This document summarizes a flywheel energy storage system developed for Ford Motor Company through the US Department of Energy Partnership for a New Generation of Vehicles program. The flywheel has a maximum speed of 30,000 RPM, can provide 40 kW of power, and stores 500 Whr of energy. It was designed, built, and tested through a $6 million, 3-year government program to develop advanced energy storage technologies for hybrid vehicles. The flywheel uses a woven carbon fiber rotor housed in a vacuum chamber and is well-suited for applications with frequent charging/discharging such as electric buses or trains. It is available for continued development or collaboration.

1. SURGE POWER FLYWHEEL
30000 RPM, 40 kW, 500 WHr
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2. SURGE POWER FLYWHEEL
30000 RPM, 40 kW, 500 WHr
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3. FLYWHEEL MAJOR COMPONENTS
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4. SURGE POWER FLYWHEEL
EARLY PROGRAM CUTAWAY MODEL
FOR FORD SYNERGY 2010 DISPLAY VEHICLE
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5. DESIGNED FOR THE FORD MOTOR COMPANY
IN USDOE PARTNERSHIP FOR A NEW GENERATION OF VEHICLES PROGRAM
FOR THE
FORD SYNERGY 2010 FLYWHEEL HYBRID AUTOMOBILE
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6. DESIGNED FOR THE FORD MOTOR COMPANY
IN USDOE PARTNERSHIP FOR A NEW GENERATION OF VEHICLES PROGRAM
FOR THE
FORD SYNERGY 2010 FLYWHEEL HYBRID AUTOMOBILE
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7. $6 MILLION US DOE & DARPA FUNDED
PNGV FLYWHEEL DEVELOPMENT PROGRAM
• DESIGNED, BUILT & TESTED IN THE 3-YEAR
$6 MILLION USDOE & DARPA FUNDED PARTNERSHIP FOR A
NEW GENERATION OF VEHICLES PROGRAM
• PHASE I (12 MONTHS / $3.94M)
– CONDUCTED COST, SIZE, WEIGHT & PERFORMANCE OPTIMIZATION STUDIES
– CREATED COMPONENT LOSS, ANALYTICAL & DESIGN MODELS
• PHASE II (12 MONTHS / $2.2M)
– SELECTED, BUILT, & TESTED OPTIMIZED DESIGN
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8. PNGV FLYWHEEL DEVELOPMENT PROGRAM
• PHASE I EFFORT
– MOD1: MODELED THE CONTINUOUS OPERATING SYSTEM LOSSES
– MOD II: INVESTIGATEDTHE HIGH VOLUME (100k UNITS) COST, SIZE & WEIGHT
– MOD III: MODELED THE SYSTEM ENERGY / POWER DYNAMICS
– ANALYTICAL MODELS DEVELOPED
* ROTOR STRESS ANALYSIS MODEL * ROTOR OPTIMIZATION MODEL
* ROTOR DYNAMICS MODEL * FLYWHEEL SYSTEM PERFORMANCE MODEL
* AERODYNAMIC DRAG LOSS MODEL * SYSTEM THERMAL MODEL
* VIBRATION ISOLATION MODEL * SYSTEM VACUUM MODEL
• PHASE II EFFORT
– SELECTED, BUILT, & TESTED OPTIMIZED 30K RPM, 40 kW, 500 WHr FLYWHEEL
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9. POLAR WOVEN
RESIN TRANSFER MOLDED ROTOR
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10. POLAR WOVEN
RESIN TRANSFER MOLDED ROTOR
• DEVELOPED/PROVIDED BY DOW-UNITED TECHNOLOGIES COMPOSITE
PRODUCTS
• ALLOWS THE ROTOR TO BE REINFORCED WITH CARBON FIBERS IN
BOTH THE HOOP AND RADIAL DIRECTIONS WITHIN AN EPOXY
MATRIX THUS PROVIDING SUPERIOR STRUCTURAL PROPERTIES TO
THOSE OF FILAMENT WOUND ROTORS
• THE ADVANCED POLAR WOVEN RTM PROCESS PROVIDES HIGHER
QUALITY, INCREASED PRODUCTION RATES AND LOWER COST
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11. POLAR WOVEN ROTOR
CONSTRUCTION
• WARP (CIRCUMFERENTIAL) FIBERS
– TORAY T-700S
• PICK (RADIAL) FIBERS
– HEXCELL AS4
• FIBER VOLUME FRACTION: 59.6%
• PICK TO WARP VOLUME FRACTION: 10%
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12. POLAR WOVEN ROTOR
30,000 RPM OPERATING STRESSES
• MAXIMUM LONGITUDINAL STRESS: 68 KSI
• MAXIMUM TRANSVERSE STRESS: 4 KSI
• INSIDE RADIAL GROWTH: 17.9 MILS
• GROSS ENERGY STORAGE: 576 WHR
• ROTOR TIP SPEED: 608.8 M/S
• RING SPECIFIC ENERGY: 35.6 WHR/KG
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13. MOTOR/ALTERNATOR ROTOR & STATOR
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14. FLEX-RIM HUB
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• UNIQUE FLEX-RIM HUB DEVELOPED BY Dr. RALPH FLANAGAN
AT FLYWHEEL ENERGY SYSTEMS, INC.
• SPEED SENSITIVE SPRING RATE CHANGE ENABLES ROTOR TO
PASS THROUGH FIRST CRITICAL SPEED

15. FLYWHEEL SPECIFICATIONS
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16. FLYWHEEL STATE OF CHARGE
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17. FLYWHEEL ROTOR SPECIFICATIONS
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18. FLYWHEEL MOTOR SPECIFICATIONS
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19. FLYWHEEL MOTOR / GENERATOR DETAILS
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20. FLYWHEEL CONTROLLER / AMPLIFIER SPECIFICATIONS
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21. APPROPRIATE APPLICATIONS
• FLYWHEEL ENERGY STORAGE OFFERS THE GREATEST
BENEFIT IN HIGH CHARGE/DISCHARGE CYCLE FREQUENCY
(SURGE POWER) APPLICATIONS
• THESE INCLUDE
– ELECTRIC MUNICIPAL TRANSIT BUSSES
– ELECTRIC GARBAGE TRUCKS
– ELECTRIC INNER-CITY DELIVERY TRUCKS
– ELECTRIC RAILWAY & SUBWAY TRAINS
– ELECTRIC CONSTRUCTION VEHICLES
– ELECTRIC MINING VEHICLES
– ELECTRIC AIRPORT GROUND SUPPORT VEHICLES
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22. CURRENT DISPOSITION
THIS SYSTEM IS AVAILABLE FOR SALE, CONTINUED DEVELOPMENT,
&/OR COLLABORATION
CONTACT US FOR FURTHER INFORMATION
Joseph Olbermann
Director of Engineering
Adirondack Western Engineering Associates
Email: jolbermann@aol.com
Phone: 509-551-1645
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