Abstract:
An energy storage flywheel whose energy storage capacity has been enhanced by the use of circumferentially applied composite fibers. The use of high density metal wafers being laminated with isolating low density laminations ensures maximum energy storage for a given mass and safely limits instant total energy release or the ejection of failed objects upon the event of a mechanical failure.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of Provisional Patent Application No. 61/852,000 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
       [0002]    Not applicable 
       BACKGROUND OF THE INVENTION 
     Field of the Invention (Technical Field) 
       [0003]    The present invention relates to flywheels, utilizing the mass benefits of metal, the high strength bonding capability of flexible epoxies and the structural benefits of high strength carbon composites. 
       BRIEF SUMMARY OF THE INVENTION 
       [0004]    The embodiment of the present invention is a flywheel or alternatively called a momentum wheel, assembled of structural component parts so juxtaposed as to increase the structural capability of each of the individual component thus increasing the functional capability of the assembled flywheel. 
       BACKGROUND OF THE INVENTION 
       [0005]    The energy storage capability and angular momentum of flywheels has long been recognized as a practical and efficient means to store energy and, if being held in gimbals, remains fixed in space epitomized as a conventional gyroscope. Historically flywheels were developed using solid metal configurations commonly driven by electric motors. As technology improved the speed of the flywheels was increased and ultimately reached a physical speed limit due to stresses caused by the rotational speed. When the rotational speed reaches a limit at which the stresses exceed the capability of the rotating material, it fails explosively releasing all its stored energy instantaneously. 
         [0006]    In an effort to store more energy, flywheels were developed that were made of high strength composite fibers forming the rotating member thus extending the ability to withstand rotational stresses. The function of a flywheel depends upon the mass of the rotating body and unfortunately those fibers are light in mass and therefore little storage was obtained. The function of the flywheel is also dependent upon the square of the speed of rotating body. The solution was to increase the speed more and more until finally speeds of 50-60000 RPM were used. Running a rotating body at those speed involved enormous physical problems in bearings, aerodynamic drag losses and aerodynamic heating as well since the tip speeds were supersonic. A rotor failure was of even greater concern. The sudden release of energy stored in the wheel was explosive and potentially could cause enormous damage. Containment housings were developed that are unreasonably heavy and expensive. Flywheels of designs representing prior art, used to store energy are typically buried in underground bunkers. To minimize the aerodynamic losses, the wheel must be run in a hard vacuum to reduce aerodynamic drive forces. Hard vacuums are virtually impossible to continuously maintain as the wheel ages. Elaborate bearing configurations such as active and passive magnetic, aerodynamic, liquid, cryogenic, and other sophisticated bearing techniques have been applied, all with marginal success. The speed of flywheels used as rotating bodies in gyroscopes, since it is impractical to bury them in underground or equivalent bunkers, were limited to slower speeds resulting in large safety factors or sizes that an explosive failure could be contained. That limitation has restricted the use in applications that benefit from the use of large gyroscopes. 
         [0007]    The flywheel of the present invention is an assembly of primarily dense materials and as such stores a large amount of energy at a rotational speed that does not benefit greatly from the use of a hard vacuum and allows the use of conventional bearings, thus avoiding the complications of the abnormally sophisticated bearings. 
         [0008]    Flywheels of the prior art even if constructed of high strength composite fibers relied upon the strength of the rotating material to determine the maximum operating rotational speed of the flywheel. In the present invention the ultra high strength composite fibers are not the primary source of stored energy but are used as means to extend the capability of the dense material making up the rotational mass. As a rotating mass spins, the forces imposed on the rotating material cause it to increase in circumference and as it increases in circumference, the materials of the spinning mass are stretched. As the rotational speed increases, that stretching increases until the material fails and as it fails it disintegrates and instantaneously releases all its contained energy. 
         [0009]    Random failures occur, and in prior art, when a failure occurs all the stored energy was instantaneously released. In the present invention, the mass of the rotational body is made up of assembly of circular laminations or wafers, each of which is a flywheel of itself and stores only its mass proportional share of the entire stored energy of the flywheel. If an anomaly were to occur in which that lamination were to fail, and if its fragments were to be allowed to move from their fixed, bonded in place location, only the small amount of energy that the failed lamination had contained would be released. In prior art the spinning mass was one unit; even those flywheels made of circumferentially wound fiber composites. The filaments of those circumferentially wound fiber wound wheels were bonded into a single mass. In some cases, layers of wound fiber were bonded into a pseudo laminations but a failure of a fiber would cause the entire mass to disintegrate. Descriptions are made in the prior art of having a laminated structure but in those embodiments, the laminations are really only circumferentially wound layers of continuously wound fibers creating a layered structure. In the present invention, each of the circular high density laminations is bonded to a low density, but structurally adequate adjacent circular lamination If a high density lamination were to fail, upon failure the circumferential stress (hoop stress) is instantly relieved when the lamination fractures. That leaves only centrifugal force operating upon the failed section. The entire interfacing surfaces of both the high density laminations and the low density lamination s are securely bonded together and because of the strength of the bonding material resulting from the large area of contact, the centrifugal force generated by the rotational action of the spinning wheel is only a fraction of the strength of the bond. In addition, each of the high density lamination is wrapped with a band of high strength composite fibers that have been wound under tension circumferentially around the high density lamination. As a result of these two restraining actions, upon the event if a structural failure, the fractured piece of the high density lamination will remain in place and no energy will be released. In the event of a structural failure of a low density lamination, because of its low mass, the resulting centrifugal force of the failed section is of such low magnitude that its bond to the high density lamination easily holds it immobile. Ultimately with fatigue and temperature and stress cycling, an unbalance might be detected and the use of the flywheel terminated. 
         [0010]    Metal flywheels of prior art are typically made by a forging process and then finish machined to detail the various thickness configurations of the specifically designed wheel. In order to maximize its functional performance and minimize its stresses the wheel is designed with a thicker hub, then a thinner section extending from the hub to a thickened rim. Each flywheel undergoes large non recurring engineering and tooling costs. The flywheel of the present invention provides for extreme flexibility of application since it is simply an assembly of high density material such as steel that is rolled to a flat dimension, cut to a circular shape using conventional cutting tools, bonded to laminations of less dense material using existing processes. Its functional capacity is determined by the number of laminations and the radius of their circular shape. The rolling process done at the steel mill is effectively a forging process. Being of such simple construction allows the configuration of the flywheel to easily be built to accommodate whatever functional requirement exists. 
     
    
     
       DRAWINGS 
         [0011]      FIG. 1  shows the flywheel configurations 
           [0012]      FIG. 1   a  shows a laminated fiber wrapped flywheel module mounted on a shaft, 
           [0013]      FIG. 1   b  shows two of the same type module mounted on the same shaft with a third module ready to be mounted. 
           [0014]      FIG. 2  shows flywheel construction details 
           [0015]      FIG. 2   a  shows a side view of the circular flywheel. 
           [0016]      FIG. 2   b  is a section of the flywheel module showing the details of its construction. 
           [0017]      FIG. 2   c  shows the expanded metal sleeve used to transfer the rotational drive forces. 
           [0018]      FIG. 2   d  is an enlarged detail of the assembly of the laminations and the fiber wrapping. 
           [0019]      FIG. 2   e  is a detail of the fiber and its associated epoxy encapsulate 
           [0020]      FIG. 2   f  shows a detail of the bonding material in relation to the laminations which it bonds 
         REFERENCE NUMERALS 
         [0000]    
         
             10  Outer lamination 
             12  high density lamination 
             14  Inner low density lamination 
             16  Split sleeve 
             18  Fiber 
             20  Encapsulating Epoxy 
             22  Bonding material 
             24  Axle shaft 
             26  Attachment mechanism 
         
       
       
    
    
     DETAILED DESCRIPTION 
       [0030]      FIG. 1   a  shows a laminated fiber wrapped flywheel module mounted on a shaft.  FIG. 1   b  shows two of the same laminated fiber wrapped flywheel modules mounted on the same shaft with a third module ready to be mounted on the same shaft. Each module, when mounted on the shaft is a complete flywheel and contains a given amount of stored energy. Its functional characteristics are established by its radius and the mass that results from the number of laminations. By adding modules to a common shaft the functional capability of the total flywheel assembly may be increased in increments to meet the design objective. Moreover mounting space may be an issue and to accommodate such limitation the radius of the module may be altered as necessary to fit the available space. The modular assembly with the ability to select the desired radius provides enormous application flexibility. 
         [0031]    The flywheel module is an assembly using alternate circular laminations of different density materials bonded together with a high strength bonding material and with the high density lamination being wrapped under tension with a high strength composite fiber. 
         [0032]      FIG. 2   a  shows a view of the circular shape of the flywheel module with the outer circular lamination being shown and the inner laminations being a dashed circle.  FIG. 2   b  shows the assembly of a series of laminations with a solid disc lamination of lesser density being shown as the outer element of the assembly, then a lamination of high density, and then another thinner solid disk lamination of the lesser density and thereafter, that assembly process is continued until there are a number of laminations. In the preferred embodiment, there are two outer laminations of lesser density but of greater thickness forming the outer surfaces with alternate inner laminations of high density with those laminations separated from each other by the thinner lesser density laminations. In other embodiments, any number of alternating wafers and diaphragms may be used to complete a module. Each of the laminations is bonded to the adjacent lamination by high strength bonding material. 
         [0033]    Refer to  FIGS. 2   a  and  2   b . Outer lamination  10  is a solid disc of lightweight material, typically aluminum, fiber composite or other appropriate material, with a center hole and whose outer diameter is slightly larger than the outer diameter of High density lamination  12 . 
         [0034]    A flywheel must be balanced in both rotational planes in which it runs. Manufacturing anomalies that prevent unbalance of the flywheel cause an initial unbalance. In the balancing process, material is removed from specific locations of the assembly to obtain the required balance. The removal of that material must not affect the structural integrity of the wheel. Accordingly, Outer lamination  10  is of sufficient thickness that material may be removed from its surface, making it thinner in specific locations as necessary to allow the assembled wheel to become balanced. 
         [0035]    High density lamination  12  is a high strength metal material, typically high strength steel with a center hole. The dimension of the center hole in Outer laminations  10 , Inner low density laminations  14  and high density laminations  12  allows Outer laminations  10 , Inner low density laminations  14  and High density laminations  12  to fit over Split sleeve  16  and Attachment mechanism  26 . 
         [0036]    Split sleeve  16  is a mild steel sleeve of dimension such that it its outer diameter is slightly larger than the hole in the assembly of laminations. When installed it is lightly compressed and when Attaching mechanism  26  is installed, it ensures that the interface between Shaft  24  and Attaching mechanism  26  is complete. 
         [0037]      FIG. 2  D shows an Outer lamination  10  bonded by Bonding material  22  to High density lamination  12 , which in turn is bonded by Bonding material  22  to Inner low density lamination  14  which in turn is bonded by Bonding material  22  to another high density lamination  12 —with this process continuing until four High density laminations  12  have been placed. Another outer lamination  10  is then assembled to the last remaining High density lamination  12  thus forming the other outside surface of the flywheel module. As shown in  FIG. 2  F, the entire assembly of alternating High density laminations  12 , and Inner Low density laminations i 4  is held together with Bonding material  22 . Bonding material  22  may be any flexible bonding material of predetermined adequate bond strength capability, with its curing process requiring thermal exposure of the metal elements of the flywheel to temperatures below that temperature which affects the structural characteristics of the metal elements of the flywheel assembly. 
         [0038]    As shown in  FIG. 2D , because the outer diameter of Outer laminations  10  and Inner low density laminations  14  is larger than the outer diameter of High density laminations  12 , a pocket is formed at the outer periphery of the assembly. Fiber  18  which is encapsulated by Encapsulating epoxy  20 , is wound under tension into that pocket as shown in  FIG. 2E , until the pocket is full.  FIG. 2E  shows the cross-section of the fiber pack. The strands of Fiber  18  together with encapsulating Epoxy  20  fill the pocket at the outer periphery of High density lamination  12 . With Fiber  18  being encapsulated and held under tension, Encapsulating epoxy  20  is allowed to cure. When Encapsulating epoxy  20  is fully cured, the assembled laminations and wafers are mounted on Axle shaft  24 . 
         [0039]    Attachment mechanism  26  that typically is a commercially available Ringfeder is installed over the outer periphery of Axle shaft  24  as shown if  FIG. 2B . A Ringfeder is a donut shaped device that expands peripherally when its self contained bolts are tightened. It therefore “wedges” itself between Axle shaft  24  and Split sleeve  16 . Split sleeve  16  is shown in  FIG. 2C . Split sleeve  16  expands as the Ringfeder is tightened and firmly attaches all the diaphragms and wafers to Axle shaft  24 . The expanding bolts of Retaining mechanism  26  are tightened to firmly attach the assembly as shown in  FIGS. 2A and 2B  to Axle shaft  24 . In other embodiments, the assembly of laminations may be attached to Axle shaft  24  by means other than the conventional Ringfeder retaining mechanism  26 . 
         [0040]    In the entire manufacturing process none of the metal elements are allowed to be exposed to heat processing such as flame cutting, welding or brazing. The laminations, as formed have the structural characteristics of forged materials since they are roll-formed and any exposure to heat reduces their structural capability. Additionally, other than the center hole providing lamination mounting capability, no holes or penetrations of an kind are allowed in the surfaces of the laminations. Any such interruption of the surfaces alters and deteriorates the ability of the lamination to accept its load stress. 
         [0041]    Thus the flywheel is assembled in modular increments on Axle shaft  24  providing means by which the assembled flywheel may be driven from any rotational source. 
       FUNCTIONAL DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0042]    A flywheel is designed to store kinetic energy or angular momentum which are directly related. The magnitude of its storage is a function of the speed of its rotating mass and the distribution of that mass relative to the outer diameter of the wheel. The faster it spins the more energy it contains. The further out the center of mass is from the center of rotation, the larger amount of energy it can store. The preferred embodiment employs a solid disc. Other embodiments may employ innumerable spoke configurations to distribute the mass; therefor any spoke configuration delivering the greatest energy and capable of withstanding the upper design speed is acceptable in other embodiments. The function of a flywheel is to store energy or maximize momentum. The performance of a flywheel is measured as the amount of energy it is capable of storing with its momentum being a direct derivative of that stored energy. The amount of energy it is capable of storing is a function of is rotational speed and the configuration of its mass. In the preferred embodiment the mass of the flywheel is distributed to maximize its ability to store energy. The speed at which the flywheel may be rotated is determined by its capability to resist structural failure derived from stresses that increase as the rotational speed of the flywheel increases. As the flywheel rotates, internal stresses are developed. Hoop stress is the stress that is tangential to the circumference of the wheel and as the wheel rotates the hoop stress increases and in accordance with Hook&#39;s law, causes the circumference of the wheel to increase. As the circumference increases the diameter must also increase by the relationship of Pi thus creating stresses in the wheel extending from the hub to the periphery. In the embodiment of the flywheel of the present invention, Fiber  18  that has a much higher modulus than the steel of high density lamination  12 , is wrapped under tension around the periphery of the laminations  12  thus reducing the ability of High density laminations  12  to increase in circumference as the speed of the wheel increases and thus reducing the hoop stresses in High density lamination  12 . Because Fiber  18  is capable of accepting stresses greater than those of the material of High density lamination  12 , the speed of the wheel can be increased as a function of the ratio of the strength (Modulus of elasticity-Young&#39;s modulus) of Fiber  18  to that of High density lamination  12  thus allowing the wheel to store more energy. Fiber  18  is wrapped under tension around High density lamination  12  thus causing a tension preload on Fiber  18 . Typically that preload would be the order of 5% of the ultimate fiber tensile strength. As the wheel spins and the circumference of the wheel tends to increase, the tension of Fiber  18  increases. Having it preloaded assures intimate contact with High density lamination  12  at the instant the wheel begins to expand. 
         [0043]    In the event that the wheel was driven at a speed greater than the speed that generated allowable stresses in lamination  10 , 12  or  14 , or an anomaly were to occur in the material of any of those items, a structural failure could occur. High density lamination  12  is wrapped with a high modulus fiber limiting its hoop stress, but there is an upper limit of rotational speed that yields an acceptable safety stress margin. That speed is considered to be the maximum allowable, rotation speed of that configuration of flywheel. The density of laminations  10  and  14  is significantly lower than the density of high density lamination  12  and at the maximum allowable rotational speed set by the acceptable stresses in lamination  12 , because of their low density their stresses at that speed have equal to or greater safety margins than those exhibited by lamination  12 . 
         [0044]    Statistically the failure would occur first in only one High density lamination  12 . Since there are many laminations  12  representing the entire mass of the wheel, the failure of one lamination  12  would release only that portion of the stored energy represented by the fraction of the mass of the wheel represented by the failed High density lamination  12 . The stresses in laminations  10  and  14  are always lower than the stresses in lamination  12  due to the reduced density of laminations  10  and  14 . 
         [0045]    In order for energy to be released upon a failure of High density lamination  12 , a section of High density lamination  12  must move from its position in the assembly. In order to move it must be broken to a degree that it becomes completely free of the remaining section. At the moment of fracture, all the stresses derived from hoop stress are instantly removed and the broken piece is subject only to centrifugal force. Centrifugal force is a function the mass of the broken piece and its radius from the center of rotation. High density lamination  12  could break in half or a section at the periphery could become the broken piece. In either event as the size of the broken piece increases its mass increases but also its surface held by the bonding material increases to a degree that the broken piece is held firmly in position by the bonding force holding it to laminations  10  and/or  14 . In addition the outer periphery of any potentially broken piece is also held in position by being wrapped by Fiber  18 . As a result, even if a lamination  12  sustained a failure, there would be no release of energy since the broken piece remains in position in the assembly. Thus not only do the low density laminations prevent the explosive loss of energy upon a lamination failure, they also prevent that failure from cascading throughout the entire assembly of laminations. 
         [0046]    Therefore it can be seen that the capability of the wheel to store energy is vastly improved by the carefully a designed application of high strength composite fiber that reduces the stresses in the material thus allowing a greater rotational speed with associated increased energy storage capability. By bonding the laminations together and fiber wrapping, an explosive failure is avoided but even in the highly improbable case in which a failed lamination were to escape, the explosive energy is limited to the small portion of the total energy of the wheel that is contained in that single failed lamination. 
         [0000]    t. 
       CONCLUSIONS, RAMIFICATIONS AND SCOPE OF THE INVENTION 
       [0047]    It can be seen that the capability of the flywheel to store energy has been significantly extended by the addition of a high strength fiber wrap applied to augment the natural structural characteristics of the basic high density laminations, and by the implementation of unblemished, roll forged disc laminations. Additionally, in prior art, the explosive total release of energy upon the event of a structural failure has caused flywheel installations to be contained in revetment-like enclosures. In the embodiment of the present invention, the stored energy is shared by the number of laminations. Each contains only a small fraction of the total stored energy of the flywheel. Statistically only one wafer will fail first. Because it is separated from all other laminations by a less dense lamination, its failure does not cause the failure of any other lamination. Further each lamination is held in place by the bonding material that bonds all the laminations together without affecting their structural characteristics. The bonding material is of such high strength that even if the failed wafer were to break in half the bonding material would prevent it from being ejected from between the laminations. In the embodiment of the present invention. a failure begins with a crack in a lamination at its weakest point. There will be no release of stored energy because the lamination did not change its position in the assembly of laminations. It simply cracked but remained in place. The failure might not even be noticed until ultimately fatigue may extend the crack to other parts of the lamination and it may alter its position sufficiently to unbalance the wheel at high speed 
         [0048]    Therefore it can be seen that the embodiment of the present invention not only extends the storage capability of flywheel, it also removes the hazard of instant release of stored energy.