This master thesis was provided by ABB Cooperate Research in Västerås. This study has two major purposes: (1) to identify the characteristics of a flywheel energy storage system (FESS), (2) take the first steps in the development of a simulation model of a FESS. For the first part of this master thesis a literature reviews was conducted with focus on energy storage technologies in general and FESS in particular. The model was developed in the simulation environment PSCAD/EMTDC; with the main purpose to provide working model for future studies of the electrical dynamics of a flywheel energy storage system. The main conclusion of the literature review was that FESS is a promising energy storage solution; up to multiple megawatt scale. However, few large scale installations have so far been built and it is not a mature technology. Therefore further research and development is needed in multiple areas, including high strength composite materials, magnetic bearings and electrical machines. The model was implemented with the necessary control system and tested in a simulation case showing the operational characteristics.

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.

Higher penetration of volatile renewable sources and increasing load demand are putting a strain on the current utility grid structure. Energy storage solutions are required to maintain grid stability and are vital components to future smart grid designs. Flywheel energy storage can be a strong part of the solution due to high cycle life capabilities and flexible design configurations that balance power and energy capacity. This dissertation focuses on developing design methodologies for advanced flywheel energy storage, with an emphasis on sizing flywheel energy storage and developing lumped parameter modeling techniques for low loss, high temperature superconducting. The first contribution of this dissertation presents a method for using an optimal control law to size flywheel energy storage and develops a design space for potential power and energy storage combinations. This method is a data driven technique, that utilizes power consumption and renewable generation data from a particular location where the storage may be placed. The model for this sizing technique includes the spinning losses, that are unique to flywheel energy storage systems and have limited this technology to short term storage applications, such as frequency and voltage regulation. For longer term storage solutions, the spinning losses for flywheels must be significantly reduced. One potential solution is to use high temperature superconducting bearings, that work by the stable levitation of permanent magnet materials over bulk superconductors. These advanced bearing systems can reduce losses to less than 0.1% stored energy per hour. In order to integrate high temperature superconducting bearings into flywheel system designs, accurate and reduced order models are needed, that include the losses and emulate the hysteretic, non-linear behavior of superconducting levitation. The next two contributions of this dissertation present a lumped parameter axissymmetric model and a 3-D lumped parameter transverse model, which can be used to evaluate bearing lifting capabilities and transverse stiffness for flywheel rotor designs. These models greatly reduce computational time, and were validated against high level finite element analysis, and dynamic experimental tests. The validation experiments are described in detail. / text

Recent trends in energy production have led to a renewed interest in improving grid level energy storage solutions. Flywheel energy storage is an attractive option for grid level storage, however, it suffers from high parasitic loss. This study investigates the extent to which passive diamagnetic bearings, a form of electromagnetic bearing, can help reduce this parasitic loss. Such bearings require three main components: a weight compensation mechanism (lifter-floater), a stabilizing mechanism and an electrical machine. This study makes use of a new radial modification of an existing linear multi-plattered diamagnetic bearing. Here a prototype is built and analytical expressions derived for each of the three main components. These expressions provide a method of estimating displacements, fields, forces, energy and stiffness in the radial diamagnetic bearing. The built prototype solution is found to lift a 30 [g] mass using six diamagnetic platters for stabilization (between ring magnets) with a disc lifter and spherical floater for weight compensation. The relationship between mass and number of platters was found to be linear, suggesting that, up to a point, increases in mass are likely possible and indicating that significant potential exists for these bearings where high stiffness is not needed – for instance in flywheel energy storage. The study examines methods of reducing bearing (parasitic) losses and demonstrates that losses occur in three main forms during idling: air-friction losses, electrical machine losses, stabilizing machine losses. Low speed (158 [rpm]) air-friction losses are found to be the dominant loss at 0.1 [W/m3]. The focus of this study, however, is on loss contributions resulting from the bearing’s electrical machine and stabilizing machine. Stabilizing machine losses are found to be very low at: 1 × 10−6 [W/m3] – this leaves electrical machine losses as the dominant loss. Such electrical machine losses are analysed and divided into eddy current loss and hysteresis loss. Two components of hysteresis loss are remanent field related cogging loss and remagetization loss. Eddy current losses in silicon steel laminations in an electrical machine are quite high, especially at high speeds, with losses in the order of 1 × 105 [W/m3]. Noting the further high cost of producing single unit quantities of custom lamination-based electrical machine prototypes, this high loss prompts a look at potentially lower cost ferrite materials for building these machines. A commercial sample of soft magnetite ferrite is shown to have equivalent eddy current losses of roughly 1 × 10−13 [W/m3]. The study notes that micro-structured magnetite has significant hysteresis loss. Such loss is in the order of 1 × 10−3 [W/m3] when referring to both remanence related cogging and remagnetization. This study, thus, extends its examination of loss to nano-structured magnetite. Magnetite nano-particles have shown superparamagnetic (no hysteresis) behaviour that promises the elimination of hysteresis losses. A co-precipitation route to the synthesis of these nano-particles is examined. A detailed examination involving a series of 31 experiments is shown to demonstrate only two pathways providing close-to-superparamagnetic behaviour. After characterization by Scanning Electron Microscope (SEM), X-Ray Diffractometer (XRD), Superconducting Quantum Interference Device (SQUID) and crude colorimetry, the lowest coercivity and remanence found in any given sample falls at −0.17 [Oe] (below error) and 0.00165 [emu/g] respectively. These critical points can be used to estimate hysteresis related power loss, however, to produce bulk ferrite a method of sintering or bonding synthesized powder is needed. A microwave sintering solution promises to preserve nano-structure when taking synthesized powders to bulk material. A set of proof-of-concept experiments provide the ground work for proposing a future microwave sintering approach to such bulk material production. The study uses critical points measured by way of SEM, XRD, SQUID characterization (e.g. remanence and coercivity) to implement a modified Jiles-Atherton model for hysteresis curve fitting. The critical points and curve fitting model allow estimation of power loss resulting from remanent related cogging and remagnetization effects in nano-structured magnetite. Such nano-structured magnetite is shown to exhibit hysteresis losses in the order of 1 × 10−4 [W/m3] from remagnetization and 1 × 10−7[W/m3] from remanence related cogging drag. These losses are lower than those of micro-structured samples, suggesting that nano-structured materials have a significant positive effect in reducing electrical machine losses for the proposed radial multi-plattered diamagnetic bearing solution. The lower parasitic loss in these bearings suggests excellent compatibility with flywheel energy storage applications.

The Pressure Impulse test-rig uses the principal energetic advantages of displacementcontrolled systems versus valve-controlled systems. The use of digital-control technology enables a high dynamic in the pressure curve, according to the requirements of ISO6605. Accumulators, along with inertia, make energy recovery possible, as well as, enabling the compression energy to be re-used. As a result of this, there is a drastic reduction in operating costs. A simulation of the system before starting the project allows the development risks to be calculated and the physically achievable performance limits to be shown.

The Pressure Impulse test-rig uses the principal energetic advantages of displacementcontrolled systems versus valve-controlled systems. The use of digital-control technology enables a high dynamic in the pressure curve, according to the requirements of ISO6605. Accumulators, along with inertia, make energy recovery possible, as well as, enabling the compression energy to be re-used. As a result of this, there is a drastic reduction in operating costs. A simulation of the system before starting the project allows the development risks to be calculated and the physically achievable performance limits to be shown.

The goal of this dissertation is to evaluate the effectiveness of model predictive control (MPC) for a magnetically suspended flywheel energy storage uninterruptible power supply (FlyUPS). The reason this research topic was selected was to determine if an advanced control technique such as MPC could perform better than a classical control approach such as decentralised Proportional-plus-Differential (PD) control. Based on a literature study of the FlyUPS system and the MPC strategies available, two MPC strategies were used to design two possible MPC controllers were designed for the FlyUPS, namely a classical MPC algorithm that incorporates optimisation techniques and the MPC algorithm used in the MATLAB® MPC toolbox™. In order to take the restrictions of the system into consideration, the model used to derive the controllers was reduced to an order of ten according to the Hankel singular value decomposition of the model. Simulation results indicated that the first controller based on a classical MPC algorithm and optimisation techniques was not verified as a viable control strategy to be implemented on the physical FlyUPS system due to difficulties obtaining the desired response. The second controller derived using the MATLAB® MPC toolbox™ was verified to be a viable control strategy for the FlyUPS by delivering good performance in simulation. The verified MPC controller was then implemented on the FlyUPS. This implementation was then analysed in order to validate that the controller operates as expected through a comparison of the simulation and implementation results. Further analysis was then done by comparing the performance of MPC with decentralised PD control in order to determine the advantages and limitations of using MPC on the FlyUPS. The advantages indicated by the evaluation include the simplicity of the design of the controller that follows directly from the specifications of the system and the dynamics of the system, and the good performance of the controller within the parameters of the controller design. The limitations identified during this evaluation include the high computational load that requires a relatively long execution time, and the inability of the MPC controller to adapt to unmodelled system dynamics. Based on this evaluation MPC can be seen as a viable control strategy for the FlyUPS, however more research is needed to optimise the MPC approach to yield significant advantages over other control techniques such as decentralised PD control. / Thesis (MIng (Computer and Electronic Engineering))--North-West University, Potchefstroom Campus, 2013

The goal of this dissertation is to evaluate the effectiveness of model predictive control (MPC) for a magnetically suspended flywheel energy storage uninterruptible power supply (FlyUPS). The reason this research topic was selected was to determine if an advanced control technique such as MPC could perform better than a classical control approach such as decentralised Proportional-plus-Differential (PD) control. Based on a literature study of the FlyUPS system and the MPC strategies available, two MPC strategies were used to design two possible MPC controllers were designed for the FlyUPS, namely a classical MPC algorithm that incorporates optimisation techniques and the MPC algorithm used in the MATLAB® MPC toolbox™. In order to take the restrictions of the system into consideration, the model used to derive the controllers was reduced to an order of ten according to the Hankel singular value decomposition of the model. Simulation results indicated that the first controller based on a classical MPC algorithm and optimisation techniques was not verified as a viable control strategy to be implemented on the physical FlyUPS system due to difficulties obtaining the desired response. The second controller derived using the MATLAB® MPC toolbox™ was verified to be a viable control strategy for the FlyUPS by delivering good performance in simulation. The verified MPC controller was then implemented on the FlyUPS. This implementation was then analysed in order to validate that the controller operates as expected through a comparison of the simulation and implementation results. Further analysis was then done by comparing the performance of MPC with decentralised PD control in order to determine the advantages and limitations of using MPC on the FlyUPS. The advantages indicated by the evaluation include the simplicity of the design of the controller that follows directly from the specifications of the system and the dynamics of the system, and the good performance of the controller within the parameters of the controller design. The limitations identified during this evaluation include the high computational load that requires a relatively long execution time, and the inability of the MPC controller to adapt to unmodelled system dynamics. Based on this evaluation MPC can be seen as a viable control strategy for the FlyUPS, however more research is needed to optimise the MPC approach to yield significant advantages over other control techniques such as decentralised PD control. / Thesis (MIng (Computer and Electronic Engineering))--North-West University, Potchefstroom Campus, 2013

A continuous increase in demands from the utility grid and traction applications have steered public attention toward the integration of energy storage (ES) and hybrid ES (HESS) solutions. Modern technologies are no longer limited to batteries, but can include supercapacitors (SC) and flywheel electromechanical ES well. However, insufficient control and algorithms to monitor these devices can result in a wide range of operational issues. A modern day control platform must have a deep understanding of the source. In this dissertation, specialized modular Energy Storage Management Controllers (ESMC) were developed to interface with a variety of ES devices. The EMSC provides the capability to individually monitor and control a wide range of different ES, enabling the extraction of an ES module within a series array to charge or conduct maintenance, while remaining storage can still function to serve a demand. Enhancements and testing of the ESMC are explored in not only interfacing of multiple ES and HESS, but also as a platform to improve management algorithms. There is an imperative need to provide a bridge between the depth of the electrochemical physics of the battery and the power engineering sector, a feat which was accomplished over the course of this work. First, the ESMC was tested on a lead acid battery array to verify its capabilities. Next, physics-based models of lead acid and lithium ion batteries lead to the improvement of both online battery management and established multiple metrics to assess their lifetime, or state of health. Three unique HESS were then tested and evaluated for different applications and purposes. First, a hybrid battery and SC HESS was designed and tested for shipboard power systems. Next, a lithium ion battery and SC HESS was utilized for an electric vehicle application, with the goal to reduce cycling on the battery. Finally, a lead acid battery and flywheel ES HESS was analyzed for how the inclusion of a battery can provide a dramatic improvement in the power quality versus flywheel ES alone.

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