Multiple Flywheel Hybrid System for Off-Highway Energy Storage
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Solution Overview
Problem
The increasing demands for energy storage in larger off-highway machines have led to the need for more massive and costly flywheel systems, with existing solutions focusing on higher-speed flywheels in vacuum housings, but there is a requirement for even greater energy storage and use.
Innovation Solution
A system of multiple flywheels, each with an external gear and clutch unit, connected to a single common transmission via a CVT shaft and gear arrangement, allowing for sequential operation and energy storage and release, working in concert with an internal combustion engine to provide a hybrid motive source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a single large flywheel is used to meet increasing energy storage demands, then energy storage capacity is improved, but system cost and mass increase
Solution Approach 1:
The patent divides a single large flywheel system into multiple smaller flywheels (typically three) that operate in sequence. Each flywheel stores a portion of the total energy, and they are engaged alternately to meet peak power demands. This segmentation allows the system to achieve equivalent energy storage capacity without requiring a single massive flywheel, thereby reducing manufacturing costs and complexity while maintaining the necessary energy storage capability.
2Use of energy by moving object
If flywheel size and mass are increased to meet energy demands, then energy storage capacity is improved, but system complexity and cost increase
Solution Approach 1:
By segmenting the energy storage function across multiple smaller flywheels, the patent reduces the complexity of individual components while maintaining total system capability. Each flywheel is a standardized, manageable unit that can be manufactured and maintained more easily than a single large flywheel.
Solution Approach 2:
The patent employs periodic engagement of multiple flywheels in sequence, where each flywheel is activated at specific intervals to meet transient power demands. This periodic action allows the system to distribute the operational stress and complexity across multiple components rather than concentrating it in a single large flywheel, thereby managing system complexity while achieving the required energy storage capacity.
3Power
If higher-speed flywheels in vacuum housings are used, then energy output from single flywheel is improved, but system cost and complexity increase
Solution Approach 1:
The patent segments the high-power output requirement across multiple flywheels operating at moderate speeds rather than requiring a single flywheel to operate at extremely high speeds in vacuum housings. This approach achieves equivalent total power output while reducing the speed and vacuum requirements for each individual flywheel, thereby lowering system cost and complexity.
Solution Approach 2:
The patent merges the power output capability of multiple flywheels to achieve the total energy output required for off-highway machine applications. By combining the output of several moderate-speed flywheels, the system achieves the same total power as a single high-speed flywheel would provide, but with reduced manufacturing costs and simpler system architecture.
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 allows for equivalent energy storage and release as a larger unitary flywheel, reducing costs by using smaller, more efficient flywheels, enabling the use of smaller engines and reducing energy losses, while providing a versatile hybrid system configuration.
Implementation Method 1
Engine driven flywheels have been long recognized as energy dense sources from which mechanical work may be derived
Data Source
AI summary
A kinetic energy system incorporates multiple flywheels, each flywheel situated and adapted to develop and store kinetic energy, and to subsequently impart that energy to move a work machine. Each flywheel is controlled by an ECM to operate in a selective sequence with respect to any of the other flywheels. Each flywheel has its own individual external gear and clutch unit adapted to be in communication with a commonly shared continuously variable transmission. The plurality of flywheels may be operated sequentially to develop, store, and dispense kinetic energy equivalently to that of a substantially larger unitary flywheel. In the disclosed embodiment and method of operation, the flywheel system may be employed with a traditional internal combustion engine to produce a hybrid motive source, with capability for effectively meeting transient load demands of an off-road work machine.