Flywheel Assembly with Selective Clutch Coupling for Powertrain Energy Management

Solution Overview

Problem

Flywheel energy storage devices face inefficiencies due to mechanical losses when positioned either upstream or downstream of a transmission in machines, as they either fail to efficiently capture energy during regenerative braking or struggle with spin-up due to increased mechanical losses.

Innovation Solution

A powertrain system with a flywheel assembly that allows selective coupling to the engine and lower powertrain, bypassing the transmission in different modes to minimize mechanical losses, using a bypass clutch and flywheel clutch controlled by an electronic control module to operate in upstream or downstream modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the flywheel is positioned upstream of the transmission, then the flywheel can efficiently spin up during startup, but mechanical losses increase during regenerative braking

Engineering Contradiction:

Improveflywheel spin-up speedVSAvoidmechanical losses during regenerative braking

Core Design Contradiction:

SpeedVSLoss of energy

Solution Approach 1:

The system dynamically changes the flywheel's position in the powertrain by using two clutches to selectively couple the flywheel to either the upstream side (for spin-up) or downstream side (for regenerative braking) of the transmission. This dynamic reconfiguration allows the system to optimize for different operational modes: upstream coupling enables efficient spin-up during startup, while downstream coupling minimizes mechanical losses during regenerative braking.

Inventive Principle:

Principle #15Dynamics

2Loss of energy

If the flywheel is positioned downstream of the transmission, then mechanical losses are reduced during regenerative braking, but the flywheel cannot be efficiently spun up during startup

Engineering Contradiction:

Improvemechanical losses during regenerative brakingVSAvoidflywheel spin-up speed

Core Design Contradiction:

Loss of energyVSSpeed

Solution Approach 1:

The system dynamically changes the flywheel's position in the powertrain by using two clutches to selectively couple the flywheel to either the upstream side (for spin-up) or downstream side (for regenerative braking) of the transmission. This dynamic reconfiguration allows the system to optimize for different operational modes: upstream coupling enables efficient spin-up during startup, while downstream coupling minimizes mechanical losses during regenerative braking.

Inventive Principle:

Principle #15Dynamics

3Power

If the flywheel is directly coupled to the engine output, then the flywheel can add to or subtract from engine power, but energy capture during regenerative braking is reduced by mechanical losses through the transmission

Engineering Contradiction:

Improveengine power assistanceVSAvoidmechanical losses during energy capture

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The system dynamically changes the flywheel's position in the powertrain by using two clutches to selectively couple the flywheel to either the upstream side (for spin-up) or downstream side (for regenerative braking) of the transmission. This dynamic reconfiguration allows the system to optimize for different operational modes: upstream coupling enables efficient spin-up during startup, while downstream coupling minimizes mechanical losses during regenerative braking.

Inventive Principle:

Principle #15Dynamics

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

This configuration enhances the overall efficiency of the flywheel by reducing mechanical losses during various modes of operation, such as spin-up and regenerative braking, allowing for more effective energy storage and deployment.

Implementation Method 1

Flywheels are generally known in the art for storing energy

Methodology Applied

Scientific EffectKinetic energy storage: Flywheel

Implementation Method 2

A bypass clutch may be configured to selectively couple the bypass shaft to the first flywheel shaft

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS9162560B2Flywheel assembly for a powertrain

Publication Date: 2015.10.20 CATERPILLAR INC

AI summary

A powertrain for a machine may include a flywheel and a drivetrain having multiple configurations to permit the flywheel to be mechanically connected both upstream and downstream of a transmission. A bypass clutch may be used to selectively couple the flywheel directly to the engine, while a flywheel clutch may be used to selectively couple the flywheel directly to a lower powertrain. In both upsteam and downstream modes of operation, the transmission is bypassed to increase flywheel energy storage and use, as well as expanding the functionality of the flywheel.