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Research on New Technologies for Flywheel Electromechanical Storage Systems

Objective



Objectives and content
The presently available batteries and even new types under development are not in the position to meet in a satisfactory way the requirements for application to electric vehicles traction in terms of specific energy and power, life, consistency of performance, efficiency, quick recharging and cost effectiveness.
An integrated Flywheel/motor- generator system, based on advanced technologies, appears to be a feasible mean to meet the requirements, either as a supportive peak power unit integrated with the main energy source or as a full alternative to it, namely as electromechanical battery. Other on board energy supply system like fuel cells or hybrid systems would also require electrically rechargeable supportive power devices.
A feasibility study performed under a previous programme JOULE has shown the possibility to reach energy-weight ratio comparable with the most advanced electrochemical batteries under development (some 130 Wh/Kg) but with much higher specific power, and longer endurance (for life of the vehicle).
To achieve in practice this goal, researches are needed on the key materials and components of the flywheel/motor-generator, including the identification of the related manufacturing processes in order to assure to the final product the adequate level of technical performance and cost.
The present research aims to develop the necessary technologies and related manufacturing processes for the components of high performance Flywheel motor-generator unit and for the identification of the related integration techniques, namely:
-New component materials featuring high performance and low cost -High speed, high efficiency, low cost electric machine and power electronics
-New magnetic bearing solutions
- Integration concepts and techniques among these elements for very compact, reliable and safe electromechanically storage units
The achievements of these technologies will be assessed by means of two Flywheel/motor generator units which will be tested on bench and on vehicle as peak power units. Each unit will feature the preliminary established total energy of 1,6 KWh (stored in 2 counter rotating flywheels), of which 1,2 KWh deliverable from nominal to one half of rotational speed, 60 KW maximum power and weight of approximately 25 Kg.
The manufacturing processes for new composite materials will be defined and all safety features will be tested. In addition the design will be performed for a "pure flywheel" battery constituted by modules of Flywheel-motor generator units connected in parallel, featuring a specific energy of over 100 Wh/Kg.
A side industrial achievement of the research will be availability of the above mentioned technologies for other applications, either as Flywheel units for stationary or mobile use, or in devices requiring high performance, low cost composite materials or high technology electrical machines and magnetic bearings.
The consortium comprises two big automotive manufacturers (BMW and Centro Ricerche FIAT), two component Suppliers (Ansaldo Ricerche and FIAT CIET), one engineering center (Bertin) and two Universities (RWTH Aachen-Ika and University of Sheffield).

Coordinator

N/A
Address
Corso Giulio Cesare 300
10154 Torino
Italy

Participants (9)

AACHEN UNIVERSITY OF TECHNOLOGY
Germany
Address
10,Steinbachstrasse 10
52074 Aachen
Ansaldo Ricerche Srl - Società per lo Sviluppo di Nuove Tecnologie
Italy
Address
25,Corso Perrone
16161 Genova
BMW Bayerische Motoren Werke AG
Germany
Address
147,Knorrstraße
80937 München
Bertin Technologies S.A.
France
Address
Rue Pierre Curie
78373 Plaisir
CENTRO RICERCHE FIAT S.C.P.A.
Italy
Address
Strada Torino 50
10043 Orbassano
EAST-4D GMBH LIGHTWEIGHT STRUCTURES
Germany
Address
Annaberger Straße 240
09125 Chemnitz
Labinal SA
France
Address
17,Rue De Clichy
93584 Saint-ouen
Technical Research Centre of Finland
Finland
Address
1,Tekniikankatu
33101 Tampere
UNIVERSITY OF SHEFFIELD
United Kingdom
Address
Mappin Street
S1 3JD Sheffield