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

The overall objective of the Phase I and Phase II proposed effort is to design and demonstrate the ability to develop a high-speed shock tolerant composite flywheel energy storage system (FESS) using a low cost manufacturing process. The Phase I tradeoff design studies will assess the FESS size, operating speeds and material requirements needed to achieve the energy density levels and charge/discharge rates. Tests of composite material coupons fabricated with the low cost composite material manufacturing process will be completed. Transient shock analysis will also be performed to establish the shock tolerant FESS design configuration and corresponding bearing support system. Under Phase II, the composite flywheel manufacturing approach will be validated through high speed testing. The overall goal is to verify the power and energy density gains and reduced footprint possible through effectively integrating the generator, bearing and flywheel components. To achieve the desired power and energy densities in a composite flywheel operating at speeds to 100,000 rpm in a shock and vibration environment will require robust, well damped and low loss bearings. UT-CEM as subcontractor will establish the composite flywheel structure and manufacturing layup, while MiTi will be responsible for system integration and overall fabrication.