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Kinetic/Flywheel energy storage systems (FESS) have re-emerged as a vital technology in many areas such as smart grid, renewable energy, electric vehicle, and high-power applications. FESSs are designed and optimized to have higher energy per mass (specific energy) and volume (energy density). Prior research, such as the use of high-strength materials and the reduction of stress concentration, primarily focused on designing and optimizing the rotor itself. However, a modern FESS includes other indispensable components such as magnetic bearings and a motor/generator that requires a shaft. The shaft significantly impacts the flywheel design. This paper investigates several typical flywheel designs and their stress analysis. A simplified analysis method is given for designing rotor-shaft assembly. It is found that the shaftless flywheel design approach can double the energy density level when compared to typical designs. The shaftless flywheel is further optimized using finite element analysis with the magnetic bearing and motor/generators' design considerations.

Conventional active magnetic bearing (AMB) systems use several separate radial and thrust bearings to provide a 5 degree of freedom (DOF) levitation control. This paper presents a novel combination 5-DOF active magnetic bearing (C5AMB) designed for a shaft-less, hub-less, high-strength steel energy storage flywheel (SHFES), which achieves doubled energy density compared to prior technologies. As a single device, the C5AMB provides radial, axial, and tilting levitations simultaneously. In addition, it utilizes low-cost and more available materials to replace silicon steels and laminations, which results in reduced costs and more convenient assemblies. Apart from the unique structure and the use of low magnetic grade material, other design challenges include shared flux paths, large dimensions, and relatively small air gaps. The finite element method (FEM) is too computationally intensive for early-stage analysis. An equivalent magnetic circuit method (EMCM) is developed for modeling and analysis. Nonlinear FEM is then used for detailed simulations. Both permanent magnets (PM) and electromagnetic control currents provide the weight-balancing lifting force. During the full-scale prototype testing, the C5AMB successfully levitates a 5440 kg and 2 m diameter flywheel at an air gap of 1.14 mm. Its current and position stiffnesses are verified experimentally., Comment: 12 pages, in IEEE Transactions on Transportation Electrification

Thanks to the unique advantages such as long life cycles, high power density, minimal environmental impact, and high power quality such as fast response and voltage stability, the flywheel/kinetic energy storage system (FESS) is gaining attention recently. There is noticeable progress made in FESS, especially in utility, large-scale deployment for the electrical grid, and renewable energy applications. This paper gives a review of the recent developments in FESS technologies. Due to the highly interdisciplinary nature of FESSs, we survey different design approaches, choices of subsystems, and the effects on performance, cost, and applications. This review focuses on the state of the art of FESS technologies, especially for those who have been commissioned or prototyped. We also highlighted the opportunities and potential directions for the future development of FESS technologies.