AU2020203124B2 - This invention relates to a material-shortage aware, cost-effective, environment-friendly, long-lasting massive energy storage system. It is based on the conversion between potential energy in heavy masses and electricity when containers with heavy masses are moved between low and high platforms. It uses elongated torus shaped electric machines to lift containers with heavy masses. This technology can lift up and lower down containers with heavy masses at relatively high efficiency and with the awareness of key material shortage. - Google Patents

Abstract

Elongated Torus Shaped Electric Machine based Heavy Mass Energy Storage System Abstract This invention relates to a material-shortage aware, cost-effective, environment-friendly, long-lasting massive energy storage system. It is based on the conversion between potential energy in heavy masses and electricity when containers with heavy masses are moved between low and high platforms. It uses elongated torus shaped electric machines to lift containers with heavy masses. This technology can lift up and lower down containers with heavy masses at relatively high efficiency and with the awareness of key material shortage.

Description

Field of invention

[001] This invention relates to a material-shortage aware, cost-effective, environment-friendly, long lasting massive energy storage system. It is based on the conversion between potential energy in heavy masses and electricity when containers with heavy masses are moved between low and high platforms. It uses elongated torus shaped electric machines to lift containers with heavy masses.

Background

[002] Nuclear fusion could be a high-tech solution to energy shortage but its commercialization is not foreseeable. Furthermore fossil fuel could be depleted within next 50 years. Hence energy crisis is still a pressing issue faced by us. Grid-scale massive energy storage is currently in high expectations. When striving for such massive energy storage solution, many limiting factors need be considered such as key materials availability. In the previous work done by the inventor, Daming Zhang, "Issues on Heavy Mass Energy Storage with Vertical Movement by Linear Machine", published in 9th International Conference on Power and Energy Systems (ICPES 2019) at Perth from 10-12 December, a vast amount of permeable and stainless steels need be used, though they are recyclable but massive or global-wide implementation may not be feasible. In another method developed by Daming Zhang, "Heavy Mass Energy Storage with Magnetic Levitated Wheels, Bearings and Locomotive", Journal of Multidisciplinary Engineering Science and Technology (JMEST), ISSN: 2458-9403, Vol. 6 Issue 7, July - 2019, the author proposed to use cost-effective method to lift up and lower down containers with heavy masses using locomotive. Such system suffers from low efficiency. Given the fact that the materials such iron ore etc on earth are limited, and they could be used up someday as well, designing a less-steel-use and relatively high efficient electric machine system is highly necessary. This is the motivation of the disclosed technology as described in the following writing.

Brief description of the drawings

[003] Figure 1 Top view (top figure) of the heavy mass energy storage system with multiple identical units, each of which has an elongated torus shaped electric machine positioned at the top surface linked with high platforms and side view (bottom figure) of the whole system;

[004] Figure 2 Vertical cut-cross-sectional view with simplified turning supports at each end of the machine and detailed interleaved or alternating magnetic layer in the stator in elongated torus shape;

[005] Figure 3 Vertical cut-cross-sectional view with simplified turning supports at each end of the machine and multiple mover units;

[006] Figure 4 Cut cross sectional view of electric machine and its support from A1A2 in Fig. 2 with detailed stator magnetic cores, mover conductors and mover guides, stator winding cut-cross-section view, and mechanic supports for the electric machine;

[007] Figure 5 Cut cross sectional view of electric machine and its support from A1A2 in Fig. 2 with detailed stator magnetic cores, distributed air gaps for holding mover conductors, stator winding cut cross-sectional view, and mechanic supports for the electric machine;

[008] Figure 6 Front view of the electric machine system and its mechanic support (a) without magnetic plate support; (b) with magnetic plate support;

[009] Figure 7 (a) Illustrative stator winding wound at one side of the elongated torus shaped stator core; (b) mover guide belts and driving belts;

[0010] Figure 8 Unit of mover system (a) cut-cross sectional view; (b) 3-D view;

[0011] Figure 9 Side view of illustrative two units of mover system (a) without guide belts and driving belt; (b) with guide belts and driving belt; (c) side view of wings installed on mover units for coupling with mover guide belts and driving belt;

[0012] Figure 10 Top view (top figure) of part of driving belts and guide belts and front view (bottom figure) of the wings installed on the mover units;

[0013] Figure 11 Examples of steel conveyor belt with punched holes;

[0014] Figure 12 Top view (top figure) of the container holder with four guide poles and its side view (bottom figure);

[0015] Figure 13 Side view of uplifting winding and interleaved or alternating magnetic layers (a) multiple units of position-shifted uplifting windings, (b) one unit of the uplifting windings with two sets of coils; (c) one unit of the uplifting windings with stator magnetic core; (d) front view of uplifting windings sandwiched by stator magnetic plates; (e) front view of uplifting windings sandwiched by stator magnetic plates with crowded conductors outside of the magnetic path established by stator;

[0016] Figure 14 Driving windings and interleaved or alternating magnetic layers (a) driving windings; (b) side view of interleaved or alternating magnetic layers; (c) thin copper sheet sandwiched between magnetic sheets;

[0017] Figure 15 Ring-shaped conductors for mover carbon brushes (a) for one group of driving winding; (b) for one set of uplifting winding;

[0018] Figure 16 A combination of uplifting windings and driving windings;

[0019] Figure 17 Heavy mass energy storage with multiple transitions for very deep case;

[0020] Figure 18 Vertical cross sectional view of bottom parking lot or platform, its roof cover and water drainage system.

Detailed description

[0021] For very deep vertical heavy mass energy storage system, it is not affordable to use vast amount of permeable steel for the machine and stainless steel as the supports. Instead an elongated torus shaped machine is a better choice. In this technology, such a structure is adopted. Although such a structure can save cost on reduced steel use, it cannot lift as much heavy masses as the vertical structures described in

"Issues on Heavy Mass Energy Storage with Vertical Movement by Linear Machine", published in 9th International Conference on Power and Energy Systems (ICPES 2019) at Perth from 10-12 December written by the inventor. Hence it is necessary to use multiple units each of which is installed with a proposed electric machine in elongated torus shape. Figure 1 shows the top view (top figure) of such a heavy mass energy storage system, where there are multiple identical units, each of which is installed with such an electric machine 100 as shown in Fig. 1. Figure 1 also shows the side view of such a heavy mass energy storage system, from which one can see that there are two sets of container sitters or holders driven by the two sides of the elongated torus shaped electric machine.

[0022] More details of such machine are shown in Fig. 2 and Fig. 15.

[0023] Figure 2 includes the interleaved or alternating magnetic 130 and non-magnetic 140 layers. There are top side and bottom side in such interleaved magnetic structure. At the top side, a belt 301 is mechanically coupled with the mover of the electric machine for lifting up and lowering down the containers with heavy masses. At the bottom side, another belt 302 is mechanically coupled with the mover of the electric machine for lifting up and lowering down the containers with heavy masses.

[0024] How to wind the stator windings at each side of double-U core as shown in Fig. 4 and Fig. 5 are shown in Fig. 7a.

[0025] The stator structure is in elongated torus shape and is formed by interleaved or alternating magnetic and non-magnetic layers. Different from vertical machine topology as shown in "Issues on Heavy Mass Energy Storage with Vertical Movement by Linear Machine", published in 9th International Conference on Power and Energy Systems (ICPES 2019) at Perth from 10-12 December written by the inventor, the equal layer distance should be as short as several to tens of centimetres for facilitating high speed rotation along the circumference of the elongated torus. As seen from Fig. 4 and Fig. 5, magnetic cores are in double-U shape. Between neighbouring magnetic layers, non-conductive and non-permeable spacers are used to join them, especially at two ends of the torus. To minimize the fringing effect, narrow air gaps in the stator magnetic paths are necessary. Same as in the vertical machine topology, distributed stator air gaps are used. In Fig. 4 and Fig. 5, there are only three distributed air gaps, two for accommodating driving windings and another one for accommodating uplifting winding. For a practical application, more distributed air gaps could be used to produce sufficient driving and uplifting forces. The number of air gaps for uplifting windings depends on the total weight of one mover unit, containing both driving windings and uplifting windings. The total uplifting forces should be close to 100% yet less than 100% of the total weight. To reduce air-gap distance, thin sheet copper conductors sandwiched between thin sheet permeable steel are used for both driving and uplifting windings as described in "Issues on Heavy Mass Energy Storage with Vertical Movement by Linear Machine", published in 9th International Conference on Power and Energy Systems (ICPES 2019) at Perth from 10-12 December written by the inventor. Nevertheless for the uplifting windings, another winding style as shown in Fig. 13b through Fig. 13e can be adopted, where terminals Al is joined with A2, A3 with A4, A5 with A6,

A7 with A8, A9 with A10, Al l with A12, A13 with A14, A15 with A16, A17 with A18, A19 with A20; then terminal A21 is connected with B0; terminal B1 is with terminal B2, B3 with B4, B5 with B6, B7 with B8, B9 with B10, B1 with B12, B13 with B14, B15 with B16, B17 with B18, leaving BO and B19. Terminals A0 and B19 are left as two terminals connected with DC source. Such flat conductors under magnetic path need be supported by flat stainless steel sheets or other non-permeable and non conductive mechanically strong materials. There should be joining parts to link all the support sheets and also to join with mechanic hold of other mover parts as shown in Fig. 8. To save space, outside the magnetic path, the conductors could be crowded as shown in Fig. 13e. Such a structure can effectively reduce weight of the mover. The current flowing through the complete coil from terminal A0 to terminal B19 is always to produce uplifting forces. To achieve such a purpose, the conductors as shown in Fig. b is used, where top pair of conductors are to supply currents to those uplifting coils located at the top balf structure while bottom pair of conductors are to supply currents to those uplifting coils located at the bottom half of the stator structure.

[0026] For the uplifting winding, it is necessary to consider how to produce nearly constant uplifting force. One arrangement of multiple uplifting windings is shown in Fig. 13a, where multiple pairs of uplifting coils are adopted with physical shift viewed from one pair of stator layers. Each of two coils 1 and 2 take the same physical positions, while each of two coils 3 and 4 are physically shifted by one third of the stator layer, either magnetic or non-magnetic. The same shift is applied to coils 5 and 6, coils 7 and 8, coils 9 and 10, coils 11 and 12 in sequence. By doing so, nearly constant uplifting force is produced. This conclusion is not valid when the mover coils move to two sides of the torus shaped machine. For such locations, the force from the uplifting coils points along radial direction.

[0027] In the example mover structure, there are two driving windings and one uplifting winding. They join together to form one mover unit. The distance between two sides of one driving winding is the same as that of one stator layer, either magnetic or non-magnetic. The conductor is made of thin copper sheet sandwiched between permeable steel sheets to increase mechanic strength. Other strong materials could be used to replace such permeable steel sheets. Each side of the windings contain multiple such sandwiched combinations and connected in series to form a complete winding. When one set of driving windings experience transition between stator magnetic and non-magnetic layers, there must be driving forces from other windings. To achieve this purpose, a driving winding arrangement is shown in Fig. 14, where there is only one driving winding across one stator layer. The driving windings formed by A1A2 are connected with the winding A3A4 through flex cable which facilitates the turning movement in the rotation when extension is needed. They position physically the same way viewed by one pair of magnetic and non-magnetic stator layers. Windings B1B2 and B3B4 are positioned the same but both are shifted by one-third of the distance of one stator layer, and they are also connected through flex cables. Windings C1C2 and C3C4 are further shifted by another one-third of the distance of one stator layer. In whole circumference of the elongated torus shaped stator structure, there are multiple units of such A1A2, A3A4, B1B2, B3B4, and C1C2, C3C4 windings. All those A1A2, A3A4 like windings are connected in series or they can be divided into several sub-groups for convenience of connections. So are all those B1B2, B3B4 like windings and so are all those C1C2, C3C4 like windings. Same sub groupings are also applicable to Groups B and C. The driving currents flowing through each of the three different groups of driving windings follow the same patterns as described in Issues on Heavy Mass Energy Storage with Vertical Movement by Linear Machine", published in 9th International Conference on Power and Energy Systems (ICPES 2019) at Perth from 10-12 December written by the inventor. Each group is fed with currents through the carbon brushes pressed onto three separate ring conductor pairs, each of which is the same as that shown in Fig. 15a. This is only for one side of mover driving windings accommodated in one of the first distributed air gaps in double-U topology. Three different sets of ring conductor pairs as shown in Fig. 15a should be adopted for another side of mover driving windings accommodated in the second distributed air gaps as shown in Fig. 5. Basically during the non transition moments, the currents flowing through each of the three groups of windings carry 80% of the rated value. When one group of windings experience transition between magnetic and non-magnetic layers, current in it is reduced to zero before being increased to opposite 80% of rated value after transition while currents in other two groups need be increased to 120% of the rated value. By doing so, nearly constant driving force is produced.

[0028] To facilitate the rotation of each mover unit as shown in Fig. 8 or Fig. 9a and Fig. 9b, the length of one mover unit along movement should be around 1.25-1.5 times of the distance of one stator layer. The arrangement of driving windings and uplifting windings is shown in Fig. 16. Along the complete circumference of the elongated torus shaped machine, multiple such patterns repeat.

[0029] In each mover unit as shown in Fig. 8, Fig. 9 and Fig. 10, there are protrusive mechanically strong stubs for coupling with driving steel conveyor belts with punch holes. To minimize the influence by the torque produced by driving force, it is necessary to find the right position for joining part 155 as shown in Fig. 8. The position needs be chosen in such a way that torque by the driving force calculated from the bottom support wheels is balanced by that of the systems mainly formed by weight of container with heavy masses. By doing so, both torque and force are in equilibrium during steady-state movement.

[0030] There are two sets of driving belts and container holders as seen in Fig. 1, one being formed by container holder 310A, belt 301, and container holder 310B and named as outer lifting set while the other set being formed by container holder 320A, belt 302 and container holder 320B and named as inner lifting set.

[0031] The system is designed to work in both motoring and generating modes.

[0032] During motoring mode, the following sequence is followed:

[0033] Step-1: Containers with heavy masses are placed onto the container holders 310B, and 320A at respective bottom parking lots. Then the electric machine 100 rotates in the anti-clockwise direction. Both containers with heavy masses are lifted up through their vertical passages via supporting poles

312A1, 312A2, 312A3, 312A4 and poles 311B1, 311B2, 311B3, 311B4 respectively as shown in Fig. 1. In the meantime, empty container holders 310A and 320B are lowered down through vertical passage along their respective support poles 311A1, 311A2, 311A3, 311A4 and 312B1, 312B2, 312B3, 312B4.

[0034] Step-2: When both container holders 320A and 31OB with containers reach their respective tops of the vertical passages, electric machine 100 stops. Robot arms move the containers with heavy masses from their holders and put them to the track 501 and 502 respectively. Then the containers are moved by mini-locomotives on each track to their final destination at high parking platform. In the meantime the container holders 310A and 320B reaches bottoms of their respective passages and the containers with heavy masses are put onto them.

[0035] Step-3: Electric machine 100 starts rotating in the clock-wise direction. The containers with heavy masses sitting on container holders 310A and 320B are lifted up along their respective vertical passages and container holders 310B and 320A without containers are lowered down through their vertical passages.

[0036] Step-4: When the container holders 31OA and 320B with containers with heavy masses reach the tops of their respective passages, containers with heavy masses are moved by robot arms, then to tracks 501 and 502, then further moved to the final destination at the high parking platform by mini locomotives. In the meantime, containers with heavy masses are put onto the container holders 31OB and 320A at their respective low parking platforms.

[0037] Then iteration repeats from step 1 to step 4.

[0038] During generating mode, the following sequence is followed:

[0039] Step-1: Containers with heavy masses are put onto the container holders 310A and 320B. Then the electric machine 100 rotates in anti-clockwise direction. The containers with heavy masses sitting on the container holders 31OA and 320B are lowered down through their respective vertical passages while the container holders 320A and 310B without containers are lifted up through their respective vertical passages.

[0040] Step-2: When the container holders 31OA and 320B reach the bottom of their respective vertical passages, the containers are moved by robot arms and put onto the tracks linked with low parking platforms. Then they are moved by separate mini-locomotives to their respective final destination at the low platforms. In the meantime, the containers with heavy masses are put onto the container holders 31OB and 320A at the tops of their respective vertical passages linked with high platforms.

[0041] Step-3: The electric machine 100 rotates in clock-wise direction. The containers with heavy masses sitting on the container holders 310B and 320A are lowered down through their respective vertical passages while the container holders 31OA and 320B without containers are lifted up.

[0042] Step-4: When the container holders 31OB and 320A with the containers with heavy masses reach the bottom of their respective passages, the electric machine 100 stops. The containers with heavy masses are moved by robot arms and put onto tracks linked with low parking lots and further moved by separate mini-locomotives to their respective low parking lots. In the meantime, the containers with heavy masses are put onto the container holders 31OA and 320B.

[0043] Then iteration repeats from step 1 to step 4.

[0044] To reduce the friction losses further, it is necessary to use multiple support surfaces at the corners 201, 203, and 202, 204 as shown in Fig. 1. Such support surfaces can be conventional continuous curving surface. If that is the case, small distributed bearings can be installed on the two sides along the driving belts 301 and 302 for smooth movement along the corner supports.

[0045] One can also adopt magnetic-levitated surfaces. One design is shown in "Heavy Mass Energy Storage with Magnetic Levitated Wheels, Bearings and Locomotive", Journal of Multidisciplinary Engineering Science and Technology (JMEST), ISSN: 2458-9403, Vol. 6 Issue 7, July - 2019 written by

[he inventor.

[0046] In the system described above, all necessary mechanic reinforcements especially for the mover units are applicable. Such reinforcements could be stainless steel or other mechanically strong materials.

[0047] To lift containers between high and low platforms with long vertical distance, it is possible to divide total distance into multiple terrain-like or stair-case like structures as shown in Fig. 17. At each level is installed with one or multiple electric machine systems and transitional narrow platform where containers with heavy masses are transferred between neighbouring vertical lifting mechanisms, each of which is the same as one unit in Fig. 1.

[0048] Figure 18 shows vertical cross sectional view of bottom parking lot or platform, its roof cover and water drainage system. As water seeping from neighbouring soil is possible, it is necessary to have drainage system to drain water out of low parking platforms.

Claims (3)

The claims defining the invention are as follows:

1. An electric machine system used in a heavy mass energy storage system, which is formed by an elongated torus shaped stator, which contains interleaved or alternating double-U shaped magnetic and non-magnetic layers; stator magnetic plates; distributed stator air gaps sandwiched by magnetic plates; a mover system, consisting of driving windings for producing forward driving force; and uplifting windings for producing upward-pointing lifting force; and thin stainless steel sheet guide belts for ensuring smooth rotation of the mover along the torus stator; in the heavy mass energy storage system, there are two low parking platforms and multiple high parking platforms; there are multiple identical systems, each of which contains an elongated torus shaped electric machine, four vertical passages, four sets of container holders, each two located each side of the electric machine; distributed support surfaces either magnetic levitated or non-magnetic levitated are adopted to support belts at a turning point between vertical passage and electric machine; a roof-like cover is constructed for shielding each of two low platforms; drainage system is used to avoid sink of low platforms.

2. A method for lifting-up containers with heavy masses by electric machine working in motoring mode for the heavy mass energy storage system as claimed in claim 1, which consists of the following steps: in the first step, containers with heavy masses at left-side low platform are put onto a container holder for an outer lifting set, and the containers with heavy masses are put onto another container holder at right-side low platform for an inner lifting set. Subsequently the electric machine rotates in clock-wise direction and lifts up the container holders with containers to the top along their respective vertical passages while another two container holders without containers, one for the outer lifting set while the other for inner lifting set are lowered down through the vertical passage to their respective low platforms; in the second step, electric machine stops and containers with heavy masses are moved from container holders by robot arms and moved by separate mini-locomotives to final destinations at the top platforms for both outer and inner lifting sets while containers with heavy masses are put onto container holder for the inner lifting set at the left side low platform and containers with heavy masses are put onto the container holder for the outer lifting set at the right side low platform; in the third step, electric machine rotates in opposite direction or anti-clockwise direction and lifts up the containers with heavy masses sitting on their holders through the vertical passages for both outer and inner lifting sets while the holders without containers are lowered down along their respective vertical passages for both outer and inner lifting sets; in the fourth step, electric machine stops when the container holder with containers for the inner lifting set at the left side and the container holder with containers for the outer lifting set at the right side reach the tops of the passages; then containers with heavy masses are moved by robot arms and further moved by separate mini-locomotives to the final destination at the top platforms. In the meantime, the containers with heavy masses are put onto the container holder at the bottom of the left-side passage for the outer lifting set and the containers with heavy masses are also put onto the container holder at the bottom of the right-side passage for the inner lifting set; iteration from step one to step four repeats.

3. A method for lowering down containers with heavy masses by electric machine working in generating mode for the heavy mass energy storage system as claimed in claim 1, which consists of the steps as follows: in the first step, containers with heavy masses at left-side high platform are put onto a container holder sitting at the top of vertical passage linked with high platform for an outer lifting set, and the containers at right-side high platform are put onto a container holder sitting at the top of vertical passage linked with high platform for an inner lifting set. Subsequently the electric machine rotates in an anti-clockwise direction and lowers down the container holders with containers to the bottoms along their respective vertical passages while another two container holders without containers, one for the outer lifting set while the other for inner lifting set are lifted up through their vertical passages to their respective high platforms; in the second step, when the container holders with containers with heavy masses reach the bottoms of their respective vertical passages, the electric machine stops and containers with heavy masses are moved from container holders by robot arms and moved by separate mini-locomotives to the final destinations at the low platform for both outer and inner lifting sets, while containers with heavy masses are put onto container holder for the inner lifting set at the left side top platform and containers with heavy masses are put onto the container holder for the outer lifting set at the right side high platforms; in the third step, electric machine rotates in opposite direction or clock-wise direction and lowers down the containers with heavy masses sitting on their holders through the vertical passages for both outer and inner lifting sets while the holders without containers are lifted up along their respective vertical passages for both outer and inner lifting sets; in the fourth step, electric machine stops when the container holder with containers for the inner lifting set at the left side and the container holder with containers for the outer lifting set at the right side reach the bottom of the passages; containers with heavy masses are moved by robot arms and further moved by separate mini-locomotives to their final respective destinations at the low platforms. In the meantime, the containers with heavy masses are put onto the container holders at the top of the left-side passage for the outer lifting set and the containers with heavy masses are also put onto the container holder at the top of the right-side passage for the inner lifting set; iteration from step one to step four repeats.

201 501 502 203 401 301,302 16 Mar 2022

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Figure 1

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Guide belts Top view of the driving belt and guide belts

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Figure 10 mechanics mounted on mover Top view of the driving belt and guide belts

mounted on mover Front view of belt coupled with Side view of mechanics

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