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Development of flywheel motor generator unit for peak power application in electrically propelled vehicles

Objective



Objectives

The objective of the research is to design, manufacture, test on bench and on vehicle a flywheel motor/generator unit. This will demonstrate the technical feasibility, test the operational features, evaluate the advantages in terms of energy saving for electric vehicles, and enable the assessment of the economical benefits as well as the impact in terms of global energy conservation.

The solution will be developed according to the specifications that will be defined in the first part of the research. In principle these are expected to be:
rotational speed = 50.000 to 60.000 rpm
total weight of the unit = 35 kg

Technical Approach

The objectives will be addressed (according to the work plan outlined in the following section) following a systems engineering approach based on the integration of available technological means, supported by appropriate simulations in the design phases and complemented by extensive testing on separate components and on complete flywheel units on the bench and on a vehicle.

Special care and priority will be given to the following aspects: Safety:
this aspect will be considered throughout the development process, from the calculation of rim, dimensions, containment ring with impact analysis, to dynamic analysis and bench tests, up to burst test; fatigue behaviour of components will also be taken into account.
Energy efficiency:
this issue will be tackled mainly by a new design for a low loss electrical machine and power electronics, as well as with appropriate definition of magnetic bearings system.

Expected Achievements and Exploitation

The key achievements of the envisaged solution will be:
high input/output energy efficiency over the range of the flywheel operating conditions
high specific power (over 1 kW/kg referred to the complete unit), 40 kW peak power
specific energy adequate to mission requirements (over 10 Wh/kg referred to the complete unit)
low cost to make the flywheel system economically competitive over the vehicle life cycle
compatibility with the most severe vehicle operational and environmental conditions, including the safety related aspects
high compactness for optimising the energy and power density and to facilitate the vehicle integration.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

Società Elettronica per l'Automazione SpA
Address
Corso Giulio Cesare 300
10154 Torino
Italy

Participants (8)

Ansaldo Ricerche Srl - Società per loSviluppo di Nuove Tecnologie
Italy
Address
25,Corso Perrone
16161 Genova
BMW Bayerische Motoren Werke AG
Germany
Address
147,Knorrstraße
80937 München
Bertin et Cie S.A.
France
Address
59,Rue Pierre Curie
78373 Plaisir
CENTRO RICERCHE FIAT S.C.P.A.
Italy
Address
Strada Torino 50
10043 Orbassano
Labinal SA
France
Address
17,Rue De Clichy
93584 Saint-ouen
REGIENOV - RENAULT RECHERCHE ET INNOVATION
France
Address
9,Avenue Du Golf 1
78288 Guyancourt
Technical Research Centre of Finland
Finland
Address
1,Tekniikankatu
33101 Tampere
UNIVERSITY OF SHEFFIELD
United Kingdom
Address
Mappin Street
S1 3JD Sheffield