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Thesis (MScEng)--Stellenbosch University, 2011. / ENGLISH ABSTRACT: As the push continues for increased use of renewables on the electricity grid, the problem of energy storage is becoming more urgent than ever. Flywheels with wound, composite rotors represent an efficient and environmentally friendly option for energy storage. They have already been applied successfully for voltage control on electrical rail networks and for bridging power in backup UPS systems, but lately they have also proven useful for grid-scale frequency regulation. For flywheels to be deployed on a wider scale, the high cost associated with the technology will have to be addressed. An important driver of cost is the density at which energy can be stored. Currently, flywheel designs do not consistently achieve high energy density, and this study investigates the reasons for this. A critical analysis is made of the design methodologies that have been proposed in the available literature, and some improvements are suggested. Most notably it is shown that significant improvements in energy density may be possible if the design optimization problem is formulated carefully. In addition, the problem of material selection is discussed, because material properties have a significant influence on energy density. Some guidance is given for flywheel designers on how to choose an optimal set of materials without invoking undue computational effort. It is hoped that these suggestions may be carried forward as a topic of further research. / AFRIKAANSE OPSOMMING: Namate die aanvraag vir hernubare energie op die elektrisiteit netwerk vergroot, word die probleem van energie berging van kardinale belang. Vliegwiele met silindriese rotors van samegestelde materiale bied ’n effektiewe en omgewingsvriendelike opsie vir energieberging. Hierdie tipe vliegwiele is reeds suksesvol aangewend vir spanningsbeheer op elektriese spoornetwerke en om oorbruggingskrag te voorsien aan rugsteun sisteme. Meer onlangs is hulle ook nuttig bewys vir die regulasie van frekwensie op die elektrisiteit netwerk. Grootskaalse aanwending van vliegwiele kan egter slegs oorweeg word indien die hoë koste van die tegnologie aangespreek word. Een van die onderliggende redes vir die hoë koste van vliegwiele is die relatiewe lae digtheid waarby energie geberg kan word, en hierdie studie ondersoek die redes hiervoor. Die ontwerpmetodiek wat in die beskikbare literatuur voorgestel is, word krities geanaliseer en ’n paar verbeteringe word aanbeveel. Mees noemenswaardig is die opmerklike verbeteringe in energie-digtheid wat soms moontlik is indien die optimerings-probleem deurdag geformuleer word. Omdat materiaaleienskappe ’n bepalende invloed op energie digtheid uitoefen word die probleem van materiaalseleksie ook verder bespreek. ’n Paar riglyne vir die seleksie van ’n optimale stel materiale sonder om oordrewe berekenings-inspanning te veroorsaak, word aan vliegwielontwerpers gegee. Hierdie voorstelle kan hopelik in die toekoms verder deurgetrap word as onderwerp vir verdere studies.

The electric car is a technically efficient driveline, although it is demanding in terms of the primary energy source. Most trips are below 50 km and the mean power required for maintaining speed is quite low, but the system has to be able to both provide long range and high maximum power for acceleration. By separating power and energy handling in a hybrid driveline, the primary energy source, e.g. a battery can be optimised for specific energy (decreasing costs and material usage). Kinetic energy storage in the form of flywheels can handle the short, high power bursts of acceleration and decceleration with high efficiency. This thesis focuses on the design and construction of flywheels in which an electric machine and a low-loss magnetic suspension are considered an integral part of the composite shell, in an effort to increase specific energy. A method of numerically optimising shrink-fitted composite shells was developed and implemented in software, based on a plane stress assumption, with a grid search optimiser. A composite shell was designed, analysed numerically and constructed, with an integrated permanent magnet synchronous machine. Passive axial lift bearings were optimised, analysed numerically for losses and lift force, and verified with experiments. Active radial electromagnets optimised for high stiffness per ohmic loss were built and analysed in terms of force and stiffness, both numerically and experimentally. Electronics and a high-speed measurement system were designed to drive the magnetic bearings and the electric machine. The control of these systems were implemented in an FPGA, and a notch-filter was designed to suppress eigenfrequencies to achieve levitation of the rotor. The spin-down losses of the flywheel in vacuum were found to be 1.7 W/Wh, evaluated at 1000 rpm. A novel switched reluctance machine concept was developed for hollow cylinder flywheels. This class of flywheels are shaft-less, in an effort to avoid the shaft-to-rim connection. A small-scale prototype was built and verified to correspond well to analytical and numerical models, by indirect measurement of the inductance through a system identification method.

The area of misfire detection is important because of the effects of misfires on both the environment and the exhaust system. Increasing requirements on the detection performance means that improvements are always of interest. In this thesis, potential improvements to an existing misfire detection algorithm are evaluated. The improvements evaluated are: using Gaussian processes to model the classifier, alternative signal treatments for detection of multiple misfires, and effects of where flywheel tooth angle error estimation is performed. The improvements are also evaluated for their suitability for use on-line. Both the use of Gaussian processes and the detection of multiple misfires are hard problems to solve while maintaining detection performance. Gaussian processes most likely loses performance due to loss of dependence between the weights of the classifier. It can give performance similar to the original classifier, but with greatly increased complexity. For multiple misfires, the performance can be slightly improved without loss of single misfire performance. Greater improvements are possible, but at the cost of single misfire performance. The decision is in the end down to the desired trade-off. The flywheel tooth angle error compensation gives nearly identical performance regardless of where it is estimated. Consequently the error estimation can be separated from the signal processing, allowing the implementation to be modular. Using an EKF for estimating the flywheel errors on-line is found to be both feasible and give good performance. Combining the separation of the error estimation from the signal treatment with a, after initial convergence, heavily restricted EKF gives a vastly reduced computational load for only a moderate loss of performance.

Submitted by PPG Engenharia El?trica (engenharia.pg.eletrica@pucrs.br) on 2018-10-16T14:38:56Z No. of bitstreams: 1 ANA PAULA RODRIGUES MARQUES_DIS.pdf: 2882882 bytes, checksum: a47b86d791e0aae8d3266c6fc3b8a61b (MD5) / Approved for entry into archive by Sheila Dias (sheila.dias@pucrs.br) on 2018-10-18T11:08:37Z (GMT) No. of bitstreams: 1 ANA PAULA RODRIGUES MARQUES_DIS.pdf: 2882882 bytes, checksum: a47b86d791e0aae8d3266c6fc3b8a61b (MD5) / Made available in DSpace on 2018-10-18T11:15:22Z (GMT). No. of bitstreams: 1 ANA PAULA RODRIGUES MARQUES_DIS.pdf: 2882882 bytes, checksum: a47b86d791e0aae8d3266c6fc3b8a61b (MD5) Previous issue date: 2017-05-31 / There has been a recent increase in the use of new technologies playing an important role in promoting physical fitness, due to the positive impact they have on the health and quality of life of the individual. Taking this into consideration, the present work describes the development of a vibration platform linked to a flywheel (PV?I), which permits whole-body vibration (WBV) and resistance or isoinertial training. Correct measurement of the force values given by the flywheel and amplitude, frequency and acceleration ranges provided by the vibration platform was necessary for production of the prototype. The need to adapt various pieces of equipment and materials was also identified, such as the vibrator motor, springs, vibration dampers, roller bearings, axis, flywheel and frequency inverter. The equipment was validated through laboratory testing, aimed at verifying the performance of the PV?I. A comparator clock was used to measure amplitude, and a triaxial accelerometer provided the platform acceleration data. A frequency inverter was used to regulate the platform frequency. The vibration platform frequencies chosen for the prototype operation evaluation tests were 5Hz to 60Hz, with no platform load, the vibrator motor set at minimum intensity, with acceleration on all three axes (x, y and z) and amplitude measured every 5Hz. Tests were subsequently performed with a 52kg load, simulating the weight of a person, and the vibrator motor set at a vibration intensity of 10% and 20%. Both the platform displacement amplitude and acceleration measurements were acquired at 15Hz, 20Hz, 25Hz, 30Hz and 35Hz, and acceleration alone was also recorded at 40 Hz and 45 Hz. Two further tests were performed with a 55kg load and vibrator motor set at 30% and 40% intensity. These choices were based on findings in the literature, where the most encountered frequency ranges varied between 15Hz and 44Hz. The results demonstrate a relationship between frequency and amplitude; when one is altered the other also changes. The acceleration values collected during testing were used to analyze the vibration levels, in accordance with the ISO 2631-1 (1997) standard. The vibration levels of the platform, in the test configurations used, were confirmed as being acceptable. / O uso de novas tecnologias, que desempenham um papel importante em promover o condicionamento f?sico, tem se intensificado recentemente pelo impacto positivo que causam na qualidade de vida e na sa?de das pessoas. Com base nisso, o presente trabalho descreve o desenvolvimento de uma plataforma vibrat?ria associada a um volante de in?rcia (PV?I), os quais permitem treinamento de vibra??o de corpo inteiro (TVCI) e resistido ou isoinercial. Para a confec??o do prot?tipo, foi necess?rio o correto dimensionamento dos equipamentos, a partir dos valores de for?a oferecidos pelo volante de in?rcia e da faixa de amplitude, da frequ?ncia e da acelera??o fornecidas pela plataforma vibrat?ria. Foi tamb?m identificada a necessidade de adapta??o de diversos equipamentos e materiais, tais como motovibrador, molas, amortecedores de vibra??o, mancais de rolamento, eixo, volante de in?rcia e inversor de frequ?ncia. Para a valida??o do equipamento, foram realizados testes em laborat?rio, com o objetivo de verificar o funcionamento da PV?I. A medi??o de amplitude foi feita por um rel?gio comparador, enquanto os dados da acelera??o da plataforma foram adquiridos com o uso de um aceler?metro triaxial. A frequ?ncia aplicada ? plataforma foi regulada atrav?s de um inversor de frequ?ncia. As frequ?ncias da plataforma vibrat?ria escolhidas foram de 5Hz a 60Hz nos testes de avalia??o do funcionamento do prot?tipo sem qualquer carga sobre a plataforma e com o motovibrador em intensidade m?nima, sendo a acelera??o nos tr?s eixos (x, y e z) e a amplitude medidas a cada 5Hz. Ap?s, foram realizados testes com carga de 52kg, simulando a massa de uma pessoa, e o motovibrador regulado a uma intensidade de vibra??o de 10% e 20%. As amplitudes de deslocamento da plataforma foram adquiridas em 15Hz, 20Hz, 25Hz, 30Hz e 35 Hz, enquanto a medida da acelera??o incluiu tamb?m 40 Hz e 45Hz. Outros dois ensaios foram feitos com carga de 55kg e o motovibrador regulado a 30% e 40%. Tais escolhas foram feitas com base na literatura onde a faixa de frequ?ncia mais encontrada variam entre 15Hz e 44Hz. Os resultados demonstraram que h? uma rela??o entre frequ?ncia e a amplitude, pois quando se altera a frequ?ncia, a amplitude tamb?m se modifica. As acelera??es coletadas durante os testes serviram para fazer a an?lise dos n?veis de vibra??o, tendo como base a norma ISO 2631- 1 (1997), comprovando que s?o aceit?veis os n?veis de vibra??o da plataforma nas configura??es utilizadas nos testes.

<p>Combustion supervision by evaluating flywheel speed variations is a common approach in the automotive industry. This often involves preliminary measurements. An adequate model for simulating flywheel speed can assist to avoid some of these preliminary measurements. </p><p>A physical nonlinear model for simulating flywheel speed based on cylinder pressure information is investigated in this work. Measurements were conducted at Scania in a test bed and on a chassis dynamometer. The model was implemented in MATLAB/Simulink and simulations are compared to measured data. The first model can not explain all dynamics for the measurements in the test bed so extended models are examined. A model using a dynamically equivalent model of the crank-slider mechanism shows no difference from the simple model, whereas a model including a driveline can explain more from the test-bed measurements. When simulating the setups used at the chassis dynamometer, the simplest model works best. Yet, it is not very accurate and it is proposed that optimization of parameter values might improve the model further. A sensitivity analysis shows that the model is fairly robust to parameter changes.</p><p>A continuation of this work might include optimization to estimate parameter values in the model. Investigating methods for combustion supervision may also be a future issue.</p>

<p>Production and consumption of electricity have grown enormously during the last century. No mater what the primary source of energy is, almost all generation of electricity comes from conversion of a rotational movement in a generator. The aim of this thesis is to see how high voltage technology influence production and storage of electricity. Power flow in the generators used to convert mechanical movement to electric energy is analyzed using Poynting‘s vector. The impact of new generator technology for efficient extraction of hydroelectric power is shown. Simulation of a large permanent magnet turbo generator is presented. A flywheel storage system for electric vehicles utilizing high voltage technology is also presented. In pulsed power applications, a cheap method for intermediate storage of energy during milliseconds, which enables an inductive primary storage is presented and experimentally tested.</p>

Production and consumption of electricity have grown enormously during the last century. No mater what the primary source of energy is, almost all generation of electricity comes from conversion of a rotational movement in a generator. The aim of this thesis is to see how high voltage technology influence production and storage of electricity. Power flow in the generators used to convert mechanical movement to electric energy is analyzed using Poynting‘s vector. The impact of new generator technology for efficient extraction of hydroelectric power is shown. Simulation of a large permanent magnet turbo generator is presented. A flywheel storage system for electric vehicles utilizing high voltage technology is also presented. In pulsed power applications, a cheap method for intermediate storage of energy during milliseconds, which enables an inductive primary storage is presented and experimentally tested.

In this study, a novel concept for a downhole flywheel energy storage module to be embedded in a bottom-hole-assembly (BHA) is presented and modeled, as an alternative power source to existing lithium-ion battery packs currently deployed in measurement-while-drilling (MWD) or logging-while-drilling (LWD) operations. Lithium-ion batteries disadvantages include deteriorated performance in high temperature, limited lifetime that necessitates frequent replacement which elevates operational costs, and environmental disposal. Extreme and harsh downhole conditions necessitate that the flywheel module withstands temperatures and pressures exceeding 300 ?F and 20 kpsi, respectively, as well as violent vibrations encountered during drilling. Moreover, the flywheel module should adhere to the geometric constraints of the wellbore and its corresponding BHA. Hence, a flywheel sizing procedure was developed that takes into consideration the required energy to be stored, the surrounding environmental conditions, and the geometric constraints. A five-axis magnetic levitation control system was implemented and tuned to maintain continuous suspension of the flywheel under the harsh lateral, axial and torsional drilling vibrations of the BHA. Thus, an integrated finite element model was developed that included the rotordynamic behavior of the flywheel and the BHA, the component dynamics of the magnetic levitation control system, and the cutting dynamics of the drillbit for both PDC and tricone types. The model also included a newly developed coupling between lateral, axial and torsional vibrations. It was demonstrated through simulations conducted by numerical integration that the flywheel maintains levitation due to all different types of external vibration as well as its own lateral vibration due to mass unbalance. Moreover, a passive proof-mass-damper (PPMD) was developed that suppresses axial bit-bounce vibrations as well as torsional vibrations, and was extended to also mitigate lateral vibrations. Optimized values of the mass, stiffness and damping values of the PPMD were obtained by the hybrid analytical-numerical Chebyshev spectral method that was superior in computational efficiency to iterative numerical integration. This also enabled the fine-plotting of an operating stability chart indicating stability regions where bit-bounce and stick-slip are avoided. The proof-mass-damping concept was extended to the flywheel to be an active proof-mass-damper (APMD) where simulations indicated functionality for a light-weight BHA.

Self-bearing machines for kinetic energy storage have the advantage of integrating the magnetic bearing in the stator/rotor configuration, which reduces the number of mechanical components needed compared with using separated active magnetic bearings. This master's thesis focus on building a MATLAB/Simulink simulation model for a self-bearing cone-shaped Lorenz-type electrical machine. The concept has already been verified analytically but no dynamic simulations have been made. The system was modeled as a negative feedback system with PID controllers to balance the rotor. Disturbances as signal noise, external forces and torques were added to the system to estimate system robustness. Simulations showed stability and promising dynamics, the next step would be to build a prototype.