High-Rate Flywheel Energy Source for Electro-Mechanical Actuators Used for Thrust Vector Control

The innovation proposed is a flywheel energy storage system designed specifically to serve as a high rate energy source for electro-mechanical actuation (EMA) systems. Recent advances in composite materials, permanent magnet motors, bearings, and power control electronics have led to flywheel energy storage systems with specific power and energy densities exceeding those of virtually all other energy storage systems for applications requiring high power, short duration pulses of electrical power. This technology is ideal for the development of light weight, low volume, low maintenance, water resistant modules capable of delivering 25KW-100RM at over 200 VDC for up to several hundred milliseconds. The system proposed integrates new developments in flywheel rotors, electrical converters, motor/generator, and bearing technologies. The baseline energy storage module incorporates a graphite epoxy flywheel, silicon nitride bearings, and a neodymium/iron PM motor driven by a compact pulse width modulated converter operating at 80 kHz. The goal of this program is to develop an energy storage module concept having outstanding energy and power density characteristics. Phase I will consist of concept experimental investigations, definition, initial design analysis, and detailed planning for Phase II. Phase II will consist of design, fabrication, and testing of the prototype hardware concept.