A Novel Sensor & Diagnostic System for High Speed Composite Flywheels

This proposal describes the development of a novel inductive/dielectric sensor-based composite flywheel diagnostic system for high rotational speed applications such as locomotive drivetrain energy storage. The proposed diagnostic system will combine composite flywheel strength and fatigue models developed by SatCon Technology Corp. with innovative sensor and data processing technology developed by JENTEK Sensors, Inc., to provide: 1. An initial assessment of "virgin" composite flywheel quality; 2. The real-time operating state of integrity of the flywheel; 3. An estimate of the remaining life at current or modified operating conditions; 4. Shutdown warning and/or prescription for modified operating conditions. The key developments here include the adaptation to composite materials of JENTEK Sensors, demonstrated to provide reliable fatigue life indications in metallic components, as well as the integration of this sensor data into a rotor diagnostic system under development at SatCon. A broad spectrum of flywheel energy storage (FES) systems will be covered by these developments, ranging from low cost/moderate performance to high performance composite rotors. JENTEK's dielectrometry sensors are well suited to the non-conductive and low cost glass-epoxy composites, while their magnetometry sensors are aimed at high performance graphite-epoxy composites.