Segmented Flywheel Disc Stack for High-Speed Energy Storage
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Solution Overview
Problem
Existing flywheel designs face challenges in withstanding high centrifugal stresses at supersonic rotational speeds while ensuring safety and reducing manufacturing costs.
Innovation Solution
A flywheel design comprising a stack of discs with disc apertures and plate members, where the connection means clamps the plate members together about the stack without contacting the discs, reducing stress transfer and minimizing the risk of cascade failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the inertia element operates at very high peripheral speeds to store high levels of energy, then energy storage capacity is improved, but centrifugal stresses increase significantly
Solution Approach 1:
The inertia element is divided into multiple thin discs stacked together, with each disc experiencing lower individual stresses compared to a single monolithic structure at the same peripheral speed. This segmentation allows the flywheel to operate at higher speeds while maintaining structural integrity.
Solution Approach 2:
The flywheel uses composite construction with discs made from materials optimized for high-speed rotation, combined with bonding materials that can withstand centrifugal forces. This composite approach enables higher energy storage capacity while managing the stresses induced by high peripheral speeds.
2Strength
If monolithic steel inertia elements are used in energy storage flywheels, then structural strength is improved, but safety risks increase due to catastrophic failure modes
Solution Approach 1:
The monolithic inertia element is segmented into multiple thin discs that can fail independently rather than catastrophically. If one disc fails, the bonding structure prevents complete disintegration, significantly improving safety while maintaining structural strength for high-energy storage.
Solution Approach 2:
Bonding materials and containment structures are designed to cushion and contain potential failure fragments before they can cause catastrophic damage. This preemptive safety measure allows the flywheel to operate at high speeds with reduced risk.
3Reliability
If ultra-high quality materials and rigorous monitoring are used to prevent rotor structural failure, then reliability is improved, but manufacturing cost and time increase
Solution Approach 1:
The segmented disc structure allows for standardized mass production of individual discs using less expensive materials and processes, reducing manufacturing cost and time while maintaining reliability through the inherent safety of the segmented design.
Solution Approach 2:
The design accepts that individual discs may need replacement rather than requiring the entire rotor assembly to be replaced. This allows for cheaper, easier-to-manufacture individual discs that can be swapped out if needed, reducing overall system cost.
4Reliability
If heavy containment vessels or underground bunkers are used to ensure safety, then safety is improved, but installation flexibility and cost are worsened
Solution Approach 1:
The segmented disc design with inherent safety features reduces the need for heavy containment structures, allowing for lighter, more flexible installation options above ground while maintaining high safety standards.
Solution Approach 2:
The design converts the potential harm of high-speed rotation into a benefit by using the segmented structure to control failure modes, thereby reducing the containment requirements and enabling more flexible installation locations.
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
The design enhances safety and operational longevity at high rotational speeds by minimizing stress concentrations and preventing catastrophic failures, while also reducing manufacturing costs and enabling compact, above-ground installations.
Implementation Method 1
connection means for clamping the first and second plate members together about the stack of discs
Implementation Method 2
The inertia element stores energy by virtue of its angular momentum; the faster it rotates, the more energy is stored
Implementation Method 3
the inertia element stores energy by virtue of its angular momentum
Implementation Method 4
A major design challenge for inertia elements used in the energy storage class of flywheels is how to withstand the high centrifugal stresses induced by the high peripheral speeds
Data Source
AI summary
A flywheel (100) comprising a plurality of discs (102) arranged in a stack (104), including at least first and second end discs at either end of the stack (104), each of the plurality of discs (102) including a plurality of disc apertures (102a) therethrough, first and second plate members (106) disposed at opposing ends of the stack (104), one or both of the first and second plate members (106) including a plurality of plate apertures (106a) therethrough for alignment with the plurality of disc apertures (102a) in the first and second end discs respectively, connection means (114) for clamping the first and second plate members (106) together about the stack (104) of discs (102), the connection means (114) extending through each of the plurality of disc apertures (102a) without contacting the plurality of discs (102).