CHAPTER 2

LITERATURE REVIEW
2.1 LITERATURE REVIEW 1

“A Novel Hybrid Energy Storage Strategy Based on Flywheel and

Lead-acid Battery in Wind Power Generation System”

Qianzhi Shao, Yan Zhao, Shipeng Du and Yuanzhuo Du are invented it and worked on
In this paper, based on expounding the basic structure and operating principle of the
flywheel energy storage system, the maximum energy storage and energy efficiency of
the flywheel batteries are analyzed. Research data shows that there is still a part of the
energy left after the flywheel energy storage system doing the effective energy output.
In the premise to save this part of energy for purpose, the way of combining the
flywheel battery with lead-acid battery is proposed to put forward a new hybrid energy
storage system. At last, the structure of the new hybrid energy storage system is
designed for non-grid and grid wind power generation system.

They concluded that the working principle of flywheel energy storage system with
doing a comprehensive exposition on the maximum number of stored energy, energy
storage density and the workflow of energy storage system. Then the data shows there
is still part of energy left in the flywheel when the flywheel finishes conducting
effective energy output after researching on the use of flywheel energy storage system
energy efficiency. Based on the purpose of saving this part of energy, comparing the
flywheel batteries with lead-acid batteries, it shows they can make up the short board.
So the scheme is proposed which makes a novel hybrid energy storage system consisted
of flywheel batteries and lead-acid batteries. Compared with the simple flywheel energy
storage system, the new kind of energy storage system has longer continuous discharge
time and saves energy which makes the flywheel from a standstill to the lowest effective
speed. Compared with the simple lead-acid energy storage system, it responds to the
change of system power more quickly and reserves reaction time for lead-acid battery
while reducing the times of battery charge and discharge in order to extend lead-acid
battery life. Finally, this paper gives the structure of grid and non-grid connected wind
power system adopting novel hybrid energy storage system. The simulation analysis
will be done to this operation structure and the further verification will be made on the
correctness of the hybrid energy storage system.
2.2 LITERATURE REVIEW 2

“Flywheel in an all-electric propulsion system”

JOHAN LUNDIN is invented it and worked on Energy storage is a crucial condition

for both transportation purposes and for the use of electricity. Flywheels can be used as
actual energy storage but also as power handling device. Their high power capacity
compared to other means of storing electric energy makes them very convenient for
smoothing power transients. These occur frequently in vehicles but also in the electric
grid. In both these areas there is a lot to gain by reducing the power transients and
irregularities.

The research conducted at Uppsala University and described in this thesis is focused on
an all-electric propulsion system based on an electric flywheel with double stator
windings. The flywheel is inserted in between the main energy storage (assumed to be
a battery) and the traction motor in an electric vehicle. This system has been evaluated
by simulations in a Matlab model, comparing two otherwise identical drivelines, one
with and one without a flywheel.

The flywheel is shown to have several advantages for an all-electric propulsion system
for a vehicle. The maximum power from the battery decreases more than ten times as
the flywheel absorbs and supplies all the high power fluxes occuring at acceleration and
braking. The battery delivers a low and almost constant power to the flywheel. The
amount of batteries needed decreases whereas the battery lifetime and efficiency
increases. Another benefit the flywheel configuration brings is a higher energy
efficiency and hence less need for cooling.

The model has also been used to evaluate the flywheel functionality for an electric grid
application. The power from renewable intermittent energy sources such as wave, wind
and current power can be smoothened by the flywheel, making these energy sources
more efficient and thereby competitive with a remaining high power quality in the
electric grid.
 He concluded that thesis show that the concept of introducing a flywheel in to a
conventional electric driveline has many potential advantages. The amount of batteries
needed decreases significantly which means a lot in terms of cost but also weight and
volume. The battery losses decrease making cooling systems cheaper, lighter and
smaller. The propulsion system is highly likely to be more energy efficient with a
flywheel than without one. The weight, volume and cost introduced to the vehicle by
the flywheel is by far compensated by the advantages the flywheel brings to the system.
To conclude the flywheel based all-electric propulsion system have a set of advantages
that can be summarized as follows:

 Battery can be optimized for energy density since the flywheel care for the power
handling. This leads to a smaller amount of batteries needed
 Battery efficiency increases since their charge and discharge power decreases
 Battery lifetime is longer since the number of charge and discharge cycles decreases
drastically, especially in urban driving
 Battery can be optimized for discharging since charging normally does not occur
during driving. Charging between driving occasions are made in a smooth and
controlled way
 High efficiency leads to low energy loss and less need for cooling
 Vehicle performance enhances due to higher power capacity
 Regenerative braking is efficiently accomplished by the flywheel
 Fast charging is possible however limited by the size of the flywheel
 Operation with flywheel as sole energy source is possible
 Allows a robust all-electric propulsion system with few mechanical parts
 Can be used with any kind of fuel, both conventional and future, as long as the main
energy transmission is electric

Two models describing the high voltage/high peak power side of the driveline, one complex
and detailed Simulink model and one much more unembellished in Matlab have been
implemented. The two models are matched allowing smooth and seamless transition between
detailed small-scale and long large-scale simulations. Flywheels can also be beneficial for
stationary use, i.e. connected to the electric grid to smoothen the power output from an
intermittent energy source.

2.3 LITERATURE REVIEW 3

“On a Flywheel-Based Regenerative Braking System for Regenerative

Energy Recovery”

Tai-Ran Hsu and ASME Fellow are invented it and worked on a unique flywheel-based
regenerative energy recovery, storage and release system developed at the author’s
laboratory. It can recover and store regenerative energy produced by braking a motion
generator with intermittent rotary velocity such as the rotor of a wind turbogenerator
subject to intermittent intake wind and the axels of electric and hybrid gas-electric
vehicles during frequent coasting and braking. Releasing of the stored regenerative
energy in the flywheel is converted to electricity by the attached alternator. A proof-of-
concept prototype called the SJSU-RBS was designed, built and tested by author’s
students with able assistance of a technical staff in his school.

They concluded that A new regenerative braking system, the SJSU-RBS was developed
with the design, construction and testing of a proof-of-concept prototype. It involves a
fast spinning flywheel/alternator unit with a uniquely designed progressive braking
system and an epicyclic gear train. This new SJSU-RBS can be readily adapted to power
plants driven by renewable energies from intermittent sources such as solar, wind and
braking of electric and hybrid gas-electric vehicles during coasting and braking. The
SJSU-RBS was proof-tested for its feasibility and practicality for the intended
applications.

Despite the success in the preliminary bench-top testing of the prototype of the SJSU-
RBS as presented in the paper, a few key technical issues remain unsolved. Issues such
as the optimal design of flywheel for maximum net recovery and storage of regenerative
energies; quantification of aerodynamic and electromechanical resistance to the free
spinning of the flywheel, and the effective and optimal control of the motion of the
 flywheel and the driving shafts, etc. will have significant effects on the performance of
the SJSU-RBS or similar regenerative braking system for maximal recovery of
regenerative energies in reality.

Further research on the detailed design and integration of the SJSU-RBS to wind power
generating plants and EVs and HEVs for performance enhancements is desirable. The
success of such integration will result in great economical returns to the renewable
power generation industry. Efficient power generations by renewable energy sources
by RBS will make significant contributions to the sustainable development of global
economy and well-being of all humankind.

2.4 LITERATURE REVIEW 4

“Modeling and Analysis of a Flywheel Energy Storage System for

Voltage Sag Correction”

Satish Samineni is invented it and worked on A shipboard power system is a stiff,

isolated power system. Power is generated locally, and distributed over short distances
making the system vulnerable to system transients. Power quality problems such as
voltage sags, which arise due to a fault or a pulsed load, can cause interruptions of
critical loads. This can be of a serious concern for the survivability of a combat ship. A
series voltage injection type flywheel energy storage system is used to mitigate voltage
sags. The basic circuit consists of an energy storage system, power electronic interface
and a series connected transformer. In this case the energy storage system consists is a
flywheel coupled to an induction machine. The power electronic interface consists of
two voltage sourced converters (VSC) connected through a common DC link. The
flywheel stores energy in the form of kinetic energy and the induction machine is used
for energy conversion. Bi-directional power flow is maintained by regulating the DC
bus voltage. Indirect field orientated control with space vector PWM is used to control
the induction machine. Sinusoidal PWM is used for controlling the power system side
VSC. This paper presents the modeling, simulation and analysis of a flywheel energy
storage system and with a power converter interface using EMTDC.
 He concluded that The modeling and analysis of a flywheel energy storage system for
voltage sag correction on a shipboard power system has been presented. A control
scheme has been proposed for voltage sag correction and energy control. The sag
correction is based on negative torque command, which is a scaled error of the
difference between shipboard power system side of the synchronously rotating
reference dq voltage and its reference. An energy control system that regulates the DC
bus voltage and charges the flywheel has been described. A dq space vector based sag
detector has been modeled for sag detection. A feed forward control by the sag detector
output which disables the speed and DC bus voltage controller improves the energy
storage system performance in mitigating voltage sags.

The shipboard power system and the power converters were modeled using EMTDC,
along with the full transient synchronous reference based dq induction machine and
flywheel model. An indirect field oriented controller for the control of flywheel
induction machine was also modeled in EMTDC. The space vector PWM pulse
generator model to generate firing pulses for the flywheel converter was modeled in
MATLAB and interfaced to the switching device models in EMTDC. The overall
energy management scheme, the sag detector, and the sag corrector were all modeled
in EMTDC, along with the control scheme for the shipboard power system side VSC.

The response of the energy storage system to a balanced voltage sag was presented. The
advantage of a dq space vector based sag detector over RMS based sag detector has
been shown. The instantaneous voltages are compensated within 2 cycles to keep the
voltage tolerance within 5% of rated voltage. The main advantage of this FESS is high
power density. It can mitigate long duration voltage sags efficiently.

2.5 LITERATURE REVIEW 5

“Flywheel Energy Storage System”

AFS Trinity Power Corporation invented it and worked on The broad goal of this
project was the development and demonstration of a complete prototype Flywheel
Power System (FPS) and successful proof of the feasibility of this energy storage
technology. The AFS Trinity M3AM system, as demonstrated in this contract, can
discharge at 100kW for 15 seconds, and recharge immediately at the same rate. The
duty cycle is thus 30 seconds, and the available energy is 0.42kWh. A duty factor of
40% is sustainable for 100 successive discharges, and a duty factor of 23% is
sustainable indefinitely. The system has a footprint smaller than 4 sq ft, and typically
has 680V DC output. It is based on a Halbach array motor generator and a high strength
all-carbon composite rotor. Proprietary motor control software and hardware
implement a deadband control scheme to give good voltage regulation on the DC bus.
Maximum design speed of the system is 40,800 rpm, and the verified factor of safety is
greater than 2.0 based on rotor burst testing. The final laboratory prototype systems
have undergone extensive functional testing. The next step in development will be final
system modifications for the transition from laboratory to field testing, and interface
engineering for a field experiment.

AFS Trinity plans to commercialize this system for applications in load-following of

advanced distributed generation, power quality, and industrial power management.

In addition to the Energy Commission, the Federal Transit Authority (FTA), Defense
Advanced Research Projects Agency (DARPA), Department of Energy (DOE), and
equity investors in AFS TRINITY have co-funded this project.

They concluded that

1. Scalability: At the inception of the contract we believed it would be a feasible task
to create a design that was scalable over a wide range of sizes. This expectation is
captured in one of the summary goals of the project: “The FPS design will be
scalable...” We no longer believe that there is a fully predictable path for scalability.
While one can preserve general system architecture, there will be many details that must
be worked out afresh at each new size, and as the percentage increase in size becomes
larger, the general expectation is that the level of difficulty will increase in the scaling.
The greater the scale step, the more iterations will be required before the new design
meets requirements. So definition of the term “scalable” is difficult, and the word may
imply that the process is easier than in fact it is. We consider the primary uncertainties
to arise in rotor fabrication, and consider the scale-up of the controls and power
electronics to be more predictable in budget and schedule.
2. System Storage: The system we have designed, fabricated, and tested delivers
0.42kWh at rated power (and somewhat more energy at lower power ratings). Our
market research indicates that the resulting ride-through time of 15 seconds is well
matched to the needs of several applications, including load following for distributed
generation, ride through for voltage sags and standby generator startup, and heavy
hybrid electric vehicles.

3. System Power: The system power rating is 100kW. We have determined that an FPS
is unlikely to be economically feasible compared to batteries for long discharge times,
such as the one-hour discharge time inherent in the original contract objectives.
Although several development groups were seriously engaged in addressing this market
in 1998 when we wrote the proposal, all the private companies engaged in this endeavor
have now come to the same conclusion, and ceased development of such a machine. It
is at the relatively short discharge times of seconds to a few minutes that most
technologists now expect flywheels to play an important role. One of the difficulties in
customer understanding of energy storage is that the conclusions on appropriate
technology change with the characteristic discharge time of the application: there is no
“one size fits all” solution.

4. System Cost: Initial cost estimates have been compiled on the basis of existing small
quantity purchases for the pre-production M3 and labor to assemble the components in
a non-production shop. The cost of the Flywheel is comprised of approximately 60%
electronics and packaging, and 40% for the flywheel motor/generator. Approximately
80% of the total cost is in material and 20% in labor. Initial cost of the M3 will be high
in comparison to the mature cost, which should be reduced by 60%. The cost reduction
will be achieved systematically on three major fronts: 1) labor will decrease by 50%
due to the learning curve of the work force as volume and experience increase, 2)
material costs will be reduced by 50% as a result of the volume increase and supplier
rationalization, and 3) a cost reduction program will focus on lean manufacturing and
design for manufacturability and assembly to further reduce labor and material costs to
meet the mature cost target.
5. System Volume: The integrated FPS is in a cabinet whose outer dimensions are
smaller than the Commission contract objective. Energy per unit volume is comparable
to, though fractionally smaller than, the objective. Power per unit volume is
dramatically higher than its objective. We now believe that within a certain range,
system volume is not a strong driver of customer acceptance.

6. System electrical performance: The FPS is designed to connect to a DC bus. Our

system controller uses a deadband control scheme. The flywheel charges when the
voltage rises to the top of the deadband, and discharges when the bus voltage drops to
the lower setting. The width of the deadband, allowed voltage droop on discharge, and
voltage recovery time are adjustable to customer requirements. We continue to believe
that this approach is generally consistent the technical requirements for nearly every
power management application of which we are aware.

7. System response time: In response to a step change in load, the DC bus voltage
regulated by the flywheel system will droop momentarily and then recover to the
voltage level that existed prior to the application of the load. The droop will be on the
order of 10s of volts and will have a duration of 10s of milliseconds with exact values
depending on the magnitude of the step load change and the settings entered into the
user interface. Response characteristics can be tailored to the application requirement.

8. System efficiency: Depending on the application, system efficiency may matter a

great deal, or not at all, in the energy budget of the installation. System roundtrip
efficiency acts as a discount on energy only when the system is required to discharge,
and while some applications require very frequent discharge, others do not. Otherwise,
the system standby power consumption is what imposes energy costs on the user.

9. System standby power consumption: In light of our extensive system testing, we

now expect that we will dramatically reduce system standby power consumption in the
next round of upgrades of the ancillary systems.

10. Ancillary system maturity: The ancillary systems that we use in the engineering
prototypes are industrial products with good reliability and would be suitable for use in
field test units and commercial products. The cost of this equipment comprises a
 significant part of the total system cost and development work on ancillary systems will
seek to reduce cost by combining functions (rotor system that also performs vacuum
pumping) and reduce capacity (less expensive heat exchangers). Ancillary systems are
also the only portions of the system that require routine scheduled maintenance and
future development will seek to eliminate required maintenance to the greatest practical
extent.

11. Interface issues: The DC bus and keypad interface provide good basic operability.
Many applications will benefit from relatively high bandwidth communication between
the flywheel system and the application and individual flywheel units when multiple
units are operated in parallel. We are addressing this by designing subsequent
generations of system controllers to incorporate CAN bus communication capability.

12. System lifetime: We expect that the existing system would demonstrate a cycle life
exceeding 105 cycles and possibly 106 cycles but are unable to execute a program to
demonstrate this due to the prohibitively cost of high-cycle spin testing. There is no
firm design life limit to the primary flywheel components and a 20-year life is believed
to be a conservative expectation. In practice, power electronics and ancillary systems
are expected to have much shorter service lives than the flywheel itself and life
improvement will be part of continued engineering of ancillary subsystems.

2.6 LITERATURE REVIEW 6

Heinrich Arnold1 November 2001: Rather long re-investment cycles of about 15 years have
created the notion that innovation in the machine tool industry happens incrementally. But
looking at its recent history, the integration of digital contro ls technology and computers into
machine tools have hit the industry in three waves of technology shocks. Most companies
underestimated the impact of this new technology. This article gives an overview of the history
of the machine tool industry since numerical controls were invented and introduced and
analyzes the disruptive character of this new technology on the market. About 100 interviews
were conducted with decision-makers and industry experts who witnessed the development of
the industry over the last forty years. The study establishes a connection between radical
technological change, industry structure, and competitive environment. It reveals a number of
important occurrences and interrelations that have so far gone unnoticed.
2.7 LITERATURE REVIEW 7
Dr. Toshimichi Moriwaki (2006): Recent trends in the machine tool technologies are
surveyed from the viewpoints of high speed and high performance machine tools, combined
multifunctional machine tools, ultra-precision machine tools and advanced and intelligent
control technologies.

2.8 LITERATURE REVIEW 8

Frankfurt-am Main, 10 January 2011.: The crisis is over, but selling machinery remains a
tough business. Machine tools nowadays have to be veritable “jack of all trades”, able to handle
all kinds of materials, to manage without any process materials as far as possible, and be
capable of adapting to new job profiles with maximized flexibility. Two highly respected
experts on machining and forming from Dortmund and Chemnitz report on what’s in store for
machine tool manufacturers and users. Multi-purpose machines are the declarations of
independence. The trend towards the kind of multi-purpose machining centers that are able to
cost efficiently handle a broad portfolio of products with small batch sizes accelerated
significantly d uring the crisis. “With a multi-purpose machine, you’re less dependent on
particular products and sectors”, explains Biermann.