Development of Next-Generation Composite Flywheel Design for Shock and Vibration Tolerant, High Density Rotating Energy Storage

Under this Phase II effort, the design of a modular 60 kw (3.6 MJ) shock tolerant composite flywheel for backup/ride through power will be finalized. This composite flywheel design will make use of a novel low cost thermal press cure process to fabricate the individual composite rings used to build up the flywheel. The manufacturing process parameters used in previous hydroburst testing of initial cylindrical large scale test coupons will be refined for fabrication of the flywheel banding. This program will also use the MiTi developed shock tolerant foil bearings to support the rotor system in a low ambient pressure environment. Upon completion of the composite flywheel design, the flywheel rings will be fabricated using the out of autoclave thermal press curing process. The individual bands will then be assembled into the test composite flywheel. Once fully assembled, MiTi will conduct spin tested to verify the structural integrity of the flywheel using the low cost thermal press curing manufacturing process.