Design and Modeling of an Integrated Flywheel Magnetic Suspension for Kinetic Energy Storage Systems
Abstract
:1. Introduction
- There are very limited winding losses because the steady-state suspension force is always applied by the PM flux;
- There are no flux variations in static conditions, resulting in negligible rotor losses and the possibility to adopt solid magnetic cores instead of laminated stacks;
- Possible eddy currents generated at dynamic condition provide a damping effect, improving the stability control;
- The flywheel itself provides a high surface available for the axial force application, without introducing additional rotating cores;
- There is independent control for the UCs and the LC;
- Simpler UCs control assessment as the force current characteristic is almost linear because of the DC bias due to the PM flux;
- There is an inherent self-centering effect in the radial direction, possibly controlled by both the coil currents.
2. System Description
- The rated air-gap length must be large enough to deal with high-rate disturbances, the compensation of which could require high electrical and thermal stresses to the AHMB coils;
- Temperature increase deteriorates the PM properties with possible loss of the stable condition;
- The lower the coercivity, the thicker the PM must be, therefore decreasing the useful steel surface; the consequent higher can be obtained only with higher PM and core volumes.
3. AHMB Electromagnetic Design
- (a)
- radial bounds defined by and ;
- (b)
- equal annular cross section for all the pole shoes, that are (h = 1, …, 4) for the upper side and (j = 1, 2) for the lower side; such a condition should ensure uniform flux density distribution, resulting in evenly distributed axial force among the pole shoes on the same side;
- (c)
- equal height for all the pole shoes (upper side , lower side );
- (d)
- equal annular cross section of the core legs (h = 1, …, 4) for the upper side and (j = 1,2) for the lower side; and are decreasing factors to enable enough room for the coil placement; their choice must consider local magnetic saturation, even with the coil mmf contribution;
- (e)
- equal cross section of the upper coils considering that they should provide the same mmf with the same current density;
- (f)
- PM operation near the maximum energy point (little higher than ) at the rated air-gap length with unexcited coils;
- (g)
- fixed variation range for the PM height and radius for manufacturing and cost issues.
3.1. Upper Side
- the suspension force at the air-gap due to the only PM;
- the suspension forces and with augmented air-gap due to the PM only and in the presence of current excitation (current density ), respectively;
- the coil per-turn inductance in the same condition as is calculated; because of the series connection and the chosen current polarity, it is , with being the inner and outer coil inductances, respectively, and being the mutual inductance coefficient.
3.2. Lower side
- constant coil section with variable aspect ratio ; it follows that and ;
- variable pole shoe height + with fixed value for .
4. Control System
4.1. Model of the Suspension Dynamics
4.2. Electrical Model
4.3. Overall Model
- an external force added to the force balance; in practical cases, such contribution can derive from vertical attraction forces between the rotor and the stator of the electrical machine;
- an air-gap variation caused, for instance, by a sudden motion of the AHMB fixed parts;
- a superimposed vertical velocity , simulating, for instance, the effect of an earthquake (instantaneous data of a seismic velocity).
5. Simulation Results
6. Conclusions
Author Contributions
Funding
Conflicts of Interest
List of symbols
weighting coefficients of the performance index P | |
per-unit variables used for the parametrization of the upper pole shoes geometry | |
per-unit variable used for the parametrization of the lower pole shoe geometry | |
upper and lower coil ampere-turns | |
slot openings of the upper cores | |
PM remanence, coercivity, and temperature coefficient | |
mean air-gap flux density (axial component) | |
saturation flux density and magnetic permeability | |
, | standard deviations of the axial flux density in the lower core legs |
net axial force with lower coil excitation | |
air-gap deviation with respect to and its maximum value | |
air-gap disturbance | |
pole shoe widths of the inner and the outer cores (upper side) | |
width of the inner pole shoe of the lower side core | |
resultant, PM, upper side and lower side force contribution | |
requested force for the total mass suspension | |
rated value of the PM suspension force | |
, | PM suspension forces at and ; |
upper side suspension forces at with current excitation; | |
PM force deviation at the maximum and minimum air-gap bounds; | |
contributions of upper side force model dealing with temperature variation | |
force and air-gap disturbances | |
air-gap length at balanced condition with no coil supply | |
upper and lower air-gap length | |
height of the upper and lower pole shoes | |
height and width of the inner coil (upper side) | |
height and width of the outer coil (upper side) | |
height and width of the lower coil | |
PM height, length and volume | |
flywheel shape factor, rated energy amount, and rotational inertia | |
weighting coefficient to model the force with temperature variations | |
coil filling factor, upper and lower coil cross sections | |
per-turn inductance, resistance, and PM flux | |
upper and lower coil inductance | |
flywheel and additional masses | |
maximum flywheel speed and speed ratio | |
performance index | |
operating temperature and temperature coil rise | |
mass density, ultimate and low-cycle fatigue stresses | |
, | copper resistivity at and thermal coefficient |
upper and lower coil current density | |
radial coordinates of the upper pole shoes | |
radial coordinates of the lower pole shoes | |
mean PM radius | |
mean coil radius of the lower side coil | |
outer and inner radius of the flywheel rotor rim | |
mean coil radius of the upper side coils | |
upper and lower coil ohmic resistance | |
rim surface and surface utilization factor | |
annular cross section of the k-th pole shoe (up: upper side, lp: lower side) | |
annular cross section of the k-th core leg (ul: upper side, ll: lower side) | |
supply voltage and coil turns | |
, | maximum and minimum flywheel angular speed |
width of the inner and of the outer core legs (upper side) | |
width of the lower side core legs | |
thickness of the inner and outer yokes (upper side) |
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FESS | Materials | |||
---|---|---|---|---|
Rated energy | 2.2 kWh | AISI 4340 | Ultimate strength | 1790 MPa |
Maximum speed | 32000 rpm | Steel density | 7830 kg/m3 | |
Speed ratio | 3 | Magnetic permeability | 600 | |
Shape factor | 0.75 | Saturation flux density | 1.8 T | |
Rotational inertia | 1.59 kg m2 | NdFeB | Remanence @20 °C | 1.1 T |
Flywheel mass | 74 kg | Coercivity @20 °C | −838 kA/m | |
Outer radius | 200 mm | Temperature coefficient | −0.12%/°C | |
Inner radius | 132 mm | AISI 1008 | Maximum permeability | 1250 |
Additional mass | 50 kg | Saturation flux density | 2.3 T |
Quantity | Value | Quantity | Value |
---|---|---|---|
Rated air-gap | 2 mm | Operating temperature | 80 °C |
Maximum air-gap deviation | 1 mm | Coil filling factor | 0.6 |
Average flux density | 0.24 T | Maximum core flux density | 1.8 T |
Pole section | 131.4 mm2 | Core leg section | 263 mm2 |
Maximum current density | 7 A/mm2 | Coil section | 110 mm2 |
Pole shoe height | 4.5 mm | PM volume | 64 cm3 |
PM thickness | 10 mm | PM height | 6 mm |
Quantity | Reference Value | Optimal Value |
---|---|---|
[N] | 1210 | 1212 |
[N] | 1211 | 1205 |
1.21 | 1.11 | |
1 | 0.979 | |
[mm] | ||
[mm] | ||
[mm] | ||
[mm] | ||
[mm] |
Quantity | Value | Quantity | Value |
---|---|---|---|
Coil section | 200 mm2 | Coil aspect ratio | 4.25 |
Pole shoe height | 4 mm | Pole shoe width | 29 mm |
Core leg reduction factor | 0.4 | Current density | 6.25 A/mm2 |
Coil mean radius | 164 mm | Pole shoe tapered height | 8 mm |
Standard deviation (inner leg) | 0.364 T | Coil per-turn inductance | 11.17 μH |
Standard deviation (outer leg) | 0.249 T | Net axial force | −59.1 N |
Parameters | Upper Side | Lower Side |
---|---|---|
Design current density | 4 A/mm2 | 6 A/mm2 |
Winding design voltage | 60 V | 60 V |
Maximum converter voltage | 200 V | 200 V |
Turns/coil | 33 | 46 |
Ohmic resistance @20 °C | 21.2 mΩ | 6.1 mΩ |
Current regulator | ||
Anti-windup constant | 10−4 | 5∙10−5 |
Air-gap regulator | ||
Temperature range | {20 °C, 80 °C} |
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Andriollo, M.; Benato, R.; Tortella, A. Design and Modeling of an Integrated Flywheel Magnetic Suspension for Kinetic Energy Storage Systems. Energies 2020, 13, 847. https://doi.org/10.3390/en13040847
Andriollo M, Benato R, Tortella A. Design and Modeling of an Integrated Flywheel Magnetic Suspension for Kinetic Energy Storage Systems. Energies. 2020; 13(4):847. https://doi.org/10.3390/en13040847
Chicago/Turabian StyleAndriollo, Mauro, Roberto Benato, and Andrea Tortella. 2020. "Design and Modeling of an Integrated Flywheel Magnetic Suspension for Kinetic Energy Storage Systems" Energies 13, no. 4: 847. https://doi.org/10.3390/en13040847
APA StyleAndriollo, M., Benato, R., & Tortella, A. (2020). Design and Modeling of an Integrated Flywheel Magnetic Suspension for Kinetic Energy Storage Systems. Energies, 13(4), 847. https://doi.org/10.3390/en13040847