TECHNICAL FIELD

[00011 The invention concerns a key component of a flywheel energy storage system, a device that functions as a motor and a generator, referred to herein as a homopolar motor.

BACKGROUND

DESCRIPTION OF THE RELATED ART

[00021 A flywheel energy storage system stores kinetic energy in a flywheel rotor. Kinetic energy is transferred to or stored in the rotor by accelerating the angular rotation velocity of the rotor. And, vice versa, energy is extracted from the rotor by decelerating the rotor.

[00031 Thus, it is with respect to these considerations and others that the present invention has been made.

SUMMARY

[00041 Embodiments of the subject invention are directed to a homopolar motor and its mechanical coupling with a flywheel rotor. The homopolar motor includes a rotor and no additional bearings, shafts, gears, pulleys, etc., are required to couple the the flywheel rotor and the rotor of the homopolar motor.

[00051 The homopolar motor includes a stator with a stator laminate and a number of stator pole pieces. The pole pieces generate magnetic flux across a first radial gap to the rotor assembly to generate torque. The rotor assembly is coupled to and rotates with shaft which in turn rotates the flywheel rotor. The rotor assembly includes a rotor laminate stack and a field coupler. The field coupler has a top portion that rotates with the shaft and a bottom portion that attaches to a housing and remains stationary. The stationary bottom portion of the field coupler is magnetically coupled to the stator by a low reluctance magnetic path. This low reluctance magnetic path may be constituted of solid steel, or other magnetically permeable material. Further, this low reluctance path may be incorporated within the homopolar motor housing, the overall flywheel housing, or any combination.

[00061 The homopolar motor further includes a field winding that generates magnetic flux across the gaps between the two interleaved portions of the field coupler. The gap formed by the interleaved portions of the field coupler are referred to as a second, or auxiliary, gap.

[00071 In certain embodiments the homopolar motor has a p-pole design for the rotor and stator elements. In one embodiment, the rotor laminate has with 4 lobes and 8 poles and the stator has 12 teeth and 12 slots. In certain embodiments, each tooth is implemented as a pole piece and a slot is formed by the space between two adjacent pole pieces. Each pole piece forms a sector of stator and each pole piece is formed by installing a winding, or coil, around a laminate sector of the stator.

[00081 In certain embodiments, the cross-section of the top portion of the field coupler appears as one, two, or more successive isosceles triangles that narrow from top to bottom. The cross section of bottom portion of the field coupler is inverted from that of top field coupler, i.e. it appears as one, two, or more successive triangles of the same size, which narrow from bottom to top. Further, there is a uniform, second, gap between the surfaces of the top portion and the bottom portion of the field coupler. The sloped surfaces of the field coupler and the resulting gap they form increases the overall area of the interface gap, resulting in proportionally reduced magnetic flux density crossing the gapped surface. Since the magnetic flux is directed in the direction normal to the gap surfaces, the axial component of the resulting total force is reduced by cos(0), where Θ (theta) is the angle between the base of the isosceles triangle and each of its two equal length sides.

[00091 In general, the profiled sub-surfaces of the coupler need not be restricted to isosceles triangles. This choice is one convenient geometry among many possibilities.

BRIEF DESCRIPTION OF DRAWINGS

[00101 The disclosed embodiments have other advantages and features which will be more readily apparent from the detailed description, the appended claims, and the accompanying figures (or drawings). A brief introduction of the figures is below.

[00111 Figure (FIG.) 1 is a simplified cross section view one embodiment of a flywheel energy storage system, also referred to as a flywheel unit.

[00121 FIG. 2A shows the rotational elements of the embodiment of the flywheel unit of FIG. 1, including elements of an embodiment of a homopolar motor.

[00131 FIG. 2B shows a simplified cross section of one embodiment of a homopolar motor used to drive a flywheel unit.

[00141 FIG. 3A illustrates an embodiment of a polar configuration of the rotor and stator of the homopolar motor.

[00151 FIG. 3B illustrates an embodiment of a pole piece from the stator of the homopolar motor.

[00161 FIG. 4A is an isometric view of an embodiment of a field winding and a non- rotating portion of a field coupler of the homopolar motor.

[00171 FIG. 4B is a cross section view of an embodiment of a field winding and a non- rotating portion of a field coupler of the homopolar motor.

[00181 The figures depict embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein. DETAILED DESCRIPTION

[00191 Modern flywheel energy storage systems operate in a vacuum enclosure, in order to avoid frictional losses from residual gas drag. As such, it is preferred to integrate an electromagnetic motor/generator with the energy storage rotor within the vacuum enclosure, and to make the integration as seamless as possible. For example, it is preferred to avoid belts, pulleys, gears, long shafts, etc. Ideally, the rotor of the electromagnetic

motor/generator is very tightly coupled to the flywheel rotor, avoiding the need for substantial additional mechanical coupling elements.

[00201 The integrated electromagnetic motor/generator described herein is operated with an electrical interface to accelerate or decelerate the energy storage rotor as required in any given energy storage application.

[00211 Some constraints on the type of motor/generators that are suitable for use in flywheel energy storage systems include avoiding contacting or sliding contacts associated with slip rings, brushes, and/or commutators, so as to avoid the lifecycle hazards associated with wear and tear, and the contamination of the vacuum environment. As such, the preferred machine types are AC machines that do not include such sliding contacts.

[00221 Another constraint is on the allowed power dissipation associated with the rotor. Power dissipated in the rotor can only be transferred to the housing via radiation, weak convection with the enclosed residual gas, or very limited conduction via mechanical bearings if present. As such, conventional ac induction machines have not generally been used in modern flywheel systems, due to their intrinsic rotor losses. Although conventional induction machines are sometimes considered for use in flywheel energy storage systems, an induction machine is usually not preferred due to its intrinsic rotor losses and relatively weaker rotor construction in relation to some of the above mentioned options. As noted above, rotor losses present a thermal management challenge for operation in vacuum environment. [00231 A homopolar synchronous machine, also referred to as a homopolar machine, a homopolar motor, a homopolar motor and generator, motor and generator or simply a motor/generator, is a synchronous machine with a stationary field winding, in contrast to conventional synchronous machine types that have a rotating field winding and

accompanying slip rings. As such, the homopolar machine avoids the need for slip rings, and the associated lifecycle and contamination hazard. Since the homopolar machine has operating characteristics analogous to a conventional synchronous machine, it has full capability of adjustment of field winding excitation and associated operating point. For example, to effect very low loss standby coasting, the field excitation can be de-energized, resulting in virtually zero electromagnetic losses. Homopolar synchronous machines are further advantageous because they are easily designed for negligibly low rotor losses.

[00241 Further, the field excitation can be adjusted at each operating speed, and for each operating power level, to optimize overall system efficiency. Losses due to conduction, electromagnetic core loss (e.g. iron loss), and power electronic conversion can be minimized in aggregate at each speed and power level. This level of adjustment is not readily available with a permanent magnet type machine, since the field intensity is not easily adjusted. A synchronous reluctance machine does permit field adjustment, but is typically constrained to a relatively low power factor.

[00251 Homopolar synchronous machines typically require three-dimensional flux paths. The field or dc bias magnetic flux is effected by the stationary field winding, which directs flux through gaps and solid, or non-solid, steel permeable magnetic pathways. The purpose is to magnetically energize the gap in between the active rotor lobes and the stator. Each of the active rotor lobes can be thought of as a North pole, with each of the valleys between these lobes thought of as a South pole. Since flux is unidirectional in this layout, the machine is termed homopolar. Without loss of generality, it should be noted that the flux path could be entirely reversed in response to an opposite field excitation. With application of the dc field excitation, the machine inherits the main features of a conventional synchronous machine.

[00261 Stator windings for this type of machine can be arranged with the conventional three-phase pattern with the appropriate pole count, with two poles per rotor lobe. The stator winding can be installed in slots with a conventional tooth-slot arrangement, or directly within the air-gap in a slotless arrangement.

[00271 The present invention includes embodiments of a homopolar synchronous machine, homopolar motor, or homopolar machine. The principal application of the homopolar motor described herein is for flywheel energy storage systems. However, the homopolar polar motor described herein is not so limited and can be used in other energy storage systems and other machines.

Flywheel Energy Storage System

[00281 Figure (FIG.) 1 is a simplified cross section view of one embodiment of a flywheel energy storage system, also referred to as a flywheel unit 100 that mounts a power electronics subsystem, or power electronics unit 120 to a flywheel housing 1 10, according to one embodiment. Flywheel unit 100 includes a flywheel rotor assembly 130 or simply flywheel rotor 130, a motor and alternator 140, also referred to as motor/alternator 140 because both functions are typically performed by a single subsystem, a flywheel housing 1 10, a power electronics unit 120, a power line 150, which may be AC or DC, and a control line 160. For example, power line 150 may be a conventional three-phase 60 Hz AC line. Generally, hereinbelow, the term flywheel energy storage system, or flywheel unit refers to a single flywheel housing 1 10 and any rotors, motor/alternators and other elements that it houses as well as any power electronic elements, which may be housed and mounted on flywheel housing 1 10, as depicted in FIG. 1 or may be incorporated inside flywheel housing 1 10 or separately from flywheel unit 100. [00291 In certain embodiments, power electronics unit 120 includes a power electronics housing 125 that encloses and houses electrical components including a power converter for converting the input alternating current into an alternating current acceptable to the motor/alternator 140. Alternatively, in other embodiments, power electronics unit 120 converts the alternating current from the motor/alternator 140 into a direct current output. Power electronics unit 120 may also include sensors, processors, memory, computer storage, and network adapters as necessary to perform communications, control and status monitoring of flywheel unit 100. Sensors may include multi-axis accelerometers, gyros, proximity sensors, temperature sensors, strain sensing elements and the like. Power electronics 120 receives and provides power via a power line 150 which may be AC or DC. In certain embodiments, power electronics 120 has a control line 120 for receiving and transmitting control signals. Control line 160 may be a physical cable such as an ethernet cable;

alternatively it may communicate over a wireless communications link such as WIFI or BLUETOOTH.

[00301 Motor/alternator 140 converts between electrical and mechanical energy, so that energy can be stored in or drawn from the flywheel 130. Motor/alternator 140 combines the function of a motor and an alternator and thus may also be referred to as motor and alternator 140. Motor/alternator 140 couples to flywheel rotor 130 either directly, or indirectly, for example using a stub shaft that also connects to a supporting bearing. Motor/alternator 140 is coupled to power electronics unit 120 via wires or other electrical couplings that typically run through a vacuum feedthrough through the flywheel housing 110.

[00311 Although flywheel housing 110 is shown as enclosing a single flywheel rotor 130 and a single motor/alternator 140 in other embodiments a single housing may enclose multiple rotors and motor/alternators.

Integration of Flywheel Rotor with Motor/ Alternator [00321 FIG. 2A illustrates one embodiment of a mechanical coupling of a flywheel rotor 130, a shaft 210 and a rotor assembly 205 of a homopolar motor 200 (illustrated in FIG. 2B). Homopolar motor 200 is one embodiment of motor/alternator 140. In this arrangement, no additional bearings, shafts, gears, pulleys, etc., are required to couple the two rotors. In this embodiment, shaft 210 is shown as a stub shaft attached to rotor 130. In other embodiments, shaft 210 may emanate directly from rotor 130 or may be connected in other ways, rather than using a stub shaft configuration. Embodiments of a stub shaft that may be used in the subject invention are described in U.S. Patent Application No. 2016/0061289, filed on July 28, 2015, which is incorporated in its entirety by reference herein. In certain embodiments, homopolar motor 200 couples directly to a flywheel rotor. In such embodiments, a shaft is not required to couple the flywheel rotor 130 with the rotor assembly 205.

[00331 FIG. 2B shows a simplified cross section of one embodiment of homopolar motor 200. Homopolar motor 200 applies torque to shaft 210, which is shown as a stub shaft.

[00341 Homopolar motor includes a stator that includes a stator laminate stack 240 and a number of stator pole pieces 242, referred to henceforth as pole pieces 242. Pole pieces 242 guide (or direct) flux across a first, or principle, radial gap 1 to rotor assembly 205 to generate torque. Rotor assembly 205 is coupled to and rotates with shaft 210 which in turn rotates flywheel rotor 130. Rotor assembly 205 includes a rotor laminate stack 250 and a top portion of a field coupler 230, referred to as field coupler 23 OA. A bottom portion of field coupler 230, referred to as field coupler 230B attaches to a housing 260 and remains stationary. Rotor laminate stack 250, also referred to as rotor laminate 250, is formed of a stack of identical steel laminations that serve to block AC eddy currents. Alternatively, rotor laminate 250 may be formed of solid steel.

[00351 Homopolar motor 200 further includes a field winding 220 that generates magnetic flux across the gaps, collectively referred to as gap 2, between the two interleaved portions of field coupler 230, namely the top portion of field coupler 23 OA, which rotates with shaft 210 and the bottom portion of field coupler 230B which remains stationary. Field coupler 230 provides a path for magnetic flux generated by field winding 220 from its stationary part 23 OA to its rotating part 230B.

[00361 In certain embodiments, field winding 220 is formed by a coil of insulated or anodized, thin, aluminum or copper. This provides a low resistance electrical conductor.

[00371 Homopolar motor 200 along with flywheel rotor 130 are easily assembled by lowering the assembled rotor assembly 205, comprising flywheel rotor 130 shaft 210, rotor laminate 250, and top portion of field coupler 23 OA into flywheel housing 110 without any impediment. Field coupler 230 and and gaps 1 and 2 do not impede or in any way interfere with this simple assembly step. No assembly steps in the rotating group are required after the flywheel rotor is inserted into the flywheel housing.

P-pole Design

[00381 FIGS. 3 A-B illustrate an embodiment of a p-pole design for the rotor and stator elements of homopolar motor 200.

[00391 FIG. 3 A illustrates an embodiment of a rotor with 4 lobes and 8 poles and a corresponding stator with 12 teeth and 12 slots. In homopolar motor 200, each tooth is implemented as a pole piece 242 and a slot 244 is formed by the space between two adjacent pole pieces 242. Each pole piece 242 comprises a sector of stator 240. Each pole piece 242 is formed by installing a a winding, or coil, around a laminate sector of the stator.

[00401 The configuration of FIG. 3 A is a p-pole design with a 3/2 relationship between the number of slots, or teeth, on the stator and the number of poles on the rotor, i.e. the number of slots = 3/2*p where p is the number of poles. Each tooth has a stator coil, and effectively spans 2/3 of a rotor pole, providing a strong fundamental flux linkage function, but while requiring a very minimal conductor endturn length. Further, since the individual coils are non-overlapping, the windings are very easy to manufacture either in-situ or on individual stand-alone tooth sections. [00411 There are several possible choices of the number of slots, and hence pole pieces, and poles, p. Some simple rules must be observed: (1) the number of slots, and hence pole pieces, must be a multiple of 3 to accommodate 3 phase power generation in a balanced way; (2) good choices often have p close to, but not equal to, the number of slots; and p is an even integer since poles are in pairs. While the configuration illustrated in FIG. 3A has 12 slots and 8 poles, the . 3/2 ratio is not a requirement. For example, other effective choices include 12 slots and 10 poles, and 12 slots and 14 poles.

[00421 FIG. 3B illustrates an embodiment of one stator pole piece 242 from the stator of homopolar motor 200. Pole piece 242 directs magnetic flux across gap 1 to the rotor, which includes rotor laminate 250 and rotor lobes 252. This arrangement optimizes the use of the stator conductor with respect to cost and efficiency. Specifically, the winding configuration has relatively short endturns in relation to conventional multi-slot windings. This is important for an implementation with a short stack length. And, further, the non-overlapping windings simplify manufacture, and, again reduce endturn length.

[00431 It may be appreciated that an alternative arrangement is to use a single integral stator laminate, and to install windings on each tooth, to manufacture the stator.

Path of DC Field Magnetic Flux

[00441 FIGS. 4A-4B illustrate an embodiment of field coupler 230, which forms an auxiliary coupler gap 2, in order to energize the principle active rotor-stator gap 1. Gap 2 presents several problems since it is potentially associated with intense flux density, substantial MMF drop, magnetic force, and associated negative magnetic stiffness. One embodiment of an auxiliary coupler that is used to energize the principle rotor gap 1, shown in Figures 4A-4B, and referred to as field coupler 230, substantially solves these problems.

[00451 FIG. 4A is an isometric view of an embodiment of field winding 220 and the bottom, non-rotating, portion of field coupler 230, referred to as field coupler 230B. [00461 FIG. 4B is a cross section view of an embodiment of a field winding and field coupler 23 OA, the lower, non-rotating portion of a field coupler 230, and field coupler 230B the top, or upper, rotating portion of field coupler 230. As illustrated, field coupler 230 has two interleaved portions: top field coupler 230A and bottom field coupler 23B. The cross- section of top field coupler 230A appears as one, two, or more successive isosceles triangles that narrow from top to bottom. The cross section of bottom field coupler 230B is inverted from that of top field coupler 230B, i.e. it appears as one, two, or more successive isosceles triangles of the same size, which narrow from bottom to top. Further, in certain embodiments the gap between the surfaces of top field coupler 23 OA and bottom field coupler 230B, gap 2, is of uniform distance.

[00471 While the illustrated cross section of field coupler 230 is depicted as two interleaved isosceles triangles on the top and bottom in certain embodiments one triangle or more than two triangles may be used. Further, in certain embodiments the triangles may not be isosceles. Yet further, other geometric shapes other triangles may be used, such as rectangles or other quadrilaterals; the general requirement being an interlocking pattern between the cross-section shape of top field coupler 230A and bottom field coupler 230B.

[00481 Field coupler 230 directs flux to travel normal to its sloped surfaces. This approach increases the overall area of gap 2, resulting in proportionally reduced magnetic flux density crossing the gapped surface. This mitigates problems with magnetic saturation, and with attractive magnetic forces normal to the interfacing surfaces. In this embodiment, the overall magnetic flux intensity at gap 2 is reduced by cos(0) where Θ is the angle the field coupler 230 internal surfaces makes with the horizontal, i.e. angle between the base of an isosceles triangle and each of its two equal length sides, as depicted in FIG. 4B. Next, since the magnetic flux is directed in the direction normal to the surfaces of gap 2, the axial component of the resulting total force is reduced by cos(0). It may be appreciated that large and variable axial forces present a challenge for the flywheel bearing and suspension system. With this arrangement, field coupler gap flux density is reduced by cos(0), resulting in a reduction of the attractive force density (magnetic stress) normal to the surface by cos ² (0). Since the force is directed obliquely to the principle axial direction, it is further reduced by cos(0). Thus, field coupler 230 surface surface area is increased by l/cos(0), and net axial force is reduced by cos ² (0), which substantially reduces the chances of magnetic saturation.

[00491 In a most preferred embodiment the angle 0 is between 75 and 85 degrees. In other embodiments, angles between 30 and 90 degrees may be used.

Additional Configuration Considerations

[00501 Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs through the disclosed principles herein. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the method and apparatus disclosed herein without departing from the spirit and scope defined in the appended claims.