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Abstract-This paper describes the design essentials of an out- signs, which was housed in a vacuum enclosure.
side rotor Permanent Magnet Halbach array motor with a hy-
brid magnetic bearing, intended for kinetic energy storage. The The objective of this exercise was to develop and evaluate
theoretical estimations are compared to Finite element analysis the viability of a unit economical enough for rural area and
as well as an approximated model using standard shape magnets.
stand alone applications in the developing world.
A dipole Halbach array produces a uniform flux distribution in-
side the cylindrical stator, where straight windings on an Iron-
less stator are placed near the inner boundary. The position of 2. MOTOR DESIGN
the windings inside this field does not affect the efficiency of the
motor. When the motor is operated continuously, these varia- The heart of the motor, with an outside rotor design, is a di-
tions become insignificant. pole Halbach array, establishing a uniform flux within the sta-
tor area, as shown in figure 1. A uniform flux is needed for
The motor is suspended on a hybrid magnetic bearing without operating the motor on a magnetic bearing, where slight
active control. Two radial repelling magnetic bearings are used movement of the stator inside the air gap is inevitable. Hal-
in combination with an axial journal bearing. The theoretical
bach [3] describes the flux density for a dipole with the equa-
values were found to be consistent to that of a working model.
tions :
For high speed kinetic energy storage it is essential that the
flywheel, which incorporates the motor and hybrid magnetic
bearing, is operated in a vacuum. Under these conditions, the
motor / bearing system approaches near 100% efficiencies e.g.
the approximated Halbach array motor model showed an electri-
B,B rem4log
_`
r2
r1
4Ç (1)
[ \
cal to mechanical efficiency of 97%. The flywheel target storage 2Í
capacity was 150 W-h with a minimum power rating of 40 W at sin
a maximum operating speed of 48000 rpm. It is intended that M
multiple modules of this basic unit can be used in parallel to in- Ç, (2)
crease the overall energy storage capacity for rural and isolated 2Í
power supplies. M
1. INTRODUCTION
B = Resultant uniform flux, Brem = Remnant flux in perma-
Kinetic energy storage in general requires a high efficiency nent magnets, r2 = outer radius, r1 = inner radius and M =
motor, taking into account that this method of storage is still number of poles.
expensive, and the energy has to move through the device at
least twice, i.e. charging and discharging. Inspection of (1) reveals that the wall thickness of the array
has a direct impact on the resultant flux density. Plotting the
Being able to store the energy for a reasonable time further flux density versus the wall thickness results in figure 2. This
imposes that the frictional losses should be low. This consists wall thickness is limited by commercial magnet dimensions,
mainly of bearing and air friction losses. The air friction is strength considerations due to centrifugal forces, cost of ma-
adequately catered for by removal, i.e. operating in a vac- terials and dimensional constraints.
uum. Limiting bearing losses can be achieved by combining a
passive magnetic bearing and dry lubricated journal bearing. When the number of magnets approaches infinity in (1), it
has a limit value of :
[ \
The design of this particular development was based
mostly on the work of R.F Post [1] and J. D. Steinmier [2], 2Í
which were both developed for vehicle applications. There sin
M
are few commercially available kinetic energy storage units lim M l ,1 (3)
and are very expensive. The commercial units are in the hun- 2Í
dreds of kW range and intended for power quality applica- M
tions. New costs can be justified for power quality applica-
tions in the developing world, but not for rural applications.
This result is not practical, unless one such magnet could
The above designs are both 1 kWh units, suspended on be manufactured. To use a large number of magnets is costly,
magnetic bearings. The Steinmier [2] model used a hybrid because each magnet has to be magnetised in a unique direc-
magnetic bearing with an active bearing backup. Both incor- tion, the wedges become smaller and assembly becomes in-
porates filament wound multiple rim graphite composite de- creasingly cumbersome.
24 r2/r1
Number of Magnets
20 Fig. 5: Effect of the ratio between the inner- and outer radii
16
The resulting design therefore reduces to a steel cylinder
12 with mass produced magnets oriented in the preferential di-
8 rection as shown in figure 6.
4
To estimate the value of the remnant flux, Brem, in (1) for
0 the approximation, the flux has to be reduced in proportion to
0.1 0.3 0.5 0.7 0.9 the ratio of the actual volume of magnetic material to the total
0 0.2 0.4 0.6 0.8 1
volume of the material. For unity depth, (2) becomes :
_`
Factor
Amagnet r2
Fig 2: Effect of the number of magnets on resultant flux B,B rem 4log 4Ç (4)
Asteel r1
An eight magnet array gives an acceptable result, shown in
figure 3, which was used for this model. Amagnet = cross sectional area of the magnets and Asteel =
cross sectional area of the steel.
N N
Fig. 6: Finite Element results of an approximated 8-seg-
ment Halbach array
d»
Vi = induced voltage, N = number of turns and =
dt
rate of change of magnetic flux.
30Ê 11Ê The maximum stress that an aligned continuous fibre com-
Ï ×, 4Î4Õ24r o 20 4r 2 (11) posite material can withstand, as in the case of the filament
4 30Ê i wound outer rim of the flywheel, can be estimated by [8] :
Ï r,
30Ê
4Î4Õ 4r o1r i
2 2
(12) Ï ,Ï m 11 f 0Ï f (13)
8
σ = composite tensile stress in the direction of the fibres,
σθ = maximum hoop stress, σr = maximum radial stress, ρ = σm = tensile strength of a matrix, σf = tensile strength of a
density of the cylinder, ro, ri = cylinder outer and inner radii, fibre and f = fibre volume fraction.
ω = angular speed and υ = poisons ratio.
Philips [8] describes the strength of a short fibre composite.
This depends on the critical fibre length, i.e. the length at
which fibre and the matrix fails at the same strain. This length
is calculated by :
Ïfd
l c, (14)
Ï xy
TABLE 3
DUAL RIM FLYWHEEL SPECIFICATIONS
Outer diameter 210 mm
Length 160 mm
Safe operating speed 48000 rpm
Safety factor 1.5 (on the outer rim)
Total Weight 6.234 kg
Capacity 157.42 W-h
Inertia 26.55 x 10-3 kg m/s
Fig.13: Axial journal bearing using synthetic gemstones
Specific energy 25.25 W-h / kg
The remaining degree of freedom in the axial direction has
4. HYBRID MAGNETIC BEARING to be confined to allow rotation of the shaft only. Axial sup-
port is achieved by resting the rotating part of the motor with
Steinmier et al. [2] describes the operation of a stable hy-
a hard ball on top of a hard flat plate, as shown in figure 14.
brid magnetic bearing system. This system is constructed of
two passive radial magnetic bearings (figure 12) and a journal TABLE 4
thrust bearing, shown in figure 13. Steinmier [2] calculated
the rotational frictional moment at the point of contact as: STIFFNES OF RADIAL MAGNETIC BEARINGS
Fig. 12: Radial Magnetic Bearing Fig. 14: Hybrid Magnetic bearing
An experimental prototype magnetic bearing was con- For a flywheel exerting 60 N on a single ball the frictional
structed out of commercially available NeFeB magnets. The losses will be as indicated in Table 5 [10].
dimensions and stiffness are shown in Table 1. The total ra-
dial stiffness for two pairs is 6000 N/m or 6 N/mm.
2500
Ball Plate Coefficient Torque Power
of Friction [Nm] @ 50000 2450
Speed [rpm]
[10] rpm [mW] 2400
Ruby / sap- Sapphire 1.5 x 10-4
2350
phire 0.1 152
2300
Hard Steel Hard Steel 0.42 6.0 x 10-4 628
Cast iron Cast Iron 0.15 2.2 x 10-4 230 2250
1750 that of the steel on Teflon lubricated steel surface, used in this
1500 prototype, is due to the steel surfaces not being entirely
1250 smooth, flat and aligned. This causes the ball to slide over the
1000
surface, in small circular movements, instead of rotating on
750
one point.
500
250
0
5. SYSTEM OVERVIEW
0 84 146 269 390 500 620 717 771 824 924
45 115 203 322 439 573 687 742 803 860 981 Shown in figure 17 is a schematic, illustrating a solar array
application of a kinetic energy storage system.
Time [s]
Fig. 15: Rundown Curve in a Vacuum
0.9 Í r 2 F4É4Õ,I 2 R (17) The solar array provides DC power to a user, sharing a
common bus with a bidirectional DC-DC converter, perma-
The theoretical maximum speed from the motor can now be nently connected to a kinetic energy storage unit. The control
rewritten as: logic limits the current flow in and out of the motor and moni-