Mechanical Flywheel Brake Ring for Emergency Rotor Deceleration
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Solution Overview
Problem
Flywheel systems face challenges in rapidly and safely reducing rotor speed during malfunctions or external perturbations, such as seismic events or bearing failures, as existing solutions like magnetic levitation and touchdown bearings have limitations in size, weight, and durability.
Innovation Solution
A mechanical braking system featuring a stationary annular ring made of metal or surfaced with brake pads, mounted below the rotor, which allows for rapid deceleration by contacting the rotor when the magnetic levitation system fails, acting as both an emergency brake and a sliding touchdown bearing, eliminating the need for external loads and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If magnetic levitation or touchdown bearings are used to support and control the rotor, then the rotor can operate at high speeds with reduced friction, but the system becomes limited in size and weight capacity
Solution Approach 1:
The patent introduces a mechanical braking ring as an intermediary component between the rotor and the housing. This braking ring serves as a mediator that enables the rotor to be rapidly decelerated and stopped during emergency conditions without compromising the magnetic levitation system's ability to support heavy rotors at high speeds during normal operation. The braking ring acts as a safety intermediary that allows the system to handle larger, heavier rotors while maintaining speed control capability.
2Reliability
If conventional braking systems are added to rapidly stop the rotor during emergencies, then safety is improved, but the device complexity increases
Solution Approach 1:
The patent extracts the braking function from complex external braking systems and integrates it directly into the housing structure through a simple, stationary braking ring. This braking ring is a straightforward mechanical component that contacts the rotor periphery to provide rapid deceleration. By taking out the complexity of external braking mechanisms and replacing them with this simple integrated ring, the system achieves reliable emergency stopping capability while minimizing added complexity.
Solution Approach 2:
The braking ring serves multiple functions: it acts as a mechanical brake for rapid emergency stopping, provides a touchdown surface for the rotor during shutdown or failure conditions, and enables the system to safely handle larger, heavier rotors. This multi-functional design improves reliability without requiring separate specialized components for each function, thereby avoiding increased device complexity.
3Quantity of substance
If larger and heavier rotors are used to increase energy storage capacity, then energy storage is improved, but the ability to rapidly decelerate the rotor during emergencies deteriorates
Solution Approach 1:
The patent implements a preliminary action by pre-positioning the stationary braking ring within the housing before any emergency occurs. This braking ring is already in place and properly positioned to contact the rotor periphery, ensuring that when an emergency deceleration is needed, the system can immediately apply braking force without delay. This preliminary preparation allows larger, heavier rotors to be rapidly decelerated when needed, resolving the contradiction between increased energy storage capacity and emergency deceleration capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables safe and rapid deceleration of high-speed flywheel rotors without damaging the rotor or bearings, allowing for larger and heavier rotors with increased energy storage capacity, reducing downtime and maintenance costs, and maintaining operational safety without the limitations of current state-of-the-art solutions.
Implementation Method 1
a rotor supported by a pair of magnetic levitation (maglev) or rolling element bearings
Implementation Method 2
the rotor is held in a vertical position by a magnetic system
Implementation Method 3
The braking ring is made of bare metal such as steel or cast iron or surfaced with brake lining pads bolted to the ring
Data Source
AI summary
The flywheel device includes a sealed housing section; a rotor located in the sealed housing section where the rotor is held in a vertical position by a magnetic system; a controller coupled to the magnetic system; and a braking annular ring mounted to the sealed housing section below the rotor, where the rotor contacts the braking annular ring when the rotor is lowered or otherwise dropped from the vertical position. The controller performs operations to provide control signals to provide first power to the magnetic system to hold the rotor in the vertical position and provide second control signals to provide second power to the magnetic system to lower the rotor.