft disposed within the upper bearing assembly is shown.

[0041] Figure 5B A cross-sectional view of an exemplary lower shaft disposed within the lower bearing assembly is shown.

[0042] Figure 5C An exemplary flywheel is shown, which is coupled to a portion of a magnetic lifting component.

[0043] Figure 6A An exemplary upper bearing, magnetic motor coupler, and magnetic lifting component are shown.

[0044] Figure 6B A top view of an exemplary magnetic lifting component is shown.

[0045] Figure 6C A bottom view of an exemplary magnetic lifting component is shown.

[0046] Figure 6D A bottom view of the internal components of an exemplary magnetic lifting member is shown.

[0047] Figure 6E A top perspective view of an exemplary magnetic lifting component is shown.

[0048] Figure 7A An exemplary magnetic coupler is shown.

[0049] Figure 7B An exemplary magnetic coupler is shown, with the bottom of the outer rotor and other components removed. Detailed Implementation

[0050] This specification includes several improvements to prior solutions, such as those described in the background section. This document describes a mechanical energy storage unit, its components, and assembly fixtures. Some aspects of this technology include components that reduce the vertical forces exerted on the bearings by a large flywheel, such as an improved magnetic lifting system. Other aspects include bearings, magnetic couplers, clamping plates, and / or other systems that can further improve the mechanical energy storage unit.

[0051] In some implementations, one or two mechanical energy storage units 102 may be installed at the residence to provide backup power during power outages, store electrical energy generated using the residence's solar panels, or offset fluctuations in electricity production and use (e.g., the power company may control the mechanical energy storage unit 102 at the residence to regulate the energy use / production balance of the residence, neighboring residences, or the entire power grid). The mechanical energy storage unit 102 may be buried next to a distribution box, placed in a shed outside the residence, installed in a garage or equipment room, or stored off-site.

[0052] In some implementations, multiple mechanical energy storage units 102 can be combined to expand the backup energy capacity of large facilities such as enterprises or power companies. For example, a power company may install, bury, or otherwise utilize multiple mechanical energy storage units 102 within its facilities. The multiple mechanical energy storage units 102 may be communicatively interconnected or connected to a central server to control the storage and distribution of stored energy (e.g., by controlling the rotation frequency of each flywheel 202 to maintain an efficient rotational speed).

[0053] This document describes various implementations and features of a flywheel energy storage system (FESS). Compared to existing energy storage units, including other flywheels 202, this disclosure proposes several improvements. For example, the technology described herein provides numerous improvements, features, and advantages, including improved flywheel systems or components, improved bearings, improved flywheel-motor couplers, improved flywheel housings, improved flywheel plates, improved assembly fixtures, and assembly and usage methods, etc.

[0054] For example, flywheel 202 may include a rotatable mass component, which may comprise multiple stacked plates 122, cylinders, or other components, and is equipped with one or more bolts or clamping plates 120, one or more shaft 208 members, and other features. For example, the technology described herein includes multiple plates whose profile edges are designed according to the associated support structure, thereby increasing rotational speed while reducing failure modes. For example, the support structure may include clamping plates 120 that apply pressure to the stacked plates 122, thereby generating friction between the plates to hold them in position and transferring rotational momentum between these plates and one or more shafts 208. In some embodiments, two clamping plates 120 may be clamped together by bolts or other fasteners, thereby applying pressure to the mass plates (e.g., in the axial direction), which may be referred to herein as stacked plates 122. The two clamping plates 120 also increase the friction between the stacked plates 122, which in some cases allows the stacked plates 122 to be used without additional fasteners, thereby improving safety and efficiency. Other features and advantages of flywheel 202 will be described below. Not only has the plate been improved, but its support structure has also been improved, in addition to other advantages. More implementation methods and features allow for the expansion, positioning, and use of the flywheel 202, thereby further enhancing its performance.

[0055] Among other improvements, the technology described herein also includes an improved support structure (e.g., housing 104) and support system, which may include a sealed housing 104, a covered vacuum assembly 108, a magnetic coupler 118, multiple bearings, and a positioning mechanism. Housing 104 may include a magnetic lifting aid 152 that fully or partially supports the weight of the flywheel 202 (e.g., to reduce bearing wear). Housing 104 may also include a transport surface and a lifting and adjustment mechanism that moves the flywheel 202 within housing 104 from a transport or storage location and adjusts it to a working position. Housing 104 may provide support for various components, such as a supercapacitor 106, a vacuum assembly, a processor / controller / central processing unit, a motor 110, and other components. Housing 104 may include features such as maintaining a vacuum, accommodating one or more bearings, positioning the flywheel 202 during use or transport, mitigating damage from structural failures, and isolating vibrations.

[0056] Other advantages and features are described throughout this disclosure; however, it should be noted that other features and advantages are also within the scope of consideration. Furthermore, although various embodiments are described with reference to the accompanying drawings, these are provided by way of example only, and their features may be extended, modified, or deleted. For example, features described with reference to some embodiments may be added to or combined with other embodiments.

[0057] Referring to the accompanying drawings, reference numerals may be used to refer to components appearing in any of the drawings, regardless of whether the reference numeral is shown in the described drawing. Furthermore, when reference numerals include letters pointing to one of a plurality of similar components (e.g., components 000a, 000b, and 000n), reference numerals without letters may be used to refer to one or all of the similar components. It should also be noted that while various exemplary features and embodiments are described in this disclosure and the accompanying drawings, these examples do not exhaustively cover all possible embodiments, features, or permutations. For example, while a feature may be described with reference to a first embodiment, that feature may also be used in conjunction with a second embodiment, or features, operations, etc., may be interchanged between different embodiments.

[0058] The innovative technologies disclosed in this paper also have the following novel advantages: they can integrate modern technology with traditional power infrastructure; support a rapid transition to renewable energy; utilize the power grid as a backup power source; enable local power storage in nodes and regionalized node storage clusters; isolate and minimize the impact of power outages (whether caused by natural disasters, infrastructure failures, or other factors); provide an economical alternative to expensive and environmentally unfriendly electrochemical batteries; give consumers the autonomy to move away from carbon-based energy; and decentralize power production.

[0059] Figure 1A-1B An example mechanical-energy storage unit 102 (MESU 102) or flywheel assembly 102 is shown from different angles and views. For example, Figure 1A Showing a front top view, Figure 1B A cross-sectional view is shown. Figure 1C This shows a front top view of another example, MESU 102 or flywheel assembly 102. Figure 1D The front top view is shown after removing the housing cover 128 to show the flywheel 202 in the flywheel housing 104 inside the example MESU 102 component.

[0060] The improved flywheel assembly 102 can be a mechanical energy storage unit 102, whose configuration and features improve manufacturability while providing redundancy, safety, and reliability, enabling the flywheel assembly 102 to provide years of safe and relatively maintenance-free operation in a manner previously unattainable (as described, for example, in the background art and other parts of this document). Although various configurations may exist and are envisioned, the illustrated example flywheel assembly 102 may include: a vacuum housing 104 and a support structure, a large rotating flywheel 202 inside the housing 104 ( Figure 1AThe components include (not visible in the center), an electric generator 110 that may be fully or partially located outside the housing 104 and coupled to the flywheel 202, a supercapacitor 106, a driver and / or CPU, an inverter, a circuit breaker, a magnetic lifting member 152 (also referred to herein as a magnetic lifting component or mechanism), bearings, a physical or magnetic coupler 118, a vacuum pump 108, and various other components as described below, although other embodiments may exist and are contemplated herein.

[0061] The housing 104 is an example of a support structure that supports the various components of the flywheel assembly 102. Although the illustrated housing 104 is a completely enclosed structure, in some embodiments, the housing or other support structure may be open, such as cage-like, frame-like, or other configurations.

[0062] Example flywheel assembly 102 may include (but is not limited to): a sealable housing 104 for providing a vacuum, and a flywheel 202 ( Figure 1A The flywheel assembly includes (but is not visible in the text) supports, mounting structures for various components, and protection against mechanical failures. An example housing 104 for the flywheel 202 can be configured as a vacuum assembly housing with reinforced structures, including features for coupling the flywheel 202 to the housing, an improved shape, and the ability to adjust the flywheel 202 through the housing. In some instances, the housing may also include connections for generating and / or maintaining a vacuum. Example embodiments and features of the housing 104 may be described elsewhere herein, although other embodiments are possible and contemplated.

[0063] The flywheel housing 104 may be mounted and / or isolated from the mounting structure via one or more feet 114 or legs (described below), and may include mounting structures for accommodating various components of the flywheel assembly. For example, a supercapacitor 106 may be mounted to or attached to a support structure of the housing 104, and the supercapacitor 106 may buffer energy entering or leaving the flywheel 202, for example, by accelerating the rotation of the flywheel 202 via an auxiliary motor 110 or by receiving energy from it.

[0064] Furthermore, as described below, housing 104 may provide mounting points or structures (e.g., mounting bracket 132) for mounting the electric generator 110 along the rotational axis of flywheel 202. However, in other embodiments, gears may be used to couple the electric generator 110 to the flywheel 202. The electric generator 110 may be coupled to the flywheel 202 via one or more shaft 208 components. In some instances, the flywheel shaft 208 is physically decoupled from the rotor of the electric generator 110 by a magnetic coupler 118 while still transmitting force. However, physical coupling may also be used, as described below. The electric generator 110 may be electrically connected to a supercapacitor 106, inverter, driver, CPU, external power grid connection, etc., so that current flows into the electric generator 110 to drive the flywheel 202 to accelerate its rotation, or current flows out of the electric generator 110 to receive stored potential energy from the flywheel 202.

[0065] The electric generator 110 can have various configurations, as described in further detail elsewhere in this document. In some embodiments, the electric generator 110 can be an electric vehicle motor or other motors (e.g., Hyper 9). TM The motor, such as a brushless AC motor (e.g., a three-phase AC synchronous reluctance embedded permanent magnet motor), is capable of idling to allow the flywheel 202 to store energy for a longer period. The size and configuration of the motor can vary depending on the peak output / input and the size / speed requirements of the flywheel 202. For example, a smaller residential MESU 102 may include a smaller flywheel 202 and a 30-40 kW motor, while a larger commercial system (e.g., for shops, power companies, communities, etc.) may be equipped with a 300-500 kW motor, but other implementations are also possible. The motor controller and / or CPU may be adapted to different sizes of the flywheel 202 or vary depending on the specific implementation.

[0066] The electric generator 110 can be coupled to the flywheel 202 via the shaft 208 and the bearings of the flywheel 202 / flywheel housing 104. Similarly, in some embodiments, the flywheel shaft 208 and the electric generator 110 can be connected via a flywheel motor coupling, which may include a direct connector, a magnetic coupler 118, a friction clutch, a hydraulic torque converter, a gearbox, etc., as detailed below.

[0067] Exemplary flywheel 202 ( Figure 1A(Not visible in the document) can be housed in and / or supported by housing 104 and its components. An exemplary flywheel 202 and its features are described throughout this disclosure. For example, flywheel 202 may include multiple stacked plates 122 held together by a support structure (e.g., clamping plate 120) via compression and friction. This support structure may include one or more shafts 208 attached thereto, providing support for flywheel 202. As further detailed elsewhere herein, the support structure and shafts 208 are constructed to allow flywheel plates to be used without perforation by shafts 208. According to specific embodiments, shafts 208 may be vertically and / or horizontally supported by other components or flywheel housing 104 and may be coupled to electric generator 110 (e.g., as described above).

[0068] For example, shaft 208 may interact with one or more bearings (of any type, such as magnetic, metallic, ceramic, or hybrid ceramic) of housing 104, enabling flywheel 202 to rotate about an axis formed by shaft 208. As described below, housing 104 may include or be coupled to one or more bearings that provide horizontal support to flywheel 202, allowing it to rotate continuously with minimal or zero vibration. In some cases, the bearings may be made of ceramic to avoid interaction with the magnetic field of magnetic lifting member 152 or other magnetic components.

[0069] Shaft 208 can interact with bearings to provide vertical or horizontal support for flywheel 202, for example by holding the shaft in a defined position and balancing it about a defined axis of rotation.

[0070] For example, a bottom bearing may interact with the bottom of flywheel 202, and / or a top bearing may interact with the top of flywheel 202, for example, inside housing 104. In some embodiments, a magnetic levitation device or magnetic lifting aid 152 may be used to reduce friction or stress, such as friction or stress acting on one or more bearings. For example, a magnetic levitation device may be positioned at the bottom of flywheel 202 to apply an upward force thereto, thereby limiting the force of gravity on the bottom bearing and / or balancing the force between the top and bottom bearings. In some embodiments, a magnetic lifting aid (also referred to as a magnetic lifting member) 152 may be positioned at the top of flywheel 202 / housing 104 to pull housing 104 upward, thereby reducing the force of gravity on the bottom bearing. As further detailed elsewhere herein, the lifting force of the magnetic lifting aid 152 may be less than, equal to, or greater than the weight of flywheel 202, such that the bottom and / or top bearings bear partial, small, or no weight load.

[0071] As described elsewhere in this document, the weight carried by the magnet of the magnetic lifting aid 152 can be adjusted by changing the distance from the magnet. For example, an installer can manually adjust the flywheel, or in some embodiments, the housing 104 may include or be coupled to one or more flywheel positioning components that can adjust the position of the flywheel 202, for example, to ensure that the flywheel 202 is kept at the correct distance from the magnetic lifting aid 152, the top bearing, the bottom bearing, or other components of the assembly 102. For example, the flywheel positioning components can move the flywheel 202 (e.g., inside the housing 104) from a transport position to an engaged position, positioning it correctly relative to the bearing to minimize bearing wear and friction.

[0072] It should be noted that although the housing 104 is shown as a fully enclosed structure, including reinforcements, welds, seals / O-rings, etc., to maintain an internal vacuum while accommodating the flywheel 202, it should be understood that other implementations are also considered and permitted herein, such as housing 104 employing a fully or partially open structure.

[0073] In some embodiments, the flywheel assembly 102 may include various components mounted on the housing 104 (e.g., via a mounting plate or bracket of the cover 128 assembly) that support the operation of the flywheel 202. For example, the flywheel assembly 102 may include a supercapacitor 106, an electric generator 110 (and associated mounting hardware), a driver and CPU / controller 112, a vacuum pump 108, various inverters, wiring harnesses, circuit breakers, and other devices, but other embodiments are also contemplated and permitted herein.

[0074] like Figure 1A-1D As shown in the example, the flywheel housing 104 can be designed as a cylindrical structure with a flat bottom and a flat top, and equipped with various reinforcing ribs. This construction not only enhances the strength of the housing 104 to prevent buckling deformation caused by the internal vacuum, but also prevents external damage in the event of a mechanical failure of the flywheel 202. It should be noted that the housing 104 can also be square, hexagonal, etc., and may have curved sides (such as...). Figure 1D (as shown) or flat side (such as) Figure 1A As shown). Figure 1A As shown, the mounting plate can be positioned on the top of the housing 104, and related components are mounted on the mounting plate. Specific details will be further described below.

[0075] In some embodiments, as shown, the flywheel assembly 102 may include one or more motor mounting brackets 132 (illustrated as three-arm and four-arm) that are coupled to and extend upward from the cover 128 of the flywheel housing 104 to support a motor mount; the motor mount may include a ring for maintaining alignment of the rotational axes of the electric generator 110 and the flywheel 202. In some cases, the motor mounting bracket 132 may include a linear actuator for vertically lifting the electric generator 110 to decouple the motor from the flywheel 202 coupling, such as a magnetic coupler 118, which will be detailed below. The flywheel assembly 102 may include a cover assembly mounting plate 130 that is coupled to the top stiffener or other structure of the housing 104 and provides mounting points for the various components of the flywheel assembly 102. In some cases, the cover 128 or the cover assembly mounting plate 130 may have various through-holes for the electric motor mounting bracket 132, shaft 208, motor-flywheel 202 coupling, vacuum pump 108 connection, and other components to pass through. Therefore, these components can be securely mounted to mounting plate 130, cover 128, housing 104 or other locations (e.g., as shown in the illustration) to speed up assembly and improve stability.

[0076] like Figure 1A As shown in the example, the housing 104 may have multiple reinforcing structures, such as reinforcing ribs, reinforcing rings, etc.

[0077] The housing 104 may also include one or more legs 114 or other supports for providing support for the stiffeners of the housing 104 (e.g., side or bottom stiffeners) or other structures (e.g., base plate) to secure the flywheel assembly 102, support the weight of the flywheel 202, and / or isolate the movement / vibration of the flywheel 202; however, it should be noted that vibration is preferably limited by balancing the flywheel 202, and acceleration sensors, temperature sensors or other sensors may be located in bearings, shafts 208, housing 104 or other components.

[0078] Figure 1BAn example cross-sectional view of the flywheel assembly 102 is shown. For example, as shown, the flywheel 202, having multiple stacked plates 122 and top and bottom shafts 208b, is located inside the housing 104. The bottom shaft 208b of the flywheel 202 interacts with bottom bearings that support the flywheel 202 horizontally and / or vertically. The top shaft 208a of the flywheel 202 passes through a magnetic lifting member 152 and enters a magnetic coupler 118, which couples the shaft 208 to the stator of an electric generator 110 (directly or via other components, the shaft 208, drive shaft, gears, etc.), which is held vertically above the shaft 208 by a motor bracket 132. Additionally, as described elsewhere herein, various sensors may be located throughout the assembly, such as an RPM sensor mount 116 located near the magnetic coupler 118, and sensors adjacent to the motor 110, bearings, and other components of the flywheel assembly, such as temperature sensors, acceleration sensors, etc. These and other embodiments and features will be described in further detail below.

[0079] Figure 1C Another example MESU 102 or flywheel assembly 102 with a different embodiment of housing 104 is shown. As shown, housing 104 can be a cylindrical housing having a base cylinder 126 and a cover 128. Housing 104 may also include one or more legs 114 for supporting the flywheel assembly 102 (e.g., Figure 1C (Three are shown in the figure) or legs. Legs 114 may include bushings or other components for isolating vibrations, and bolt holes for bolting the flywheel assembly 102 to the floor or other location.

[0080] In the example shown, relative to Figure 1A The electric generator 110 can be mounted at a higher position on the motor mounting bracket 132 and / or base, for example, to facilitate the installation or removal of the electric generator 110, magnetic coupler 118, bearings, or other components. Furthermore, although... Figure 1A The other components shown are not in Figure 1C As shown, they can also be mounted to other locations on the cover 128 or flywheel assembly 102. For example, vacuum pump 108, supercapacitor 106, chemical cell, driver, CPU, etc. can be mounted to the cover 128, cylinder 126, other parts of flywheel assembly 102, or other locations.

[0081] Figure 1D It shows Figure 1C An example flywheel assembly 102 is shown, omitting the cover 128 and other components to illustrate an example large flywheel 202 within a housing 104. As shown, the flywheel 202 may be positioned at the center of the housing 104, but other implementations are also possible. Figure 1DAs illustrated in the example, the flywheel 202 may include one or more clamping plates 120 (top clamping plate 120a is shown in the figure), one or more stacking plates 122, one or more bolts for securing the clamping plates 120 to each other and / or to the stacking plates 122, and one or more shafts 208. These and other features and implementations are described in further detail in other parts of this document.

[0082] Figure 2A-3D An exemplary flywheel 202 and its various components, views, and structures are illustrated. The flywheel 202 features several innovative characteristics. For example, the flywheel 202 may include flywheel plates (120 and / or 122) coupled together by friction, a coupling method that may be combined with, or replaced by, other connection methods such as adhesives, welding, etc. Some embodiments of the flywheel 202 include bolts through the components, while other embodiments do not. Similarly, some embodiments of the flywheel 202 include two separate shafts 208—a top shaft 208a and a bottom shaft 208b. For example, while a previous flywheel 202 might have used bolts to attach its components together, some embodiments of the flywheel 202 described herein may separate the shafts 208 and / or utilize the clamping force generated by the clamping plates 120 (and / or shafts 208) to enhance the friction between the stacked plates 122. This helps improve the manufacturing process and reduces points of failure when the flywheel 202 rotates at high speeds.

[0083] In some embodiments, clamping plates 120 may be used at the top and bottom of the flywheel 202 to support it, for example, by coupling the stacked flywheel plates 122 to each other and / or to the shaft 208. As described elsewhere herein, the top clamping plate 120a and the bottom clamping plate 120b may be tightened by bolts at or near their peripheral edges, thereby applying inward pressure to the stacked plates 122 in the axial direction and increasing friction. This friction also allows rotational forces to be transmitted through the stacked plates 122 while preventing the stacked plates 122 from shifting out of alignment, which could otherwise lead to imbalance of the flywheel 202.

[0084] According to a specific embodiment, the clamping force from the clamping plate 120 can be applied directly to the stacking plate 122 (e.g., through direct contact between the clamping plate 120 or the stacking plate 122), and / or through other components, such as a portion of the shaft 208 or other contact points (such as bushings or washers as described below). For example, the clamping plate 120 can apply force to the center of the stacking plate 122 through the top shaft 208b and the bottom shaft 208b (and / or washers, ball washers, bushings at the outer edge or arm end, etc.).

[0085] In some embodiments, the mass of the clamping plate 120 may be less than that of the stacking plate 122 (although other embodiments may exist as described herein), so each type of plate may expand (and may become thinner) to varying degrees, especially at the peripheral edges. Therefore, in some cases, bushings or other components allow the stacking plate 122 to move relative to the clamping plate 120 while continuously subjected to clamping forces.

[0086] The clamping plate 120 may have various profiles and configurations to allow it to apply clamping forces and perform other functions. In some embodiments, the stacking plate 122 may be configured differently from the clamping plate 120, and its primary function is to add rotational mass to the flywheel 202 to store energy. The stacking plate 122 may be a generally circular, large-mass plate, or may include various profiles depending on its interaction with the clamping plate 120 or the assembly fixture. Example stacking plates 122 and clamping plates 120 will be described in more detail below.

[0087] As described in more detail elsewhere in this document, the shape, construction, or features of the clamping plate 120 may be designed to improve its interaction with the magnetic lifting member 152, for example, to increase space, enhance magnetic attraction, etc. In some cases, it may also be configured to reduce eddy currents induced by the magnetic lifting member 152. These and other features will be further detailed below.

[0088] Figure 2A A side top view of an exemplary flywheel 202 is shown. As shown, multiple stacked plates 122 may be stacked sequentially with their surfaces in contact with each other to minimize footprint and reduce bending while increasing friction. Fourteen stacked plates 122 are illustrated, but other embodiments are also contemplated and covered herein. As shown, a gap 142 may exist on one or both sides between the clamping plate 120 and the stacked plates 122. Although this gap 142 appears relatively large and uniform in the illustration, it may be smaller or nonexistent for one or both shafts 208. For example, the top clamping plate 120a may contact the topmost stacked plate 122, while the bottom clamping plate 120b may have only a few millimeters of gap with the bottommost stacked plate 122, which may vary depending on the applied clamping force and the degree of bending of the clamping plates 120.

[0089] like Figure 2A and 2BIn the example flywheel 202 shown, the bottom shaft 208b can be coupled to the bottom clamping plate 120b. The bottom clamping plate 120b then interacts with the bottom flywheel stack plate 122 (e.g., via bushings, shaft washers 232b, a portion of the shaft 208, etc.). Depending on the required energy capacity, different numbers of stacked flywheel plates can be stacked together, as described elsewhere in this document. Similarly, the top clamping plate 120a can interact with the topmost flywheel stack plate 122 (e.g., via bushings, shaft washers 232a, etc.). The top clamping plate 120a can be coupled to the top shaft 208a. In other embodiments, the bottom surface of the top clamping plate 120a can directly abut against the top surface of the topmost stack plate 122.

[0090] In some implementations, each stack plate 122 may be identical, and each clamping plate 120 may also be identical, but other implementations (e.g., dimensions, construction, etc.) are also possible and are considered, as described below. Similarly, the top shaft 208b and the bottom shaft 208b may be identical or different (e.g., having different lengths, interacting with different bearings or constructions, as shown herein).

[0091] As shown in the figure, during assembly, the clamping plate 120 of the flywheel 202 can be aligned with the stacking plate 122. In some embodiments, the clamping plate 120 may be star-shaped (e.g., as shown in the figure). Figure 3A and Figure 3B As shown), each arm or branch of the clamping plate 120 has a bolt hole at its tip for receiving bolts to clamp the clamping plates 120 together. In some embodiments, the clamping plates 120 may have other shapes (e.g., as shown). Figure 2C and Figure 2D (As shown), including one or more perforations near the outer edge.

[0092] Similarly, the construction of the stack plate 122 may be based on the shape of the clamping plate 120 (e.g., the location and number of branches), as described in further detail below. For example, the bolt points of the stack plate 122 may correspond to the bolt points of the clamping plate 120, regardless of whether the stack plate 122 is in contact with bolts.

[0093] Figure 2BA cross-sectional view of an exemplary multi-component flywheel 202 is shown. As shown in the example embodiment, a top clamping plate 120a may be coupled to a top shaft 208a. For example, the top shaft 208a may pass through the top clamping plate 120a, such that the top clamping plate 120a can apply a downward force to the shaft 208. In some embodiments, the shaft 208 may include multiple components, such as shaft 208 portions and shaft washers 232a or 232b, wherein the washer 232 (or the bottom of the top shaft 208a) contacts the topmost stacked plate 122. Thus, the top clamping plate 120a can apply force to the stacked plate 122 via the shaft 208. It should be noted that other configurations are also possible without departing from the scope of this disclosure, such as direct contact or contact via another means. Thus, the clamping plate 120 can apply pressure at the center of the stacked plate 122 via the washer and / or the shaft 208.

[0094] Similar to the description of the top shaft 208a above, the bottom shaft 208b can be coupled to the bottom clamping plate 120b and can apply force to the bottommost stacked plate 122. It should be noted that other configurations are also possible, such as direct contact, integration of shaft 208 with clamping plate 120, integration of shaft 208 with one or more stacked plates 122, etc.

[0095] Furthermore, as described in further detail below, forces can be applied (e.g., axially) to the center, outer edge, and / or other areas of the stacking plate 122. For example, bolts can be tightened on the clamping plate 120, thereby applying force to the outer edge of the stacking plate 122. This force can be applied through direct contact between the clamping plate 120 and the stacking plate 122, or through intermediate means (e.g., bushings or washers, such as ball washers or shaft washers 232). In some cases, the clamping plate 120 can be bent between the shaft 208 and the bolt to provide pressure. Accordingly, the frictional force between the stacking plates 122 is increased. In some embodiments, the stacking plate 122 can be a simple solid plate (e.g., as shown in the image). Figure 3C As shown), instead of providing through holes for fasteners on the board, this may reduce strength and create stress concentration points due to centrifugal force, and may lead to increased complexity and an increase in failure modes. In other embodiments, the stacked board 122 may have through holes (e.g., as shown). Figure 2C (or as shown in 2D), bolts can pass through these perforations, which may increase the radius of the plate, simplify the manufacturing process, or enhance the inter-plate forces (e.g., due to friction).

[0096] As described below, different levels of tension can be applied to the bolts to generate friction. Although different configurations may exist and are envisioned, as described elsewhere in this document, the flywheel 202 may include eight bolts located around or near its outer edge. Each bolt may be tightened before torque is applied or to provide a specified torque based on the applied force (e.g., 2600 pounds of force applied to each bolt), which can accumulate on the stacking plate 122 to generate a relatively uniform clamping force and friction (e.g., 16000-21000 pounds of clamping force).

[0097] In addition to their role in the clamping assembly of the clamping plate 120, the bolts may also include other functions, such as mitigating failures of one or more stacked plates 122 (e.g., by securing a slipped or broken stacked plate 122 or portion thereof). In some cases, the bolts may be replaced with other bolts of different weights to aid in balancing the flywheel 202. Other details and implementations may exist and / or be described elsewhere herein.

[0098] It should also be noted that the top axis 208a and the bottom axis 208b (e.g., as shown in the image) Figure 4A and 4B As illustrated in the example, alignment should be as precise as possible to reduce vibration and improve alignment with bearings, etc. While other implementations may exist, a spherical washer (e.g., 232) may be used with shaft 208 to provide some adjustability during assembly, thereby improving alignment. It should be noted that flat washers or no washers may also be used (e.g., shaft 208 may be a single component, rather than being disassembled into shaft body and shaft washer 232).

[0099] When the shaft 208 or shaft washer 232 contacts the stack plate 122, the clamping force applied by the bolts may cause one or more clamping plates 120 (e.g., their arms) to bend slightly, thereby increasing the force applied at the center by the shaft 208 / shaft washer 232. According to embodiments, the thickness of the shaft washer 232 (or similar component) and the construction of the clamping arms minimize the distance between the ends of these arms (e.g., to the stack plate 122) when the plates are clamped. In some embodiments, in addition to applying a clamping force at the center of the stack plate 122, or as an alternative, the clamping plates 120 may apply a clamping force along the peripheral edge of the stack plate 122.

[0100] Figure 2C A side top view of another example flywheel 202 according to some embodiments is shown. Figure 2CIn the example shown, the clamping plate 120 is X-shaped, with two bolt holes near the radial edge of each arm. In the illustrated example, the bolts may be angled as they extend from the top clamping plate 120a through the stacking plate 122 to the bottom clamping plate 120b. By angled bolts, the rotational force between the clamping plate 120, the stacking plate 122, and the shaft 208 can be increased, thereby reducing the probability of plate misalignment when the flywheel 202 increases or decreases its rotational speed via the shaft 208.

[0101] In the example shown, the bolts can be tilted closer to or further away from each other on alternating clamping plate arms, which improves the uniformity of force distribution (e.g., circumferential and axial) and rotational balance. For example, in the first arm, the bolts are tilted further away from each other at the top plate, while in the second arm, which is 90 degrees from the first arm, the bolts are tilted closer to each other at the top plate, as shown, and this arrangement can be repeated. When the top clamping plate 120a and the bottom clamping plate 120b are identical, they can be rotated 90 degrees to match the tilt angle of the bolts with the holes on each plate. For example, the bolts can be perpendicular to the radial direction of the flywheel 202 and tilted near the outer edge, for example, at an angle to the axial direction of the flywheel 202.

[0102] exist Figure 2C In the example shown, the bolt extends through the top clamping plate 120b and the bottom clamping plate 120b, and through a perforation in the stacking plate 122. In an example embodiment where the bolt is angled, the bolt may employ a wedge-shaped washer, allowing the force generated by the bolt to be applied to the clamping plate 120. In some embodiments, whether the bolt is angled or straight (e.g., axial), the bolt and its mating nut may be designed to be tapered, allowing them to partially extend into a countersunk hole in the clamping plate 120.

[0103] exist Figure 2C In the example shown, the top and bottom surfaces of the top clamping plate 120a (and possibly the bottom clamping plate 120b) can remain substantially flat, allowing it to contact the stacking plate 122 and / or interact with the magnet lifting assembly 152. For example, the top clamping plate 120a interacting with the magnet lifting assembly has a very flat top surface, which reduces eddy currents generated in the top clamping plate 120a due to rotation relative to the magnet lifting member 152.

[0104] Figure 2DA side top view of another example flywheel 202 according to some embodiments is shown. In the illustrated example, bolts extend axially through perforations 222 in the top clamping plate 120a, the stacking plate 122, and the bottom clamping plate 120b. According to embodiments, the stacking plate 122 may have the same number of perforations 222 as the number of bolts in the clamping plate 120, while the clamping plate 120 may have additional perforations 222 near its peripheral edge. These additional perforations 222 can be used to balance the flywheel 202, for example, by drilling or adding plugs to the holes. As described elsewhere in this document, one or more gaps may exist between the clamping plate 120 and the stacking plate 122. For example, there may be no gap between the top clamping plate 120a and the top stacking plate 122 (e.g., as shown at 142), which can prevent the top clamping plate 120a from bending, thereby improving its flatness and interaction with the magnetic lifting member. In some implementations, a small gap / space may exist between the bottom clamping plate 120b and the bottommost stacked plate 122, which allows for some elasticity during clamping (e.g., to increase the force at the center / axis 208). For example, a portion of the bottom axis 208b and / or an axis washer (whether a ball washer or a flat washer) may be used to provide space between the center of the bottom clamping plate 120b and the bottommost stacked plate 122.

[0105] As described below, in some embodiments, the stacked board 122 (e.g., in...) Figure 3C (In any example) a profile or fan-shaped notch 310 may be included at the outer edge, which can reduce failure points due to radial stress around bolt holes and / or help align the plates. For example, the fan-shaped notch 310 may be a fan shape or profile that is removed or omitted from the outer edge of the stacked plate 122.

[0106] Figures 3A-3D Example components, views, and construction of flywheel 202 are shown. Flywheel 202 has several innovative features. Flywheel 202 can stack flywheel plates (e.g., 120 and / or 122) through friction, which can be combined with other methods, such as adhesives, welding, etc., or replaced by these methods. For example, the illustrated example may include stacked plates 122 using friction mating to improve the manufacturing process and reduce failure points when flywheel 202 rotates at high speeds.

[0107] For example, clamping plates 122 can be used at the top and bottom of the flywheel 202 to support it, for example, by coupling the stacked flywheel plates 122 to each other and / or to the shaft 208. For example, the top clamping plate 208a and the bottom clamping plate 208b can be tightened by bolts near their outer edges (e.g., at the tips of the star / arm), thereby applying inward pressure to the stacked plates 122 and increasing friction. Friction allows rotational force to be transmitted through the stacked plates 122 while preventing them from becoming misaligned, which could otherwise disrupt the balance of the flywheel 202.

[0108] According to specific embodiments, the clamping force from the clamping plate 120 may be applied directly to the stacked plates 122 (e.g., through direct contact between the clamping plates or the stacked plates) or through other components. For example, the clamping plate 120 may apply force toward the center of the stacked plates 122 through a washer 232 (e.g., a ball washer) or other portions of the shaft 208 and / or bushings at the outer edge of the clamping plate 120. For example, in some embodiments, because the mass of the clamping plate 120 may be less than that of the stacked plates 122, each type of plate may expand (and may become thinner) to varying degrees, especially at the outer edges. For example, bushings or other components may allow the stacked plates 122 to move relative to the clamping plate 120 under continuous clamping force.

[0109] The stacking plate 122 may be constructed differently from the clamping plate, and its main function is to add rotational mass to the flywheel to store energy. For example, the stacking plate 122 may be a circular, large-mass plate, or it may include various profiles depending on its interaction with the clamping plate 120.

[0110] Figure 3A An exemplary flywheel support structure is shown, which, according to some embodiments, may include a bottom shaft 208b, a bottom clamping plate 120b, bolts, a top clamping plate 120a, and a top shaft 208a. In the example shown, the stacking plate 122 has been omitted for clarity. Figure 3A Example support structures can correspond to Figure 2A Example implementation of the flywheel 202.

[0111] like Figure 3A As shown in the example, the top shaft 208a may be coupled to and / or extend through the top clamping plate 120a, and the bottom shaft 208b may be coupled to and / or extend through the bottom clamping plate 120b. In some embodiments, the primary purpose of the clamping plate 120 may be to generate friction and transmit force to the stacking plate 122. Figure 3A(Not visible in the center) / Transfers force from the stacking plate 122, rather than increasing the moment of inertia. Accordingly, the clamping plate 120 can be designed (e.g., by being thinner and / or extending radially outwards a distance less than the stacking plate 122) to apply a vertical force to the plate 122, while potentially reducing the high-stress areas at the outer edges of the clamping plate 120 that may fail at high speeds. Accordingly, clamping pressure can be increased, and the risk of structural / material failure can be reduced. Example embodiments of the clamping plate 120 will be described below in conjunction with Figure 3B To provide a more detailed description.

[0112] Furthermore, the clamping plate 120 may include a connection region for coupling with the shaft 208, which allows rotational forces to be transmitted between the plate 120 and the shaft 208. For example, as described elsewhere herein, the shafts 208a and / or 208b may extend wholly or partially through the clamping plate 120 and have one or more shapes or structures that allow rotational and clamping forces to be applied to the stacking plate 122 (e.g., through the shaft 208). In some embodiments, the shaft 208 may be provided with shaft washers 232 / spherical washers that extend beyond the inner edge of the stacking plate to apply forces to the stacking plate (e.g., simultaneously leaving a gap or space between the clamping plate 120 and the stacking plate 122). Although the dimensions of the washers 232 shown in the figures are approximately equivalent to the through-holes in the clamping plate 120, it should be noted that they may be omitted, coupled with the shaft body, have a radius smaller than the through-hole, or be larger than the through-hole (e.g., to apply forces to the stacking plate 122 over a larger area).

[0113] As shown in the figure, several bolts may extend through the ends of the clamping plates 120 arms and, by tightening, bring the clamping plates 120 closer together. Since the shaft 208 or shaft washer 232 may contact the stacking plate 122, the clamping force applied by the bolts may cause slight bending of the arms, thereby increasing the force applied at the center by the shaft / shaft washer 232 and / or directly by the clamping plates 120. The thickness of the shaft washer 232 (or similar component) and the configuration of the clamping arms should minimize the distance between the ends of these arms (e.g., the distance to the stacking plate 122) when the plates 120 and / or 122 are clamped.

[0114] In some embodiments, in addition to applying a clamping force at the center of the stacking plate 122, or as an alternative, the clamping plate 120 may apply a clamping force along the peripheral edge of the stacking plate 122. For example, the end of the arm may directly or indirectly contact the stacking plate 122 to apply a clamping force closer to the outer edge of the stacking plate 122 and increase inter-plate friction. In the case of indirect contact, this can be achieved by another component, such as a bushing or pivot point, or another intermediate device. The bushing allows the stacking plate 122 to move relative to the clamping plate 120, for example, because the stacking plate 122 may elongate more than the clamping arm under load, due to its relative mass and mass position (e.g., the clamping plate 120 has vertical strength but a smaller weight per unit volume / cross-section). Therefore, the clamping force at the outer edge is enhanced, thereby improving the ability to transmit torque through the stacking plate 122, the clamping plate 120, and the shaft 208.

[0115] A top shaft 208a may be coupled to and / or extend through a top clamping plate 120a, and a bottom shaft 208b may be coupled to and / or extend through a bottom clamping plate 120b. The clamping plates 120 may generate frictional forces and transmit or receive forces from the stacked plates 122. Therefore, the clamping plates 120 should be designed to apply axial forces to the plates while avoiding high-stress areas at their outer edges, thereby preventing failure of the clamping plates 120 during high-speed operation. Accordingly, clamping pressure can be increased, and the risk of structural / material failures can be reduced. Exemplary constructions of the clamping plates 120 are described elsewhere in this document.

[0116] The clamping plate 120 can be made of aluminum, steel, or other materials. For example, the plate 120 can be made of ferromagnetic steel (e.g., AR500 steel plate) and can be stamped, formed, or machined into the desired shape. When made of steel, the example weight of the clamping plate 120 can be 66-68 pounds, but other embodiments are also possible.

[0117] Figure 3B An example clamping plate 120 is shown. As shown, the clamping plate 120 may have a shaft connection region 342, a flat central region 344, a tapered region 346, and an outer arm portion (also referred to as an arm) 348. For example, the clamping plate 120 may be star-shaped, with the contour of its outer edge defining the arm portion 348. It should be noted that although eight arms 348 are illustrated, other numbers may be used depending on the required strength and maximum rotation frequency (e.g., the clamping plate 120 may be as follows). Figure 2D The circle shown, or having such Figure 2C (The four arms shown).

[0118] In some embodiments, the shaft connection region 342 may be connected to the shaft 208 to transmit forces between the clamping plate 120 and the shaft 208. The shaft connection region 342 may include a shaft interaction step 350, which allows the clamping plate 120 to apply a clamping force to the shaft 208 (e.g., applied to a corresponding flange or step of the shaft 208), although the shaft 208 may be integrated with the clamping plate 120, or the force may be applied to the shaft 208 only through the bottom edge of the clamping plate 120 (e.g., in some embodiments, the step may not be included). For example, the shaft connection region 342 may include a through-hole in the clamping plate 120 through which the shaft 208 or a portion thereof may pass. For example, a shaft washer 232 may be coupled to the shaft at the step 350, or a portion of the shaft 208 itself may interact with the step 350.

[0119] In some embodiments, various mechanisms may be used at the interface or connection area 342 between the shaft and the clamping plate to maintain the mechanical connection between the shaft 208 and the clamping plate 120, thereby allowing rotational force to be transmitted between them. For example, the hole in the clamping plate 120 accommodating a portion of the shaft 208 may have an elliptical, circular, ridged shape and / or a planar region (e.g., regardless of the size of the planar region, the shape is similar to the letter D), which prevents them from twisting relative to each other. For example, providing a small planar region or using an elliptical shape at the interface can reduce stress concentration points in the plate, which may be particularly beneficial at higher revolutions per minute. For example, in some embodiments, the interface between the clamping plate 120 and the shaft 208 may be shaped to introduce minimal stress to the shaft 208 or the clamping plate 120 while allowing torque transmission, rather than using a bolted through connection or a square or other shape with large protrusions, which may increase stress in the flywheel 202, especially when the flywheel 202 is heavy or rotates at high speeds.

[0120] For example, the through portion of the shaft connector 342 may include various shapes that interact with the corresponding shape of the shaft 208. The perforation, or a portion thereof, may be elliptical, ridged, or have flat or "D"-shaped areas, keys, or other shapes that allow torque to be transmitted between the stack plate 122 and the shaft 208 (e.g., in addition to the torque that the shaft 208 may experience through its contact with the topmost / bottommost stack plate 122) without significantly increasing material stress at the connection point. In some embodiments, the shape may be applied to the entire perforation, or only to a portion thereof, or a stepped portion (e.g., the stepped portion shown). The shape may be small, for example, with a diameter deviation of 1 / 8 inch or a flat cross-section. In some embodiments, the clamping plate 120 and the shaft 208 may be integrated (e.g., machined from a single piece or welded together).

[0121] While other implementations are possible, the shaft 208 and the perforation diameter (e.g., at 342) can be 3-5 inches. For example, the first (e.g., illustrated at the top of the figure) perforation / shaft diameter can be 3.75 inches. The second (e.g., illustrated downwards from the first perforation) perforation (e.g., a step in the perforation) / shaft diameter can be 4.25 inches to allow force to be applied from the first diameter to the shaft 208 and then transmitted to the stack plate 122. While other implementations are possible and considered in this document, in an implementation where the second step / perforation / shaft portion is elliptical, the ellipse can vary, for example, from 4.375 inches to 4.250 inches.

[0122] In some embodiments, a flat region 344 of the clamping plate 208 may extend outward from the shaft connector 342 and provide a magnetic lifting aid / mechanism 152 that can interact with it to lift the position of the flywheel 202. For example, the flat region 344 of the top clamping plate 120 may interact with the magnetic field of the magnetic lifting aid 152 to lift the flywheel 202. In some cases, it may additionally or alternatively interact with a bearing (e.g., a top bearing). For example, the flywheel 202 may be lifted until the flat region 344 contacts the magnetic lifting aid, and then slightly lowered to create a gap, which can reduce friction. Adjustments may also be made to increase or decrease the distance from the magnetic lifting member 152, the top bearing, etc.

[0123] As shown in other accompanying figures (e.g.) Figure 2C and Figure 2D As shown in the figures, the flat region 344 may extend further along the clamping plate 120. For example, the exemplary embodiments in these figures show the clamping plate 120 as a flat sheet. Advantageously, the clamping plate 120 may be flat in the region closest to the magnetic lifting member 152 when the flywheel assembly 102 is assembled. For example, the top and / or bottom surfaces of the clamping plate 120 may be shaped, assembled, or machined to improve flatness. Similarly, the clamping plate 120 may omit any holes, bolts, or other similar structures located directly or nearly below the magnetic lifting member 152. These features reduce eddy currents induced in the clamping plate 120 (and / or adjacent stacked plates 122), thereby reducing the generated heat and energy loss. The clamping plate 120 may be made of a metal that can be attracted by a magnet, such as steel, iron, etc. In some embodiments, composite materials or other materials may be used to maintain magnetism but reduce conductivity. Other embodiments are also possible and are considered herein.

[0124] In some embodiments, when the flywheel 202 is in the transport position, the flat area 344 of the bottom clamping plate 120 can be placed on the transport ring or device; when in the working position, it is lifted off the transport ring. It should be noted that the top clamping plate 120a and the bottom clamping plate 120b can be the same or different, for example, the size or shape of the flat portion is designed to match the transport ring, magnetic lifting aid 152 or other construction.

[0125] The flat region 344 can have various sizes or configurations. For example, the flat region 344 may be defined at its center by a through-hole in the shaft connector region 342 and may have various outer diameters (e.g., 11 inches). Although the clamping plate 120 can have various thicknesses, an example thickness of the flat region may be approximately 1 inch (e.g., 0.960 inches). For example, in some embodiments, as referenced... Figure 4B and Figure 4C The clamping plate 120 may be a flat or flat area, most or all of which may be flat.

[0126] In some embodiments, the clamping plate 120 may have a tapered region 346 between the flat region 344 and the end of the thinner arm 348. This provides additional strength to the clamping plate 120 near the shaft connector 342, the magnetic lifting auxiliary region, and / or the transport ring interaction region, while also providing reduced weight and / or increased flexibility near the end of the arm / towards the outer radius. Without departing from the scope of this disclosure, the tapered region may extend partially into the arm 348, partially into the arm 348, or extend entirely to the end of the arm 348. The tapered region may be positioned away from the magnetic lifting member 152 (e.g., radially outward) to reduce the likelihood of direct interaction between the magnet and this region. Similarly, when bolt holes, balancing holes, etc., are provided on the clamping plate 120, they may be positioned away from the magnet of the magnetic lifting member 152 (e.g., not directly below, not within a defined distance). For example, as Figure 2A , 2C As shown in the 2D examples, these structures can be positioned as far away from the magnet as possible while maintaining clamping and radial (e.g., for centrifugal force) strength.

[0127] If a conical / tapered region 346 exists, its shape, size, and construction can be determined based on clamping forces, eddy currents, and / or centrifugal forces. For example, the conical region can be designed to reduce radial stress due to its mass while balancing clamping forces. Its dimensions can vary, but for example, its inner radius can match the outer radius of the flat region, which is 20 inches (e.g., 20.102 inches). Similarly, the conical region 346 can begin from the flat region and gradually thin outwards radially, for example, with a thickness of about half an inch, but other dimensions are also possible. For example, Figure 2C and2D The example clamping plate 120 in the example may be larger than Figure 2A The examples in the text are thicker, for example, 1 inch, 2 inches, 3 inches or more. This thicker construction helps to maintain flatness while allowing most of the flywheel's mass to remain in the stacked plate 122, although other implementations are also possible.

[0128] In some embodiments, the clamping plate 120 may include a plurality of arms 348 arranged in a balanced manner about a rotation axis (e.g., as shown in the figure). Figure 2A and 2C (As shown). Arm 348 may be defined by a fan-shaped notch cut out in the clamping plate 120, with a smooth profile near its outer edge to reduce high-stress areas, such as those with insufficient mass support. The radius of curvature of the fan-shaped notch or profile of arm 348 may be approximately 1.750 inches, but other embodiments are also possible. The illustrated embodiment includes eight arms 348 equidistantly distributed around the clamping plate (e.g., arranged in 45-degree angular increments). These fan-shaped notches and profiles can be used to align the clamping plate 120 and / or the stacking plate 122.

[0129] In some embodiments, the clamping plate 120 may include a bolt region 352 that engages with bolts and / or the stack plate 122 (e.g., at 308). For example, the bolt region 352 may include a flat or contoured area sized and shaped to engage with an associated bolt head, nut, or washer (e.g., Belleville). TM (Washers, tapered washers, or spring washers) interact with each other.

[0130] In some embodiments, the lower surface of the clamping plate 120 may include one or more grooves for receiving or securing the bushing.

[0131] For example, one or more bushings may be located at bolt area 352, and the tip of arm 348 may be shaped according to the configuration of the bushings. For example, when two bushings are located on both sides of the bolt hole, the end of arm 348 may be generally flat or square; while when a single bushing is located radially inside or radially outside the bolt hole, the end of arm may be round.

[0132] It should be noted that the clamping plate 120 can have various configurations, as described in more detail above. For example, although several example embodiments are provided herein, various variations may exist. For example, the clamping plate 120 may employ any combination of the components described herein, or may vary in its performance of the functions described herein.

[0133] Figure 3C A top view of an example embodiment of the flywheel stacking plate 122 is shown. Figure 3A Examples can be compared with Figure 2AThe example flywheel 202 shown is used in conjunction with other implementations, such as... Figure 2C and Figure 2D As shown or in other embodiments.

[0134] Stacking plate 122 can be a flat metal sheet, such as steel. Although stacking plate 122 may include profiles or perforations (e.g. for bolt holes or possibly for shaft holes), in some embodiments they are solid plates without perforations (e.g., as shown in the image). Figure 2A and 3C (As shown or otherwise), this may increase internal stress when rotating at higher revolutions per minute. For example, the diameter of the stacking plate 122 may be 25 to 35 inches (e.g., the diameter of the example embodiment may be 27.71, 29.25, etc.), but other sizes may also exist. The stacking plate 122 may have various thicknesses, such as 1 / 8 inch to 2 inches. For example, the thickness of the stacking plate 122 may be 0.25, 0.47, 0.5 inches, etc. For example, the weight of each stacking plate 122 may be 20-200 pounds (e.g., 47, 94 pounds, etc.). Furthermore, any number (e.g., 10, 14, 24, etc.) of the stacking plates 122 may be stacked without departing from the scope of this disclosure.

[0135] The shape and configuration of the stacking plate 122 may vary depending on the specific implementation. For example, the stacking plate 122 may include a clamping portion 308 or a clamping location located at or near its peripheral edge, where the stacking plate 122 may be clamped (e.g., as an additional or alternative method to clamping at the shaft 208). For example, the flywheel stacking plate 122 shown includes a clamping portion 308 / location shaped based on bolt locations (e.g., associated with the size / shape of the clamping plate 120).

[0136] While the outer edge of the stacking plate 122 at the clamping position 308 may be flat (or curved based on the plate's radius of curvature), it may be shaped to increase the contact area with the clamping bolt. For example, where the bolt and / or associated nut has a rounded top or the bolt is connected to the stacking plate 122 via a round washer (described below), the clamping position 308 may be shaped around the bolt / washer to allow for force and stress dispersion.

[0137] When clamping force is applied to the stacked plate 122 through one or more bushings, the clamping position 308 can be designed based on the force applied by the bushings to avoid excessive stress on the plate at higher rotational frequencies. In some embodiments, the edge of the stacked plate 122 at the clamping position 308 may be partially (e.g., as shown in the image). Figure 3C (as shown) or completely (e.g., as shown) Figure 2C and 2DThe stack plate 122 extends around the bolt to allow the bolt to pass through it. For example, it can extend any distance (e.g., a few degrees to nearly 360 degrees) around the bolt in the stack plate 122 to form a profile of 0.5 inches, 1 inch, or other radii (e.g., 0.55 inches, 2 inches, etc.). It should be noted that, depending on the specific embodiment, the edge of the stack plate 122 may or may not contact the bolt. For example, to reduce external stress on the bolt (especially where the stack plate 122 may expand outward at a high rotational speed / frequency), a gap can be provided between the bolt and the edge of the stack plate 122 so that the stack plate 122 does not exert centrifugal force on the bolt. Similarly, if the bolt may bend more than the stack plate 122, space can be provided radially outward of the bolt to allow it to bend without exerting additional stress on the stack plate 122. In other embodiments, the stack plate 122 may be designed to support the outward bending of the bolt (e.g., to strengthen weaker bolts or to take advantage of the higher strength of the stack plate 122).

[0138] In some embodiments, the stacking plate 122 may include one or more fan-shaped notches 310 at its peripheral edge to reduce unsupported areas of the stacking plate 122 that experience greater stress at higher rotational frequencies due to insufficient support. For example, as Figure 3C As shown, the stacked board 122 may include fan-shaped regions 310 on both sides of each clamping area. The fan-shaped regions 310 may have gently rounded corners or contours to avoid creating more fault-prone areas within the board. The fan-shaped regions 310 may be designed as partially circular or have other shapes, such as... Figure 3C The shape shown in the example. For example, finite element analysis can be performed to determine the loads in each region of the stack plate 122 (or other components of the flywheel 202), thereby determining the shape of the sector region 310, for example, based on the configuration of the clamping position 308.

[0139] In some embodiments, between the fan-shaped notches 310, the flywheel 202 may include non-fan-shaped regions 310 that can be adjusted during the balancing process of the flywheel 202 (e.g., as described below) without compromising the structural stability of the plate.

[0140] By using notches, cutouts, and / or fan-shaped notches 310, the overall safety factor of flywheel 202 can be improved, and / or it can be allowed to operate at higher speeds without material failure or outward stretching; however, it should be noted that the plate may bend under high speed / high load, and flywheel 202 can be designed to accommodate this shape change, as described below.

[0141] In some implementations, the fan-shaped notch 310 is designed to interact with one or more locations of the assembly fixture, or otherwise improve alignment and manufacturability.

[0142] In some embodiments, the techniques described herein allow the use of solid plates, even without welding, through-plate pins, and / or through-plate shafts 208. Therefore, depending on the specific implementation, safety and maximum rotational speed can be improved while avoiding failure modes or balance issues introduced by other methods, such as pins, shafts 208, or welding, which could introduce weak points leading to structural failure.

[0143] Figure 3D Example flywheel shafts 208a and 208b are shown. Other sizes and configurations may exist. Figure 3D A top shaft 208b and a bottom shaft 208b with shaft washers 232 (e.g., spherical washers) are shown. Depending on the specific embodiment, the top shaft 208b and the bottom shaft 208b may be identical or differ in, for example, in their length, whether they include washers or shaft washers 232, or whether they include a motor connection portion 366. Some features of the shaft 208 are described with respect to one of the top shaft 208b and the bottom shaft 208b, but they may be present on both or on the other shaft 208.

[0144] According to a specific embodiment, shaft 208 may include a smooth shaft 364 (e.g., a shaft 364 with a diameter of 50-70 mm) portion that interacts horizontally with one or more bearings to keep flywheel 202 aligned. Shaft 364 may contact one or more seals to maintain vacuum and may be polished to avoid friction with the seals.

[0145] Shaft 208 may include one or more bearing shoulders / steps 368 that interact with the bearings to provide vertical support for flywheel 202 (e.g., to vertically raise, lower, or hold flywheel 202).

[0146] In some embodiments, shaft 208 may include one or more clamping shoulders / steps 370 that interact with clamping plate 120. For example, clamping step 370 may be a wider area than shaft 364, such that clamping plate 120 applies pressure on clamping step 370 to secure shaft 208. In some embodiments, as described above, shaft 208 extends beyond clamping step 370 and flywheel step 368, such that shaft 208 applies pressure to stacking plate 122. Contact with stacking plate 122 may be achieved by a washer, such as shaft washer 232 (which may be a flat washer or a spherical washer). Clamping step 370 may interact with an edge or corresponding step on clamping plate 120.

[0147] In some embodiments, the clamping step 370, shaft washer 232, or another portion of the shaft 208 may be shaped to interact with a corresponding shape or structure in the clamping plate 120. For example, it may include planar sides, ellipses, protrusions, or other structures to allow torque transmission between the shaft 208 and the clamping plate 120 and / or the stacking plates 122 (e.g., the top or bottom stacking plates 122 may include a shape that matches this structure). For example, as further detailed above, elliptical or planar sides may be employed to avoid stress concentration points in the material (e.g., the material of the clamping plate 120).

[0148] In some embodiments, one or both shafts 208 may include a motor connection 366, which may be a portion or extension of a shaft 364. The motor connection 366 may include a planar, elliptical, D-shaped, or other structure / shape (e.g., a key or groove) to allow torque transmission (e.g., via a magnetic coupler 118 as described elsewhere herein) between the shaft 208 and another structure (e.g., a generator 110). The motor connection 366 may additionally or alternatively include keys or other protrusions to improve the connection between the shaft 208 and another structure (e.g., the magnetic coupler 118, the generator 110, etc.).

[0149] although Figure 3D (Also as) Figure 2B Spherical washers (located at 232) are shown on both the top shaft 208a and the bottom shaft 208b (as shown), but other implementations are possible and considered. For example, spherical washers can be used to provide a small amount of adjustability for the alignment of shafts 208 when the top shaft 208a, bottom shaft 208b, stack plate 122, and clamping plate 120 are aligned. As shown in the example, two shafts 208 can be used, in which case the two shafts 208 are physically disconnected from each other.

[0150] In some embodiments, the bottom of the spherical washer may be flat to contact the stack plate 122, while its top may be rounded to contact a corresponding curved surface in the shaft body. Therefore, the position of the shaft 208 can be slightly moved during assembly to position the shaft 208. As shown, in some embodiments, bolts can couple the shaft washer 232 to the shaft body to secure it in place during assembly.

[0151] It should be noted that in some embodiments, shaft 208 is used in conjunction with a flat washer or without a washer.

[0152] Figure 4AAn example flywheel housing 104 is shown, featuring a motor mount, a magnetic coupler 118, and other features coupled thereto. Various components, such as the electric generator 110, CPU, vacuum 108, and mounting plate 130, have been removed to expose the underlying structure. As shown, four motor mounting brackets 132 are coupled to the top plate of housing 104 (e.g., part of cover 128) and extend upward to provide rigid support for a motor mounting base 406. The motor mounting base 406 can be circular or any other shape to accommodate various components, such as the electric generator 110, magnetic coupler 118, bearings, shaft 208, etc. For example, the top of the motor mounting base 406 can be circular to receive and mount (e.g., using fasteners such as bolts) the electric generator 110; it has a through-hole through which the flywheel shaft 208 and / or motor shaft, etc., can pass; and it can allow various other components to be coupled or mounted thereto. For example, the magnetic coupler 118 can be mounted to or integrated with the motor mounting base 406 for easy attachment to housing 104.

[0153] As shown in the figure, the motor mounting bracket 132 and base 406 can be configured to lift, accommodate, and / or hold other components. For example, a motor coupler (such as the magnetic coupler 118 shown) can be coupled to the bottom surface of the motor mounting base 406 to interact simultaneously with the top shaft 208a and the electric generator 110. Similarly, this positioning (e.g., as shown in the figure) Figure 1A , 1C (As shown in 4A) This allows for the installation or maintenance of the top bearing below the bracket / base. Similarly, as described elsewhere herein, reinforcing members or structures of the flywheel assembly 102 can support the motor, prevent undesirable torsion of the components, and secure the bearings and / or magnetic lifting members 152.

[0154] Figure 4AVarious assembled structures of the flywheel housing are also shown, which may include a cover 128 and a cylinder 126. The cover 128 (described further below) may include a top plate, top stiffeners, a motor mounting bracket 132, a mounting plate, and various other structures. For example, a top ring 408 may include a ring of material (e.g., a steel ring or a set of curved portions on a steel plate) arranged around shaft 208a / axis of rotation to provide torsional stiffness to the housing 104 and / or the top stiffeners; these top stiffeners may radiate outward from the top ring, providing strength to the cover 128 to support the motor mounting bracket 132, mounting plate, vacuum pump 108, etc., and to prevent buckling of the top plate under stress. The top ring 408, top stiffeners, top plate, and / or other structures may work together to withstand the air pressure generated by the internal vacuum and / or the weight of the flywheel 202. For example, the magnetic lifting mechanism 152 may be coupled to the cover 128 (e.g., at a central location near the shaft 208a) to lift part or all of the flywheel's weight, thus the strength of the cover 128 is particularly important. Depending on the specific embodiment, the cover 128 may be constructed from a quarter-inch to half-inch thick steel plate, or employ a thicker structure (e.g., Figure 1C As shown in the example, it can be flat, welded, and / or have various curved shapes to further enhance rigidity. For example, the top ring 408 and the top stiffener may include one or more longitudinally curved structures to improve their strength and the ability to mount components thereon.

[0155] As further detailed below, the housing cylinder 126 may include one or more sidewalls surrounding the flywheel 202, which may be a continuous ring formed of material or bent metal (e.g., steel) or other plates welded together. The sidewalls provide vertical strength to the housing while mitigating mechanical failure of the flywheel 202. As shown, side stiffeners (e.g., steel plates welded to the sidewalls, such as top stiffeners) may also be mounted around the sidewalls to provide additional strength and prevent inward or outward buckling. The side stiffeners and / or sidewalls may be coupled to a wall ring (e.g., by welding, bonding, bolting, etc.), to which the cover may be bolted; simultaneously, the side stiffeners and / or sidewalls may also be coupled to a base plate (which may have a structure as described below, such as bottom stiffeners).

[0156] For example, Figure 4AThe example illustrates a magnetic coupler 118. The magnetic coupler 118 couples a flywheel shaft 208 (e.g., 208a) to the shaft or rotor of an electric generator 110. The magnetic coupler 118 may be supported above the shaft 208 by a motor mounting base 406, a top ring 408, or other components of the flywheel assembly 102. The magnetic coupler 118 may include an outer rotor bottom 410 and an outer rotor top 412, internally accommodating arrangements such as magnets and / or bearings, as detailed below. The magnetic coupler 118 may include an inner rotor top 414 with a round-headed mechanical key 416 that mates with a corresponding slot in the shaft and / or rotor of the electric generator 110 to enhance the mechanical connection strength between these components. A similar structure may be additionally or alternatively applied to the shaft 208a. The magnetic coupler 118 will be described in further detail below.

[0157] Figure 4B An exemplary flywheel housing is shown after the magnetic coupler 118 and other components have been removed. As shown, the top shaft 208a of the flywheel 202 passes through an upper bearing and an O-ring housing 422, which houses one or more bearings (e.g., for vertical or horizontal support of the top shaft 208a). In some instances, the bearings and / or housing 422 may include O-ring seals that help maintain a vacuum inside the housing 104, as described in further detail elsewhere in this document. O-rings or other seals may form an hermetically tight seal between the interior and exterior of the housing 104.

[0158] The housing 422 can be completely removed and / or installed, or the seals or bearings can be replaced individually (e.g., through the gaps in the support 132) to allow for the installation or maintenance of these components. In some embodiments, the housing 422 may be fully or partially disposed on top of the cover 128. While these components are housed within a single housing 422, alternatively, they may be separate or located in separate housings. Additionally, although the illustrated housing 422 extends almost to the ring 408, its size, shape, or construction may differ elsewhere (e.g., Figure 1C As shown in the figure.

[0159] Figure 4C An example flywheel housing 104 with the upper bearing and O-ring housing 422 (or a portion thereof) removed is shown. As shown, the top component of the magnetic lifting member 152 can be positioned around the top shaft 208a of the flywheel 202 to engage with the top clamping plate 120a ( Figure 4C(Not visible in the image) or interact with other components of the flywheel 202. The magnetic lifting member 152 may be coupled (e.g., welded, bolted, etc.) to the top plate of the cover 128, the top reinforcing ring 408, and / or the housing 104 or other components of the flywheel assembly 102. As described elsewhere herein, for example, the magnetic lifting member 152 may be coupled to the bottom surface of the top plate of the cover 128 to be adjacent to the top clamping plate 120a of the flywheel 202.

[0160] It should be noted that although the magnetic lifting member 152, the top reinforcing ring 408, the bearing housing 422, and the magnetic coupler 118 are shown as separate components spaced apart from each other, they can be arranged more closely or integrated into a single component or fewer separate components. For example, the magnetic lifting member 152 or the magnetic coupler 118 may also include an O-ring, or the bearing housing 422 and the magnetic coupler 118 may be integrated into one unit.

[0161] Figure 4D An example of a housing cover 128 with multiple components attached is shown. For example, the housing cover 128 may be placed in the housing cylinder 126 ( Figure 4A (Not shown) A housing 104 is formed on the cover, which, according to a specific embodiment, can be vacuum-sealed. As shown, the cover 128 may include a top plate having a top reinforcing rib extending radially from a shaft 208a (e.g., from a top reinforcing ring 408) to an outer edge of the top plate. In some instances, the top reinforcing rib may extend beyond the top plate or into a cutout in the top plate. For example, the top reinforcing rib may extend partially (e.g., at its end) into a groove formed in the top plate to further enhance rigidity and improve manufacturing convenience. Other configurations of the cover 128 are also possible, for example... Figure 1C The example implementation shown.

[0162] The cover 128 may also include O-rings, O-ring recesses / channels 432, or other sealing locations around the outer edge of the top plate, a central perforation (e.g., associated with a top bearing assembly or other component), and other features for sealing the housing 104 when the cover 128 is attached to the housing cylinder 126 (e.g., via bolts at the outer edge). In some instances, the cover 128 or other components may include holes, seals, valves, etc., through which the vacuum pump 108 can be attached to actively establish or maintain a vacuum. For example, as described above, the vacuum assembly 108 may be mounted to the cover 128 assembly mounting plate or otherwise, depending on the implementation.

[0163] In some embodiments, the cover 128 may also include a motor 110 mounted thereon and other components such as a driver, controller / CPU 112, supercapacitor 106, etc. Since these and other components can be pre-assembled on the cover 128 and then placed on the housing cylinder 126 (e.g., where the flywheel 202 is pre-positioned inside the housing cylinder 126), this can improve assembly speed and ease of use.

[0164] In some embodiments, the cover 128 may have a through-hole at the axis of rotation of the flywheel to receive the shaft 208a of the flywheel 202, but other embodiments are also possible, such as the case where the top shaft 208a interacts with a magnetic coupler 118 integrated in the cover 128. For example, the magnetic coupler 118 may be sealed and / or placed at the center of the cover 128 and may interact with the top clamping plate 120a to provide interaction between the flywheel 202 and the motor 110.

[0165] In some embodiments, shaft 208a may pass through a through-hole that may include or be connected to one or more bearings 434 that support shaft 208a in the horizontal and / or vertical directions (e.g., to prevent the flywheel from contacting the magnets in the magnetic lifting member 152 downwards). One or more magnets, for example located in the magnetic lifting auxiliary member 152 / mechanism, may be attached to cover 128.

[0166] The magnetic lifting member 152 may extend downward from the bearing 434 or other components, bringing it close to the top clamping plate 120a and / or stacking plate 122 of the flywheel 202, which improves the efficiency of the magnets. Although the magnetic lifting member 152 is illustrated as a continuous loop, multiple individual magnets (e.g., arranged in a balanced manner) may also be arranged around the axis of rotation of the flywheel 202 (e.g., within the housing of the magnetic lifting member 152). In some embodiments, the height of the magnetic lifting member 152 and / or its magnets can be adjusted by tightening or loosening the bolts coupling the magnetic lifting member 152 to the cover 128, for example, from below or above the cover 128 (e.g., when the cover 128 is located on top of the housing cylinder 126). Thus, the position of the magnets (and consequently their magnetic strength) can be adjusted to further balance the system and optimize the load acting on the bearing 434.

[0167] Figure 5AA cross-sectional view of an example upper shaft 208a disposed within the upper bearing assembly of the flywheel housing 104 is shown. In the example shown, some components may be omitted for clarity. As shown, the top shaft 208a may interact with multiple bearings 434 and / or seals (e.g., within the housing 422) to provide vertical and / or horizontal support. For example, multiple (e.g., two) bearings 434 may be used on shaft 208 to increase redundancy and safety. In some instances, a temperature sensor 504 or an accelerometer may be located within or adjacent to the bearing housing 422, enabling the flywheel 202 to detect failures of one or more bearings 434, thereby increasing safety margins. Other features, such as cooling circuits (e.g., through which recirculated coolant passes), vacuum connections, etc., may also be used.

[0168] As shown, one or more seals may be located within or adjacent to the shaft shaft. For example, a seal may be housed within a bearing / O-ring housing 422 and contact the smooth side of the shaft shaft to seal a vacuum. In some cases, when a vacuum is actively established or maintained, the seal may bend inward to change its shape to improve the sealing effect. Similarly, multiple configurations of seals (e.g., dual configurations) may be used for redundancy. Other structures, such as retaining clips, may be located on one or both sides of the bearing 434 so that they can be installed or replaced individually or together with housing 422.

[0169] In some embodiments, the bearings and / or seals / shafts may be lubricated, for example, using highly durable and / or vacuum-specific lubricants. In some embodiments, the seals may be made of special materials that enable them to operate in a vacuum environment and / or eliminate the need for a separate lubricant. Depending on the specific embodiment, the bearings may be dry bearings, such as ceramic hybrid bearings, which advantageously reduce eddy currents and other problems caused by movement in a magnetic field. Additionally or alternatively, these components may use dry film lubricants.

[0170] In some implementations, as shown, an exemplary magnetic lifting member 152 may interact (e.g., attract) with a flywheel 202, such as a top clamping plate 120a (and / or stacking plate 122). For example, as shown, the magnet of the magnetic lifting member 152 may be located above, below, or beside the center of the shaft 208a. For example, the magnet may be positioned by the magnetic lifting member 152 (also referred to as magnetic lifting aid / mechanism 152) to interact closely with a planar region (e.g., 444) of the top clamping plate 120a. For example, a top bearing 434 may hold the top clamping plate 120a / flywheel 202 at a defined distance from the magnetic lifting member 152, thereby applying a defined magnetic force to lift the flywheel 202 wholly or partially. For example, as described elsewhere in this document, the magnetic boost can be less than (e.g., such that the weight still acts on the bottom bearing), equal to (e.g., such that the weight is roughly balanced between the top and bottom bearings), or greater than (e.g., such that the top bearing prevents the flywheel 202 from being pulled toward the magnet) the weight of the flywheel 202 at a set distance.

[0171] As further detailed and described below, the magnetic lifting member 152 may be positioned adjacent to the clamping plate 120a, which may be a ferromagnetic (e.g., magnetic steel) planar surface (or a shape matching the shape of the magnetic lifting member). As shown, the flywheel 202 may be positioned at the center of the housing 104, but other embodiments are also possible. As described elsewhere herein, the magnet of the magnetic lifting mechanism 152 / member may be stationary and coupled to the housing because magnets are typically made of relatively fragile materials that cannot withstand rapid rotation (e.g., because rare-earth magnets are mechanically weak). Figure 5A In the example shown, a cavity is depicted in the magnetic lifting member 152, but the cavity may include one or more magnets, as described below. The magnetic lifting member 152 may be assembled into a unit and then attached to the cover 128 of the flywheel assembly 102 by bolts or other means.

[0172] In the example shown, the upper shaft 208a can be coupled to the motor directly or via a magnetic coupler 118, as described elsewhere in this document.

[0173] Figure 5B A cross-sectional view of an example lower shaft 208b disposed within the lower bearing assembly 524 of the flywheel housing 104 is shown. In the example shown, some components may be omitted for clarity. Similar to Figure 5AAs shown in the figure, the bottom shaft 208b can interact with multiple bearings 526 and / or seals or structures to provide vertical and / or horizontal support. For example, multiple (e.g., two) bearing assemblies can be used on shaft 208b to increase redundancy and safety. In some instances, a temperature sensor or accelerometer can be located within or adjacent to the bearing housing 524, enabling the flywheel 202 to detect bearing failures, thereby increasing safety margins, improving efficiency, etc. The stacking plate 122 is also shown in the figure.

[0174] As shown in Example 7B, an end cap 528 is also illustrated. The end cap 528 seals (e.g., using washers and bolts) the internal cavity of the housing 104. The end cap 528 provides access for moving the flywheel 202 within the housing 104; installing, maintaining, or adjusting the bearing 526 and seals; and performing other operations.

[0175] In some embodiments, the end cap 528 and / or other components may be threaded, allowing the position of the bearing 526 and / or seal to be adjusted by screwing and moving it up and down; or the flywheel 202 itself may be lifted to set its position within the housing 104. In other embodiments, the flywheel 202 may be manually adjusted (e.g., to maintain a defined distance from the magnetic lifting member 152).

[0176] Figure 5C A schematic diagram showing the coupling of an example flywheel 202 with a portion of a magnetic lifting member 152 and a lower bearing assembly outside the flywheel housing 104 is provided for illustrative purposes.

[0177] like Figure 5C As illustrated, the external structure of the magnetic lifting member 152 has been omitted to show the magnet 532 (which may be a wedge magnet) and its exemplary relative position to the top clamping plate 120a. For example, the wedge magnet 532 can exert a pulling force on a planar region (e.g., 444) of the clamping plate 120a in an activated configuration, but other embodiments are possible and conceivable. It should be noted that, for ease of illustration, the magnet 532 and other components of the magnetic lifting member 152 are presented in the figure as if suspended above the top clamping plate 120a (e.g., rather than fixed to the housing 104 / cover 128).

[0178] Figure 5C The example also shows a lower bearing assembly 524 located at the bottom of the flywheel housing 104, which carries one or more bearings. For example, the lower bearing assembly 524 may be fixed to the housing cylinder 126 by welding, integral molding, or bolting. The lower bearing 524 may support all, part, or no weight of the flywheel 202. In some embodiments, the lower bearing 524 may be used solely to maintain the horizontal alignment of the flywheel 202.

[0179] The lower bearing 524 may include a transport support area 534 (e.g., a transport ring) on ​​which the weight of the flywheel 202 can be borne during transport, storage, or when not in use. The transport support area 534 may be any device capable of supporting the flywheel 202, such as a plastic or metal ring within the housing cylinder 126.

[0180] Because the number of stacked plates 122 (e.g., 10, 14, 18, 28 or other quantities) may vary, and the thickness of each plate may vary (e.g., on the order of one-thousandth of an inch), the total thickness variation of flywheel 202 may be sufficient to affect the function or lifespan of the bearing. Therefore, as shown in the figure, the height and / or relative position of the bearing must be adjustable to accommodate different height requirements.

[0181] As described elsewhere in this document, a fixed end cap 528 or other mechanism can seal the housing and / or secure the adjusting nut to prevent accidental movement, thereby locking the flywheel 202 to its Z-axis / vertical axis.

[0182] Figure 6A An example assembly of the upper bearing of the flywheel assembly 102 is shown, including a magnetic motor coupler 118, a top shaft 208a, an upper bearing seal / O-ring housing 422, and a magnetic lifting member 152. It should be noted that although these components are shown as separate parts, they can be combined or further disassembled. For example, the bearing housing 422 can be combined with the magnetic lifting member 152 and / or the magnetic coupler 118.

[0183] like Figure 6A As shown in the example, the top shaft can pass through a magnetic lifting member 152, which is a ring coupled to a cover (e.g., its underside) of the flywheel housing 104. For example, the magnetic lifting member 152 can be positioned at the very bottom of the upper bearing assembly to be as close as possible to the flywheel 202 (e.g., close to the top clamping plate 120a) to maximize the magnetic attraction. For example, when the flywheel 202 weighs 1800 pounds, the magnetic lifting member 152 can generate a pull of 1500 pounds at a limited distance, thus subjecting the bottom bearing to a load of only 300 pounds. In another configuration, when the flywheel weighs 1800 pounds, the magnetic lifting member can generate a pull of 2100 pounds, thus subjecting the top bearing to an upward thrust of 300 pounds.

[0184] The upper bearing O-ring housing 422 may accommodate one or more seals and / or one or more bearings 434 (in Figure 6A(Not visible in the document). For example, bearing 434 and seals may interact with top shaft 208a. The bearing, described elsewhere in this document, prevents top shaft 208a from moving upward (e.g., due to the action of magnetic lifting member 152) and / or prevents shaft 208a from wobbling about its axis. As mentioned above, bearing 434 may be dual-configured for redundancy. In some instances, upper bearing O-ring housing 422 may also include one or more sensors for detecting bearing problems.

[0185] The arrangement of the upper bearing 434 may be designed to reduce friction and / or provide horizontal and / or vertical support. Although the bearing 434 may be configured in dual or triple configurations for redundancy, minimal stress should be applied to the bearing by balancing the flywheel 202 and / or by using a support mechanism (e.g., magnetic lifting member 152). The bearing 434 may be a ceramic / ceramic hybrid bearing and / or may use a dry film lubricant.

[0186] The upper bearing O-ring housing 422 may additionally or alternatively accommodate one or more seals that interact with the shaft of the top shaft 208a, and / or the seals may be combined with the bearing 434 as described above. In some cases, the seals may be integrated into another component, such as the electric generator housing, the magnetic lifting member 152, the housing cover 128, and / or other components.

[0187] The upper bearing O-ring housing 422 can be connected to the top of the housing cover 128, the top of the magnetic lifting member 152, the bottom of the magnetic coupler 118, or another part of the flywheel assembly 102.

[0188] The magnetic coupler 118 may be located near the electric generator 110, for example, near the end of the top shaft 208a, to interact with the top shaft 208a. As described elsewhere herein, the magnetic coupler 118 may interact with the shape, groove, mechanical key 416, or other components of the top shaft 208a to transmit torque to or receive torque from it.

[0189] Example embodiments of the magnetic coupler 118 are described below and may include various components, such as an outer rotor top 412 and an outer rotor bottom 410, and an inner rotor top 414 and an inner rotor bottom (not visible) that are rotatable within the outer rotor top 412 and / or outer rotor bottom 410. For example, the outer rotor top 412 and / or bottom 410 may be coupled (e.g., by bolting) to a motor mount, an upper bearing O-ring housing 422, a housing cover 128, or other components, as described elsewhere herein.

[0190] Figure 6BA top view of an example magnetic lifting member 152 is shown. As shown, a top shaft 208a can pass through the magnetic lifting member 152, which can interact with the shaft 208a and / or the flywheel 202 (e.g., via the top clamping plate 120a). Figure 6B (Not visible in the image). As described above, the magnetic lifting member 152 can support a weight less than, equal to, or greater than that of the flywheel 202.

[0191] like Figure 6B As shown, the top shaft 208a may include a mechanical key 416 for improving the connection with the magnetic coupler 118 (in Figure 6B (Not visible in the middle).

[0192] As shown, bearing 434 can be held at the center of magnetic lifting member 152, for example, via upper bearing housing 604. Upper bearing housing 604 can be held by magnetic lifting member 152, upper bearing O-ring housing 422, housing cover 128, etc. For example, upper bearing housing 604 can be located inside or above the ring of magnetic lifting member 152. Magnetic lifting member 152 can be bolted to the bottom of housing cover 128 (e.g., using the bolts shown in the figure).

[0193] According to a specific embodiment, the magnetic lifting member 152 may include a magnetic levitation backing 606 (also referred to as a backing ring), to which a magnet may be attached or otherwise supported, as described below. In some embodiments, the magnetic lifting member 152 may additionally or alternatively include a magnet retainer 608, which may be coupled to the magnetic levitation backing 606 and / or the magnet. For example, the magnet retainer 608 may be a cover or structure covering the bottom of the magnet to help support the magnet, and / or connected to the magnetic levitation backing 606 by bolts.

[0194] Figure 6C A bottom view of an example magnetic lifting member 152 is shown. As shown, a magnet retainer 608 may extend below the magnet to protect the magnet and / or secure it to a magnetic levitation backing 606 or other components. In the example shown, an upper bearing housing 604 may be coupled (e.g., by bolts or welding) to the magnetic lifting member 152 and provide horizontal and / or vertical support for a bearing 434. The magnetic levitation backing 606 may be a flat plate or disc with bolt holes to which the magnet retainer 608 may be attached. Similarly, the magnetic levitation backing 606 may be bolted to a cover 128 of the housing 104. Figure 6C (Not shown in the image). The magnet holder 608 may support the magnet or simply cover the magnet, but other embodiments are also possible. The magnet holder 608 and the magnetic levitation backing 606 may be circular, have protrusions (e.g. for bolts), or have other shapes. Similarly, these components may be bolted to the center, outer edge, or otherwise supported.

[0195] Figure 6D A bottom view of an example internal component of the magnetic lifting member 152 is shown. As illustrated, the magnet retainer 608 and upper bearing seat 604 have been omitted to show the example internal structure of the magnetic lifting member 152. In the example shown, the magnetic levitation backplate 606 is coupled to a plurality of magnets 532. For example, the magnets 532 may be adhered to the magnetic levitation backplate 606 and / or secured by the magnet retainer 608.

[0196] The magnetic levitation backplate 606 may be a robust ring (e.g., a steel ring) for securing the magnet 532. The ring may include bolts or other connection points for coupling with the upper bearing housing 604, the magnet retainer 608, and / or the housing 104 (e.g., the housing cover 128), as illustrated and described herein.

[0197] Bolts are illustrated as passing through various components described herein, such as in a magnetic levitation backing 606. In some embodiments, the length of the bolt may be the same as the length of the bolt hole it occupies, for example, to reduce gaps or other discontinuities, which may further contribute to inconsistencies in eddy currents, magnetic flux, etc. For example, the bolt may be tailored to have the same size and length as the hole.

[0198] Magnet 532 can be a wedge-shaped magnet disposed around the magnetic levitation backing 606 with the magnetic flux direction downward to maximize interaction with flywheel 202. For example, as shown, magnet 532 can be located on a stationary part of flywheel 202 rather than a rotating part, because the magnet may be made of a weaker material that could break under stress at high speeds. Furthermore, placing magnet 532 on a stationary part can reduce eddy currents and the forces generated therefrom.

[0199] In some embodiments, the top clamping plate 120a may be composed of a laminated core of insulating metal sheets or made of a non-conductive material to reduce eddy currents in the top clamping plate 120a, but other embodiments may also be adopted as described in other parts of this document.

[0200] Figure 6E A top view of another example magnetic lifting member 152 is shown. In the illustrated embodiment, a back plate 606 and a magnet retainer 608 are shown. A bearing 434, secured by an upper bearing housing 604 around an upper shaft 208a, is also shown. A retaining ring 622 is shown around the upper shaft 208a, which secures the bearing 434 in place.

[0201] In the illustrated example, a cooling assembly 624 is also shown surrounding or integrated with the bearing housing 604. For example, the cooling assembly 624 may have a cooling ring 626 that allows coolant to circulate around the bearing housing 604 or another component. The cooling ring 626 may be coupled to a coolant pipe 628 that contains coolant, delivers it to the cooling ring 626, and discharges it to a pump and / or radiator (not visible) outside these structures.

[0202] In the example shown, a connector assembly 632 or connector sealing plate with a barbed tube body connector and electrical connections is also illustrated. Connector assembly 632 can accommodate pneumatic tubing for vacuum assembly 108, pneumatic tubing for cooling ring 626, electrical connections for sensors, and / or other components. Although connector assembly 632 is shown suspended above magnetic lifting member 108, it can be coupled to or integrated with cover 128 or various other components. For ease of illustration, Figure 6E Other components, such as support brackets, seals, and motors, are omitted.

[0203] Figure 7A and 7B Various views, components, and configurations of an exemplary flywheel-motor coupler (e.g., a magnetic coupler 118 coupling an electric generator 110 to a flywheel 202) are shown. While a magnetic coupler 118 is described, it should be noted that physical direct coupling, clutches, gears, or gearboxes may also be used. As shown, the magnetic coupler 118 may be positioned at the end of the top (or bottom in other embodiments) shaft 208 to interact with the flywheel 202.

[0204] Magnetic coupler 118 allows mechanical interaction between the electric generator 110 and the flywheel 202. For example, as described below, both the inner rotor 714 (which may include the inner rotor 414 described above) and the outer rotor 712 (which may include one or more of the top outer rotor 412 and the bottom outer rotor 410 described above) may include interacting magnets 702 to transmit forces. Magnetic coupler 118 can provide a damping effect between the generator 110 and the flywheel 202 to prevent the transmission of vibrations or shocks. For example, alternating magnets 702 may be used, which act as gears using their shear effect and can produce a damping effect.

[0205] like Figure 6A The example magnetic coupler 118 can be coupled to a top shaft 208a, which, according to a specific embodiment, passes through a magnetic lifting member 152 and an upper bearing housing 422. As shown, the magnetic coupler 118 can be located at the end of the top shaft 208. Figure 7A and 7B The upper bearing O-ring housing 422 is also omitted to show other components.

[0206] In some embodiments, the magnetic coupler 118 can be assembled into a single unit, which can be bolted to a motor mount (e.g., 406) and / or a flywheel housing 104. Therefore, it can be pre-assembled, improving both safety and speed in the manufacturing process.

[0207] Figure 7A An example magnetic coupler 118 is shown, with the top of its outer rotor (e.g., 412 and top assembly 414) removed to expose the internal structure of the magnetic coupler 118. As shown in the example embodiment, a series of magnets 702 may be disposed at the inner rotor 714 and the outer rotor 712. Cylindrical magnets (e.g., N52 neodymium magnets) may be used and placed in the rotors 714 and / or 712 with their magnetic poles arranged alternately, although other embodiments are also possible. In some embodiments, the magnets 702 may be rectangular or other shapes or configurations. Similarly, although the rotors 714 and 712 are arranged radially relative to each other, they may also be vertically (e.g., the magnets relative to the rotors are arranged vertically rather than radially) or otherwise oriented.

[0208] Magnet 702 can generate interacting shear forces, thereby coupling rotors 712 and 714 together. For example, opposing magnets can be oriented with their north and south poles facing each other to attract each other. In some embodiments, the shear forces can be maximized to couple rotors 712 and 714 when magnets 702 are offset from each other.

[0209] In some embodiments, a seal or diaphragm may be provided between rotor 712 and rotor 714 to maintain a vacuum inside housing 104.

[0210] As shown, the magnetic coupler 118 may include multiple bolts for coupling the various components together. For example, one or more bolts may connect the bottom of the inner rotor 714 and / or the inner rotor splitter 722 (e.g., connected to or integrated with the inner rotor 714) to other components, such as the electric generator 110 or the top shaft 208a. Similarly, other bolts may connect the outer rotor splitter 724 (e.g., connected to or integrated with the inner rotor 712) and other components together. The bolts may be used to adjust the positioning of the magnetic coupler 118.

[0211] As shown in the figure, the magnetic coupler 118 may include an inner shunt 722 and an outer shunt 724 or a backing ring (e.g., a steel backing ring). These components provide structural support for the magnet 702 and / or improve magnetic flux. For example, the shunt or backing ring allows for more precise control and focusing of the magnetic flux. In some cases, these components can also enhance the structural strength of the assembly.

[0212] In some cases, the shunt 722 / 724 or other devices or flanges that secure the magnet 702 to the rotor 712 / 714 may need to be reinforced because the rotor will not only experience hundreds or thousands of pounds (e.g., 2500 pounds) of magnetic attraction, but also significant centrifugal forces as the flywheel 202 rotates (e.g., at a speed of 12,500 RPM). As shown, to reduce the radial forces acting on the magnet 702, it can be positioned close to the axis of rotation.

[0213] Although not illustrated, in some embodiments, the electric generator may be coupled to the top of the inner rotor (e.g., at 414). In other embodiments, as described elsewhere in this document, the electric generator may be coupled directly to the top shaft 208a or via other mechanisms. In some cases, the electric generator 110 may be a separable / idle / glide synchronous reluctance motor.

[0214] Figure 7B An exemplary magnetic coupler 118 is shown, with the outer rotor bottom 412 and other components removed to reveal components of an exemplary inner rotor 714. As shown, a plurality of inner rotor shunts 722 may be located on magnet 702 ( Figure 7B (not shown in the diagram) radially inside. In embodiments where the magnet 702 is cylindrical, the bottom 714 of the inner rotor may include a profile or other structure for fixing the magnet 702.

[0215] Although not shown, the bar magnet 702 may be connected to the inner rotor 714 and the outer rotor 712. As described above, the magnetic coupler 118 may include a shunt 722 or shunt 724 for securing the magnet 702 and / or guiding the magnetic field. In some embodiments, the outer rotor 712 body and / or the inner rotor 714 body may each be clamped above and / or around the magnet 702 to secure it. For example, the inner rotor 714 body may include a flange bent around its magnet surface to secure it.

[0216] In the foregoing description, numerous specific details have been set forth to provide a thorough understanding of the technology. However, it will be apparent, however, that the technology described herein can be implemented without these specific details.

[0217] References to "one embodiment," "an embodiment," "some embodiments," or "other embodiments" in the specification mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of this disclosure. The terms "embodiment" or "multiple embodiments" appearing throughout the specification do not necessarily all refer to the same embodiment.

[0218] Furthermore, it should be understood and recognized that variations, combinations, and equivalents of the specific embodiments, embodiments, and examples may exist, are intended to include, and thereby encompass. Therefore, the present invention should not be limited to the foregoing embodiments, embodiments, and examples, but should be limited to all embodiments, embodiments, examples, and other equivalents within the scope and spirit of the invention as defined by the claims.

Claims

1. A system comprising: A large flywheel, the large flywheel comprising a rotatable mass component and one or more shafts coupled to the rotatable mass component; A magnetic lifting component having one or more magnets positioned around a central through-hole, the one or more shafts passing through the central through-hole of the magnetic lifting component, the one or more magnets pulling the large flywheel toward the magnetic lifting component; A support structure coupled to the magnetic lifting component, the support structure holding the magnetic lifting component in a stationary position relative to the support structure; as well as One or more bearings, which are coupled to the support structure and the one or more shafts to maintain the one or more shafts on a rotational axis.

2. The system according to claim 1, wherein, The rotatable, high-mass component includes: A top plate having a flat top surface, the top plate rotating about the rotation axis, the flat top surface being positioned adjacent to the one or more magnets of the magnetic lifting component, the top plate being attracted by the one or more magnets to reduce the downward force of the large flywheel acting on the one or more bearings.

3. The system according to claim 2, wherein, The rotatable, high-mass component includes: The top plate; Multiple large mass plates, said multiple large mass plates stacked together; and The base plate, wherein the plurality of large mass plates are located between the top plate and the base plate.

4. The system according to claim 3, wherein, The top plate and the bottom plate are coupled together by a plurality of fasteners, and the top plate and the bottom plate apply compressive force to the plurality of large mass plates.

5. The system according to claim 1, wherein, The one or more shafts at the rotation axis include a top shaft and a bottom shaft, the top shaft being separate from the bottom shaft, and the top shaft passing through the central perforation of the magnetic lifting component.

6. The system according to claim 1, wherein, The one or more bearings include: One or more top bearings and one or more bottom bearings, the one or more top bearings interacting with the top of the large flywheel at one or more shafts, and the one or more bottom bearings interacting with the bottom of the rotatable large mass component at one or more shafts.

7. The system according to claim 1, wherein, The one or more magnets are configured to pull the large flywheel with a force greater than the weight of the large flywheel.

8. The system according to claim 1, further comprising: One or more seals form an airtight seal between the inside and outside of the flywheel housing, the support structure includes the flywheel housing, and the large flywheel is located inside the flywheel housing.

9. The system according to claim 1, wherein, The support structure includes a cover, and the rotatable, high-mass component is positioned within the support structure; The one or more magnets are coupled to the bottom side of the cover; and The one or more magnets are positioned within the support structure.

10. The system according to claim 9, wherein, The support structure includes a sealed outer shell; Vacuum assembly, coupled to the cover to create an internal vacuum; and The one or more magnets are positioned within the internal vacuum.

11. The system according to claim 1, wherein, The magnetic lifting component includes: A backing ring, the backing ring being coupled to the support structure; The one or more magnets, the one or more magnets being disposed on the backing ring; and A magnet retainer that surrounds the one or more magnets and is coupled to the backing ring.

12. The system according to claim 1, further comprising: A magnetic coupler having a first rotor and a second rotor, the first rotor including a first set of magnets and the second rotor including a second set of magnets, the first set of magnets and the second set of magnets interacting to form a rotational coupling between the first rotor and the second rotor.

13. The system according to claim 12, in, The first rotor is positioned within at least a portion of the second rotor, the first rotor is coupled to one or more shafts, and the second rotor is coupled to a motor.

14. A mechanical energy storage unit, comprising: A large flywheel, the large flywheel comprising a rotatable mass component and one or more shafts coupled to the rotatable mass component, the rotatable mass component comprising: Top clamping plate; Multiple large-capacity boards; A bottom clamping plate, wherein the plurality of large-mass plates are positioned between the top clamping plate and the bottom clamping plate; and Multiple fasteners couple the top clamping plate to the bottom clamping plate and apply compressive force to the multiple large mass plates; A magnetic lifting component having one or more magnets positioned around a central through-hole, the one or more shafts passing through the central through-hole in the magnetic lifting component, the one or more magnets pulling the large flywheel toward the magnetic lifting component, and a top clamping plate positioned adjacent to the one or more magnets of the magnetic lifting component; A support structure coupled to the magnetic lifting component, the support structure holding the magnetic lifting component in a stationary position relative to the support structure; and One or more bearings, coupled to the support structure and the one or more shafts to hold the one or more shafts on a rotation axis, the top clamping plate being attracted by the one or more magnets to reduce the downward force of the large flywheel on the one or more bearings.

15. The mechanical energy storage unit according to claim 14, wherein, The one or more magnets are configured to pull the large flywheel with a force greater than the weight of the large flywheel.

16. The mechanical energy storage unit according to claim 14, wherein: The support structure includes a cover, and the rotatable, high-mass component is positioned within the support structure; as well as The magnetic lifting component is coupled to the cover.

17. The mechanical energy storage unit according to claim 14, wherein, The magnetic lifting component includes: A backing ring, the backing ring being coupled to the support structure; The one or more magnets, the one or more magnets being disposed on the backing ring; and A magnet retainer that surrounds the one or more magnets and is coupled to the backing ring.

18. A component for a flywheel, comprising: A magnetic lifting component has one or more magnets positioned around a central through-hole, one or more shafts of a flywheel passing through the central through-hole in the magnetic lifting component, the one or more magnets pulling the flywheel toward the magnetic lifting component, the magnetic lifting component being held by a support structure, wherein the magnetic lifting component includes: A backing ring, the backing ring being coupled to the support structure; The one or more magnets, the one or more magnets being disposed on the backing ring; and A magnet retainer coupled to the backing ring and providing support for the one or more magnets.

19. The component of claim 18, wherein, The one or more magnets are configured to pull the flywheel with a force greater than the weight of the flywheel.

20. The component of claim 18, wherein: The support structure includes a housing with a cover, and the flywheel is positioned inside the housing; The one or more magnets are coupled to the bottom side of the cover; and The one or more magnets are positioned within the housing.

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