FIELD OF INVENTION

The present invention relates to energy storages. More specifically, the invention relates to a storage in which the energy is stored in the form of rotary kinetic energy, a system for how to store and extract energy, and a method for building it, a method for how to operate it and replace wearing parts, and the overall use of the storage. The main components of the storage comprise a rotor, a support system for the rotor, electric motors and generators for input and output of electric power, and a hydraulic system that provides low friction support and enables construction, operation and repair of the system. All of this is contained in a chamber for which pressure and overall gaseous condition are controlled.

BACKGROUND OF INVENTION AND PRIOR ART

Flywheel type energy storages can be used for stabilizing frequency and current of electric power systems, for storing energy coming from such systems, and for delivering back electric power on demand.

The mechanics of flywheels has been known for hundreds of years and such devices are widely used mechanical stabilizing systems such as machines, gyros as well as for storing kinetic energy. As for energy storage, the ability to quickly accumulate and dispatch energy is in itself a desirable property. Additionally, a flywheel system may also include an electric power input which by electric motors is converted to a mechanical input which increases the energy stored. Likewise, the system can include electric generators for power output to be delivered for the desired applications. Further, when integrated with an electric grid the storage may also be used to stabilize frequency and voltage in such grid system and to bridge sudden gaps of power.

There are a series of challenges associated with flywheel energy storage. First of all, there is an unavoidable loss of energy due to friction between the rotor and support system as well as from the rotor to the surrounding atmosphere. Support conditions for the rotor thus represents a critical design element with regard to energy loss from friction. Another generic problem is imperfections in mass distribution and geometric misalignments which in turn can lead to vibrations and mechanical wear. Such unwanted performance is often referred to as “wobbling”. Yet another problem is safety issues stemming from high centrifugal forces which can lead to that the rotor fails in an explosive manner and thereby releases high amounts of kinematic rotary energy and static elastic energy. As a consequence of the risk for rotor failure a flywheel is typically contained in a very strong, enclosing shell structure.

The rotor in a flywheel typically has a mass with an axisymmetric geometry built around a strong rotary axis. The kinetic energy stored in such a body is defined by

Ek=∫V⁢⁢ek⁢dV=12⁢ω2⁢∫V⁢ρ⁢⁢r2⁢d⁢V(1)

Here ekis kinetic energy per unit volume, ω is angular velocity, ρ is mass density, and V indicates the entire volume of the rotating body. In the simplest case this may be a uniform cylinder rotating about a central axis. The energy stored in such a cylinder with external radius Reand height H may be expressed by:

Ek=12⁢ω2⁢∫0Ro⁢ρ⁢⁢r2⁢dV=π⁢⁢ω2⁢H⁢∫0Ro⁢ρ⁢⁢r3⁢dr=14⁢πρ⁢⁢ω2⁢HRe4(2)

A learning from this equation is that body radius and the angular frequency are the determining factor with regard to stored energy. Further, when energy is divided by total mass one will get the average energy content per unit mass (Nm/kg=Ws/kg):

EkM=14⁢ω2⁢Re2(3)

When considering energy content, it is also crucial to take into account the amount of stressing that the rotating body is subjected to. The centrifugal force acting on rotating mass is given by

fc=ρ⁢u¨=ρ⁢d⁢vd⁢t=ρ⁢ω⁢⁢rd⁢⁢θd⁢t=ρω2⁢r(4)

Where t indicates time and θ is rotary angle. The strongest body force occurs at the largest radius Re. Mechanically the centrifugal body force has to be counteracted by a combination of radial stress σrand hoop (ring) stress σθ. It is possible to establish a differential equation that, depending on particular materials and design, may be solved by way of analytical or numerical solution techniques. Here it suffices to point out that the outer fiber of the rotating body is stress-wise most critical since the radial stress boundary condition is σr=0 and the body force has to be taken solely by hoop stress which is given by
σθ=fcRe=σω2Re2(5)

When combining this equation with equation (3) it is seen that the energy density is governed by allowable stress σafor outer fiber stress σθdivided by mass density ρ

EkM=k⁢σaρ(6)

This particular equation may be said to form the basis for flywheel developments up until now that has been dominated by search for a material strength with a highest possible strength σain relation to weight in order to attain the highest possible energy density. k is a corrective factor associated with the form of the rotating body. As seen from equations (3) and (5) k is ¼ for a compact cylinder.

Since the principle of flywheels are well known it is clear that most patents dealing with flywheels focus on resolving particular, problematic parts of the flywheel technology as mentioned above. This may for instance relate to a new type of support system that reduces the amount of friction. Belonging to this category, technologies have been developed during recent years that enable the rotor to “levitate” in a strong magnetic field. Further, much research and efforts has gone into developing materials with extremely high tension strength; representative developments for this is the use of high strength carbon fibers, graphene and nano-tubes. Needless to say, the total energy stored in a flywheel is also function of the square of the angular frequency as seen from equation (3), hence the implicit goal is to enable rotation with extremely high angular velocity (frequency). Unfortunately, high velocity flywheels made with materials with extreme strength properties correspondingly tend to be extraordinarily expensive.

There are a few examples of flywheel storage being implemented in electric grid settings. The world's largest flywheel installation is located in Stephenstown, USA where a “battery” of 200 flywheels produced by Beacon Energy can deliver 20 MW power on immediate demand. The primary purpose of this and other flywheel installations is to provide frequency and power regulation; their performance is thus primarily rated in effect (W) and not in terms of energy stored. Each unit has a high-performance rotor assembly that is sealed in a vacuum chamber and spins between 8,000 and 16,000 rotations per minute (rpm). At such speed vacuum is absolutely necessary to reduce friction. To reduce losses even further, the rotor is levitated with a combination of permanent magnets and an electromagnetic bearing. At 16,000 rpm (ω=1700 radians per sec) each flywheel can in principle store and provide 25 kWh of extractable energy. This means that the total storage energy capacity of such a system is rather limited viewed in a grid scale energy setting.

Recently some combined “hybrid” installations of electric batteries and mechanical flywheels have been deployed.

Looking at the current state of the art it seems clear that flywheel technology has not yet been developed to a stage where it can fully serve as large scale energy storage. The path followed so far for commercial installations has been to operate a series of rather small flywheel based on the concept of high energy density and high-performance materials rather than a single, large flywheel. One exception to this is a relatively large, grid-connected flywheel that been set in operation in Ontario, Canada. In this case the rotor has been horizontally mounted and consists of compact, high strength steel. The power rating is 2 MW whereas main function is also in this case frequency regulation rather than providing reserve energy from storage. Power is transferred to the rotor by way of an electric motor that is also used as electric generator during discharge.

Examples of patents and patent applications relating to flywheels are EP 1446860 “Flywheel energy storage systems” where the flywheel and motor/generator system combination is designed to minimize bearing loads and thus increase system life, reliability and safety. Patent US 20110298293 “Flywheel energy system” focuses on a magnetic bearing assembly to carry part of the weight of the rotor and thereby supporting a significantly high portion of the weight of the flywheel. In U.S. Pat. No. 8,134,264 “Large capacity hollow-type flywheel energy storage device” the objective is to reduce the friction by a hollow shaft disposed in a vacuum chamber to be rotatable together with the flywheel. Patent CN 201543648 “Energy storage large flywheel device” relates to a specific use of flywheel used to stabilize production of seamless steel pipe and hence does not specifically relate to use of flywheels for energy storage. Patent CN 103066741 “Hundred-megawatt level heavy type flywheel energy storage system based on gas magnetic fluid float cylinder suspension” describes a flywheel with a fluid floater cylinder that is suspended on a combination of air cushion, magnetic suspension, and fluid float cylinder. The patent claims to have the possibility of 100 MW performance that is a measure of effect rather than energy stored, and rotor spinning velocity of up to 100000 rotations per minute (rpm). Needless to say, such rotational speed goes far beyond what any large rotor made of any type of material can sustain. Another case to mention is patent US 20120096984 A1 which specifically addresses the problem of stabilizing and mitigating wobbling of the rotor.

It is clear that none of the solutions described in prior art can provide a practical solution to very large scale energy storage when it is by “large scale” is meant that the energy stored is in order of MW hours and beyond. Certain traits are clearly common for all flywheel storages; they consist of a rotor mass connected to a rotor shaft, and they have devices for charging by electric motors and, reversely, discharging the energy in the form of electricity by way of electric generators. The latter may in fact be the same component as the motor operated in a reverse mode energy-wise. Clearly a main issue is to reduce loss of energy through friction within the support system and to the surrounding gas or atmosphere. A common and widely used approach is to reduce surface friction by providing vacuum conditions around the rotor. Further, use of magnetic levitation is commonly used to reduce friction in bearings. Unfortunately, magnetic levitation does not scale up for levitating very heavy rotor masses. The scale of size problem is also reflected in that much of the current development is focused on relatively small flywheels using high strength materials that can deliver high energy per mass unit during very high rotational frequency. For these reasons previous flywheel technology is primarily suited for delivering spurts of energy (large effect) for frequency and voltage regulation rather than for storing significant amounts of energy that can be time shifted for longer times for use when needed.

The current innovation takes on a diametrically different approach with the aim to enable storing as much total kinetic energy Ekas possible in a single flywheel whereas the energy density as such may not be particularly high. Large scale or “grid scale” energy storage can thereby be obtained with a single or a limited number of flywheels. Rather than aiming for use of very expensive, high strength materials the present invention advocates using a very large rotor mass with inexpensive materials. Clearly such an approach brings with it a series of new problems that have to be resolved. One such problem is that the weight of the rotor may be so large that it cannot be prefabricated, transported and mounted on site. This means that the rotor has to be assembled and completed at site within the surrounding flywheel structure. Another challenge is to provide a new inventive step to minimize the friction associated with support and spinning of a very heavy rotor. Thirdly, it must be anticipated that it will be necessary to stop the rotor in a controlled way and replace supporting parts that are subjected to wear. Finally, mass balancing of the rotor to avoid instability and wobbling should be made possible. The quest is to find a way of doing all of this when the rotor may be too heavy to lift. Consequently, the invention also describes a complete solution for all of these combined problems.

Other parts of the energy storing technology relate to transfer of electric power to mechanical energy (electric motor) and back again to electricity during energy discharge. These issues can be implemented by way of methods and means that are readily available from current state of the art. Two main approaches are feasible, either by using the total flywheel rotor directly as a rotor for the electromagnetic motor and generator. Another approach is to have one or several separate motor-generator units that can be mechanically connected with the flywheel rotor.

SOME FEATURES OF AND CONSIDERATIONS FOR THE PRESENT INVENTION

The current invention provides a real and practical, novel solution to problems relating to very large energy storing flywheels. Moreover, the current innovation provides an entirely new role for flywheel storage that goes beyond frequency and voltage regulation. The objective of the invention is to be able to store, on a very large scale, electric energy from the electric grid or directly from electricity generating devices and return this energy with very high efficiency back as electricity. The size of the flywheel has beneficial effect on relative friction loss since stored energy is a function of radius to the fourth and the support friction associated with weight is a function of radius to the second for a spinning cylinder. Outer wall surface friction grows only linearly with the radius and thereby the surface area. Moreover, the surface friction depends on the surface velocity which is relatively low for the current invention compared with smaller flywheels with high performance materials and extremely high rotary speed RPM. All of this indicated that a large rotor system will have a much less relative frictional energy loss in the storage mode than that of a small, light rotor with very high speed.

The invention can be realized using only readily available and environmentally friendly materials. In this respect it provides major advantages over the most common way of storing electric energy, namely electric batteries which commonly uses both rare earth materials that are limited resources and materials such as Lithium and electrolytes that are problematic from safety and environmental point of view and difficult to recycle. The invention has also major practical advantages with respect to cost as compared with other energy storage solutions; it can be built almost anywhere provided there are acceptable ground conditions. It can be connected with major electric grid in an optimal way; this may be a large central storage or decentralized storages close to the source or to the users. Clearly, the invention enables better utilization and more reliable use of renewable energy sources such as wind farms and major solar power installations.

An important part of the current invention is that the weight of the rotor is fully carried by a piston that is resting on a hydraulic fluid. Such fluid will in most cases be a type of oil which will be an incompressible, Newtonian fluid. By Newtonian fluid is meant a fluid for which the viscosity is not influenced by the pressure and the viscos shear stress τ is defined by the Newtonian equation

τ=μ⁢∂v∂y(7)

where the shear stress τ is proportional to the dynamic viscosity μ and the gradient of the velocity v in direction y. Clearly the shear stress occurs in the plane perpendicular to direction y.

The Newtonian equation forms the basis for determining the so-called skin friction drag which customarily is found by

τs=Cf⁢ρ⁢ν22(8)

where Cfis the skin friction coefficient which inversely depends on the square root of the Reynolds number Re. Rein turn depends on the surface velocity, geometry and the kinematic viscosity of the fluid. The kinematic viscosity is similar to the dynamic viscosity while being divided by the mass density. The physics here is an important basis for the current invention because it determines the frictional loss between the rotor piston and the fluid on which it rests. Since the rotor is large and it has a relatively slow angular velocity ω the rotational velocity at the contact surface of the piston will be very low. Note also that the rotational velocity at the fluid contact surface is directly proportional to the radial distance r from the rotor axis. This means that there is virtually no friction near the axis; even at the outer rim of the piston the friction will be very low since the piston has a much smaller diameter that the rotor. Most of all, there is no effect on friction from pressure the surface friction. Notably this is very different from so-called dry friction (Coulomb friction) where the frictional force is directly proportional to the to the contact pressure.

A further comment is that the hydraulic fluid should be chosen on the basis of optimal viscosity and wear resistance. By optimal viscosity is meant that there is a balance between, on one hand, reducing friction by having low viscosity and, on the other, reducing leakage from the piston chamber by having a higher viscosity.

There is one further issue to be mentioned for very large flywheels, and that is the consideration of forces associated with directional change of the very large rotary momentum of the spinning rotor (vector quantity). To some extent a large flywheel may be considered being a large gyroscope that is forced to change the direction of its axis of rotation along with the movement of the local surface where it placed. This 24-hour rotational cycle of the Earth gives rise to moment that is exerted upon the rotational axis through the upper and lower mechanical supports. This forcing moment, which is related to the so-called “Coriolis force”, can be calculated on the basis of location on the Earth's surface, and moment of inertia and angular velocity of the rotor. From this calculation the associated, laterally acting contact forces on the axis and possible wear conditions can be designed for.

SUMMARY OF THE INVENTION

The present invention provides a flywheel for energy storage, comprising a rotor, a housing enclosure, means for charging energy by transferring electric energy to stored kinetic energy in the rotating rotor and means for discharging energy by transferring stored kinetic energy in the rotating rotor to electric energy.

The flywheel is distinguished in that:

the rotor is vertically oriented,

the rotor has mass of over 5000 kg,

the rotor comprises a central vertical shaft,

a radial bearing is arranged to an upper end the vertical shaft,

an axial-radial bearing, consisting of a cylindrical chamber filled with hydraulic fluid into which the end of the cylindrical shaft is fitted, or separate axial and radial bearings, is arranged to a lower end of the vertical shaft.

Preferable embodiments comprise features as described and defined in the dependent claims and the description and illustrated on the figures, which features can be combined in any operative combination, each such operative combination is an embodiment of the flywheel of the invention

The flywheel preferably comprises a hydraulic axial-radial bearing arranged to a lower end of the rotor, wherein said bearing comprises a piston cylinder into which the lower end of the rotor fits or the lower end of the rotor comprises an inverse piston chamber that fits onto a support shaft, the bearing comprises a hydraulic fluid and means to pressurize the hydraulic fluid in a sealed volume between the shaft and bearing, wherein the weight of the rotor is supported by the hydraulic fluid as pressurized.

Preferably, the intermediate part of the rotor comprises a composite structure, comprising coaxial shell cylinders and steel radial armoring, said cylinders and armoring preferably made of steel, and filler material in between, said filler preferably is hardened concrete which has been poured into and hardened in the cylindrical rotor structure.

Preferably, the rotor comprises a series of channels that serve the purpose of possible mass adjustments for balancing the rotation of the rotor.

The flywheel preferably comprises:

an intermediate part of the rotor that extends radially out from the shaft, the intermediate part comprises a shoulder on the underside facing downwards, and

a seat inside the housing enclosure, adapted to receive the rotor in a resting modus, with the shoulder of the rotor supported by the seat.

Preferably, the hydraulic axial-radial bearing comprises a hydraulic lift function, a hydraulic fluid expansion tank and a hydraulic pump, for lifting the rotor to an operating mode position or lowering the rotor to a resting mode.

The flywheel preferably comprises a half-sphere shaped lower end of the rotor shaft support bearing and a matching half-spherical shaped concave surface in the underlying support structure.

The flywheel preferably comprises an integrated or coupled combined motor-generator of any type suitable for the purpose or separate motor and separate generator.

Preferably, the rotor comprises permanent magnets or electromagnetic devices.

The flywheel of the invention comprises one or more of the following features, in any operative combination:

the large size rotor has mass of more than 5000 kg and may be preassembled or assembled and completed on site, and

the rotor design consists of high strength load bearing structure made of steel or other suitable high strength material combined with a filler material where the primary load bearing material is arranged with axisymmetric and multilayer panels providing completed cylindrical enclosures, planar vertical radial panels and horizontal panels, all interconnected by welding or other connection methods, and the filler material fills voids of the load bearing structure, and

the rotor is arranged with a strong cylindrical metal shaft in its central position and provides the connection with a lower and an upper support system, and

the lower part of the shaft is shaped as a piston that closely fits within the piston chamber of the lower support system, and

there is a hydraulic load bearing and lubricating fluid in the piston chamber onto which the piston rests with the weight of the entire rotor during rotation, and

there is a pressurized hydraulic system in which the pressure is consistent with the weight of the rotor, leaked hydraulic fluid is recirculated and where the pressure is maintained by way of a pressure pump system, and

the entire rotor can be lowered into resting position by reducing the amount of fluid in the hydraulic piston chamber and transferring it into an expansion tank, thereby facilitate removal and replacement of parts that are subjected to wear in the lower and upper supports, and

the parametric geometric relations between the piston, piston block, middle block and base block is such that such replacements may be done, and

there is one or several electromagnetic motor-generator devices that by way of external electric power source converts electricity to mechanical power that is stored in the form of increased kinetic energy in the rotor and reversely can reconvert kinetic energy from the rotor into electric power made available for external use when needed

the rotor has several diametrically opposite voids that can be filled with adjustment mass components as part of rotor balancing system

the piston and the piston block have parts that can be replaced

the piston may have one or several grooves with sealing rings

the piston may have an additional edge sealing ring inside the piston chamber

there may be separate electromagnetic-mechanical devices for kinetic energy charging of the storage and for discharging

additional start of rotation devices from stand-still condition

the entire rotor and support system is enclosed in an air tight chamber with a detachable upper lid

a system that controls the air or gas environment in the sealed chamber in terms of humidity, gas pressure, and gas composition, including the ability to reduce the pressure to very low levels

a sealed entrance that allows for access to the flywheel chamber for inspection and repair bearing parts of the upper lateral support system may be replaced

a cooling system for support system outside the rim to cool the parts of the support in case of emergency touch-down on the resting seat

an electronic control system that by means of various types of sensors monitors the overall operation and condition of the storage and that is used to activate the various phases of energy charging and discharging

the total energy storage system consists of a more than one flywheel and this battery of flywheels may share one or several operational functions such as air evacuation system, electric transformation and frequency regulation, activation control system, monitoring and safety system

the invention also comprises a building method where the structural main load carrying parts of the rotor are assembled at site from several prefabricated parts and the filler material is thereafter cast step by step within the voids of this load bearing structure.

For preferable embodiments, with very heavy rotor, for example weighing more than 100 metric tons, the flywheel comprises a hydraulic axial bearing or a hydraulic axial-radial bearing supporting the vertical shaft of the rotor. For alternative embodiments, with lower rotor weight, for example weighing less than 100 metric tons, the invention can be combined with having mechanical bearings or magnetic bearings or other feature that may enhance the overall performance.

The rotor of the flywheel of the invention is heavy, weighing at least 5000 kg, and can be exemplified with any other amount of mass such as 7 metric tons, 10, 20, 50, 100, 500, 100, 2000, 6000, 10 000 or 20 000 metric tons, or any weight in this range.

The rotational speed of the rotor of the flywheel varies with the dynamic storage of energy during charging and discharging. The maximum rotational speed that the rotor can sustain depends on the materials, mass, size and geometry of the of the rotor; examples of which are maximum 6000 rpm, or 5000, 3000, 2000, 1000, 500, 100, 50 or 30 rpm or any number in this range.

In order to understand the core concept of the present invention, the features above must be compared with the teaching according to state of the art. As mentioned above, from equations (1), the total energy is a function of the square of the angular frequency and a function of the mass distribution and geometry. Further, a measure of flywheel “efficiency” is the maximum energy density as defined in equation (6); this is a function of maximum allowable stress of the material divided by its density. By combining these features, the objective of the current state of the art flywheels has been to provide solutions where the flywheels spin as fast as possible with materials that can sustain very high stresses in relation to their material density. There are associated drawbacks by such approach that should be considered. First, the friction problem grows strongly with high velocities. Much focus is thus placed on low friction suspension as with magnetic levitation and vacuum chambers. Further, the high energy density makes material failures “explosive”. Furthermore, high performance materials with high strength to mass ratio are extremely expensive. The overall outcome is that current state of art flywheels are relatively small in size they and are not economically competitive as large scale energy storage devices; they are rather used for frequency and current regulation in electric grids. The main challenge has thus remained in developing a new flywheel technology that can provide large scale energy storage at an economically competitive price level. This is the overall objective of the current invention which introduces a completely new and different way of designing flywheels.

The present invention is beneficial with respect to all of the above-mentioned issues associated with very large flywheels.

The invention provides a way of transferring and storing large amounts of energy coming from an electric source in the form of kinetic energy and thereafter deliver this back as electric energy when needed. The system can serve as both a large scale energy storage and way of providing power to stabilize frequency and voltage in an electric grid setting.

The invention provides a kinetic energy, flywheel type energy storage system that is based on receiving and delivering electric power where the main components are:

1. A foundation and foundation structure that is strong enough to bear and sustain over time the static and dynamic forces exerted by the entire flywheel system

2. A spinning rotor that in principle is scalable to a size serving the overall energy storage objective of the system

3. A structural system within the rotor that provides necessary strength for carrying static and dynamic centrifugal forces associated with the load bearing structure itself as well as any mass or filler type material in between

4. A vertical shaft that goes through the rotor that connects the rotor with lower and upper support structures. The lower part of the shaft is formed as a rotating piston within the lower support bearing.

5. The lower support bearing for the piston provides very low friction load bearing capacity for carrying the weight of the rotor. The piston pressurizes with the weight of the rotor a hydraulic fluid that is contained within a fluid filled chamber around and below the piston. Further, the chamber with the piston and the hydraulic fluid serves as a hydraulic system that can be used to elevate and lower position of the rotor by pumping in or extracting fluid from the chamber.

6. A high pressure hydraulic system with pump system that keeps the rotor at desired height level and can recirculate hydraulic fluid that has leaked from the hydraulic chamber

7. An underlying disk structure that can be removed to allow for the abovementioned support to be replaced or repaired as part of maintenance procedures

8. An upper support system that keeps the spinning shaft in place and allows for the entire rotor to be raised and lowered. Also, this system may be replaced due to wear

9. A resting support system that is not in contact with the rotor when it is in rotational mode but that provides a support along the rim and can sustain the weight of the entire rotor when it is in resting condition during operational or maintenance brake condition

10. A capability for correction of mass distribution that allows for compensation of any mass distribution inequalities that might exist within the rotor in the initial condition due to fabrication imperfections and that could lead to vibrations or wobbling from mass imbalance

11. An electric motor system that can transfers electric power into kinetic energy for the rotor

12. An electric generator system that can transfer kinetic energy from the spinning rotor back into electricity. The motor and generator system may be the same.

13. An enclosure that fully separates and seals the flywheel chamber from the surrounding atmosphere and is strong enough to sustain pressure difference between the air/gas in the flywheel chamber from the external atmosphere as well as provide necessary strength to provide a safety barrier in case parts of the rotor should fail and break away

14. An air or gas control system that keeps the air or gas in the flywheel chamber at desired condition in terms of composition and pressure including the possibility for near vacuum condition to reduce rotary surface friction

15. A system for monitoring and controlling the operation and performance of the flywheel system. This system may contain various types of control devices and monitoring devices.

16. An access or entry system to the flywheel chamber to be used during inspection and repair operations. Such access ways may be in the form of sealed doors and tunnels as well as to include the possibility of removing the upper lid structure over the rotor and is a part of the overall enclosure system for the flywheel chamber.

17. A procedure for constructing, placing and adjusting the various parts of the total flywheel system

18. A possibility for combining several flywheels in a cluster to increase the overall capability for receiving/delivering power and to achieve the target of total energy storage

The combined attributes that are described above provide the broad capabilities of the invention; however, there may be cases where certain parts of these attributes may not be necessary and the invention is represented in a simplified form.

A further description of the items listed above now follows:

Item 1 This refers to that the objective large mass flywheel will contain a very large mass of kinetic energy that may be in the order of 5 to more than 50.000 tons. The foundation must be very strong and solid to be able to support static and dynamic forces and thereby prevent dynamic vibrations followed by structural damage. In a typical embodiment of the invention the entire flywheel system would be built into an excavation on the ground, preferably into an excavated space in solid rock. There may also be cases where the storage may be built in gravel or sand type of soils. In such cases it may be necessary with extra strong foundation plate made of reinforced concrete combined with foundation piling. It may also be possible to build the storage above the ground; in such case the entire enclosing structure may have to be made extra strong for safety reasons.

Item 2 This refers to the rotor part of the system which is the active part that stores the kinetic energy in the system. The rotor has a size of mass of the order mentioned above; it is essentially a vertically oriented cylindrical body that spins around its vertical shaft. The materials used in the rotor will normally be high strength steel and high strength concrete that interact as a composite. Rock and gravel type materials from the excavation of the pit for the flywheel may be in some cases be used to make the concrete provided this material is of suitable quality. Alternative types of aggregate for concrete or for filler material may be selected on the basis of high density and/or high strength. Examples of aggregates or filler material that may be combined with concrete mortar are scrap steel, iron ore or iron pellets, or any other suitable type of rock or heavy mineral. Enhanced strength of concrete in the rotor may be obtained by use of unstressed or pre-stressed reinforcing steel bars or by use of fibers, typically steel or carbon fibers, which are mixed into the concrete itself and provide increased tension of hardened concrete.

Item 3 The rotor has to be strong enough to sustain static and dynamic forces exerted during operation. There has to be a strong, loadbearing structural system within the rotor; this is typically made of straight and curved plates of high strength steel that are welded or joined together. The steel part of the rotor system may pre-fabricated as structural blocks and welded together on site. The filler or concrete material is placed within compartments of the mention load bearing part of the rotor made of steel. The steel thus has two functions, namely to provide a load carrying structural system and secondary to serve as form work and containment for the filler or concrete. Concrete filler has also the function that it in itself may serve as a force and load carrying material, particularly with respect to carrying forces from the weight of the rotor itself.

Item 4 There is an accurately made, strong rotor shaft in the center of the rotor that connects the rotor with the lower and upper bearings. The rotor shaft is in most cases made of high strength carbon steel or suitable alloyed steel and it is integrally welded together with the load bearing structure described above. The lower part of the shaft extends below the main parts of the rotor as it provides the rotating connection part within a lower supporting system. This part of the shaft has to be made with extreme precision because it is factually a rotating piston that rests on hydraulic fluid and should as such provide a low leakage connection to the piston fluid chamber. There may be special provisions and attachments such as groves and seal rings interconnected with the piston part of the rotation shaft. The upper part of the rotation shaft also extends outside the main part of the rotor and must also be made with high precision since it shall be rotating without slack within an upper, lateral support system.

Item 5 There is a structural load bearing that carries weight and dynamic forces from rotor. In simple terms this is a strong and rather massive structure with an internal cylindrical hollow space that is consistent with the geometry of the piston part of the rotor shaft. This hollow support and containment system for the hydraulic fluid is typically made from cast or forged high strength steel. The internal cylindrical open cylindrical space is made with high precision mechanical machining. There will be drilled openings for hydraulic fluid to be filled into the hydraulic chamber to compensate for fluid being leaked out at the interconnection between the support and the rotating piston. The system is made such that this part can be removed and, if necessary, replaced since it is a part subject to wear.

Item 6 There is a hydraulic system that includes one or several pumps, valves, hydraulic fluid expansion tank, recirculation of leaked hydraulic fluid, connection with the hydraulic fluid chamber under the piston part of the rotor shaft, and automated system for monitoring and controlling amount of fluid in the piston chamber. The system is also such that the hydraulic fluid is used to raise the entire rotor from resting position on the resting support system (Item 9) to a higher position used during spinning of the rotor. Reversely, hydraulic fluid can be lowered from operation level down to resting position when the flywheel for some reasons is taken out of operational, rotating mode.

Item 7 As part of the practical implementation of the invention it may be necessary to remove the lower support bearing for maintenance or possible replacement of worn parts. This means that the support bearing has to be lowered and freed from the shaft piston while the rotor is in resting position. This may be done by letting the support bearing rest on an underlying “disk” or metal block that has sufficient thickness such that after removing the support block to the side the piston block can subsequently also be freed from the piston and worn parts are exposed for inspection, repair, or replacement. The hydraulic fluid may be drained form the fluid chamber during this operation. Notably the block on which the lower bearing rests can be attached to the foundation deck by bolts, side attachments or simply by having a shallow pit in the foundation deck. It will also be possible to make contact surface between the piston chamber and the support block as a spherical surface such that it may be possible to make precision adjustments in relation to the direction of the rotor shaft.

Item 8 The rotor shaft needs to be supported laterally at the top in order to be stable and rotate without vibrations. This can be achieved by a lateral support structure that connects the shaft with the wall of the external flywheel structure. The connecting parts between the support structure and the rotor shaft may be detachable bearing components that that will be subjected to wear and can be removed and replaced as part of the overall maintenance.

Item 9 The rotor must be stabilized and kept in resting position during construction and when the spinning is stopped for maintenance and repair. The lower outer edge zone of the rotor is made so that it can rest on a ledge or support that transfers the weight to the overall outer load bearing and support structure of the flywheel. There may be alternative positions for such a resting load transfer, preferably the support should be at edge of the lower side of the rotor. The rotor shall preferably have stopped fully before the rotor connects with the resting support system. There may be a facility for emergency stop of the rotor in which the rotor is still spinning somewhat when touch-down is made. The design should be such that the contact friction is low in order to prevent overheating of the contact surfaces. There may also be provided for a cooling system, e.g. by use of water, in order to keep contact heating under control.

Item 10 It may happen that, even with very strict tolerances for manufacturing, there may be some imbalance in mass distribution of the rotor that can exhibit unwanted vibrations or wobbling during spinning. To compensate for such rotor inaccuracies, as built, this may be adjusted for by an approach quite similar to the process of balancing a wheel of a motor vehicle. One way of implementing such adjustment is to provide vertical, open channels within the rotor. Such channels can simply be empty tubes that are cast into the rotor. The adjustment should be carried out after trial rotations and instrument readings by filling appropriate amounts of mass or plugs into the channels such that the end result is a perfectly balanced rotor in terms of vertical positioning and rotary mass balance.

Item 11 There are principally two ways by which the flywheel rotor may receive energy during energy charging. One approach is to use the rotor or the rotor shaft as the rotary part of an electric motor. Correspondingly there will be opposing stators along the rim. By alternating magnetic fields power may be transferred to the rotor. Alternatively, there will be dynamic energy charging by way mechanical force transfer from one or several electric motors by way of mechanical shafts that connects with a suitable location of the rotor. There may be cogwheels or other types of mechanical connection devices between the electric motor and the spinning rotor. It may also be possible to fully detach the connection between the flywheel rotor and the motors in order to remove energy loss from friction and magnetic fields. There are several different types of electric motor principles may be employed; this is not a part of the invention as such.

Item 12 Exactly the same approaches as described for the electric motors delivering power to the flywheel may be employed for the electric generators that transform the kinetic energy back into electric current. In fact, the motors described above may be the exactly the same as the generators. Alternatively, they may be different units for energy charging and energy recapture in form of electricity.

Item 13 The flywheel must be enclosed within a strong housing structure in order to provide sufficiently strong upper lateral support, lower vertical and lateral foundation support, and serve as an overall shell-type safety barrier that will prevent damage to the outside in case of spalling or failure of the rotor. In addition, the housing structure may provide an air tight barrier between the flywheel chamber and the outside; in this way the overall air or gas condition in the rotor chamber may be sealed off from the surroundings and also facilitate gas pressure reduction or near vacuum conditions.

Item 14 A main concern by all flywheels is to reduce energy loss from friction as much as possible. The rotor has a large outer surface and particularly the cylindrical outer wall may move at very high speed. The friction loss is a direct function of the surface speed, surface roughness and accuracy, and density of the air or gas in the flywheel chamber. It is possible to reduce the effect of all of these factors. In particular, provided that the flywheel chamber is fully separated from the surroundings by a sufficiently strong and air tight barrier it is possible to control humidity and reduce air pressure inside the rotor chamber. Air may even be replaced by another gas. However, the best effect is obtained by reducing pressure inside; this may be obtained by pumping air out of the flywheel chamber: the lower air pressure, the lower the surface friction loss will be. This principle is also well known from smaller flywheels in current use.

Item 15 There are two main functions of a flywheel monitoring and control system; first, to control the functions of charging and discharging energy into the flywheel, and, second, to ensure that the condition of the spinning flywheel is fully safe and, if not, activate measures to reduce risk of failure. Typical parameters to be monitored are rotary frequency, stresses and deformations in the flywheel structure including material fatigue and failure, unwanted vibrations in the rotor, condition of the rotor support system, the motor and generator system, and other relevant parts of the overall installation. The condition monitoring and operation control may typically be performed from an operation room and/or by remote systems.

Item 16 For safety and other reasons the flywheel chamber will be evacuated by people when the flywheel is in operation. The chamber also needs to be fully sealed off to enable air evacuation, see Item 14. However, it will be necessary to stop operations at times for inspections, maintenance and repair. One way of access is to remove the top cover (roof) of the flywheel chamber. Additionally, it will be convenient to have a separate access for people and equipment to get into the flywheel chamber. Such access may require strong, air tight doors as well as an air lock room. The most convenient access will be at down at floor level in the flywheel chamber.

Item 17 The construction process for the entire system depends on the size of the flywheel, the local ground conditions, on whether it is placed over or under ground, and what parts may be prefabricated before being brought to the construction site for installation and assembly. Acceptable size of prefabricated construction blocks may also depend on availability and condition of transportation routes by water, rail and road. Typically, the construction sequence will be site excavation, building of foundations followed by construction of the housing for the flywheel system. After mounting of the lower support system for the flywheel rotor the steel structure for the flywheel rotor may be assembled while it is resting on the edge support system. After finishing this steel construction process a mass filling material, typically some sort of concrete, may be cast into the rotor voids. Extra reinforcement and sensors may be placed in the rotor before the casting process. Post-tensioning of reinforcement may take place after concrete has hardened. Further work will typically be mounting of motors/generators, hydraulic system, instrumentation and other types of auxiliary systems. Finally, test rotations and mass balancing in the mass balancing channels may take place as a part of the commissioning.

Item 18 Clearly there are practical limits to how large one can make a single flywheel; this has to do with stressing due to own weight, increased hydraulic pressures and leakage of hydraulic fluids, magnitude of centrifugal forces, etc. However, such limits to overall energy storage capacity may be overcome by building several flywheel units next to each other. Clearly such batteries or configurations of multiple flywheels may share much of the common infrastructure. There may also be advantage with respect to flexibility in the way multiple flywheels are charged and discharged.

To illustrate the invention with some examples of how much energy one might store in a single flywheel of type defined by this invention are given below:

External radiusunitCase 1Case 2Case 3Case 4External rotor radiusm5.5789Rotor heightm12162230Total rotor masstons295363631137719554Rotary frequencys−11210.29.49Kinetic energyMWh102550100

