CN109038936B

CN109038936B - Energy-storage attitude-control dual-purpose concentric reverse double flywheel electromechanical device

Info

Publication number: CN109038936B
Application number: CN201811155636.8A
Authority: CN
Inventors: 李平
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-09-29
Filing date: 2018-09-29
Publication date: 2023-10-17
Anticipated expiration: 2038-09-29
Also published as: CN109038936A

Abstract

The invention relates to an energy storage attitude control dual-purpose concentric reverse double flywheel electromechanical device. The flywheel rotor components with identical structure functions are concentrically placed along the mirror symmetry of the bottom surface and combined and sealed together to form the electromechanical integrated high-integration structure, so that the flywheel rotor has 4-weight high-safety protection for preventing the flywheel rotor from bursting and flying out, and the flywheel rotor has the characteristics of multifunction, low cost, small volume, compact structure, simple installation, no gyro-precession effect, no interference to the movement driving of the small-sized vehicle and the ship and multiple purposes, can provide short-time high-power energy storage and large reaction moment output, and is suitable for the fields of small-sized electric vehicles and ships, walking/mobile robots, aerospace and the like: the combination of the energy storage battery and the super capacitor can be used as a high-power source of a composite energy source, so that the power performance of a small-sized vehicle can be greatly improved, the driving range can be prolonged, the service life of the power battery can be prolonged, or the use amount of the power battery can be reduced; the method can be used for controlling the postures of the vehicle and the ship body, such as preventing the rolling of the 4-wheel vehicle, reducing the casualty rate of road traffic accidents, stabilizing and stabilizing the ship, realizing the self-balancing and standing of the front and rear 2-wheel vehicles, realizing the industrialization of brand new 2-wheel electric vehicles and the like.

Description

Energy-storage attitude-control dual-purpose concentric reverse double flywheel electromechanical device

Technical Field

The invention relates to an energy storage attitude control dual-purpose concentric reverse double flywheel electromechanical device, which relates to the fields of small electric vehicles, ships, walking/moving robots, aviation, spacecrafts and the like: the high-power energy source can be combined with an electrochemical energy storage power battery or a super capacitor to serve as a high-power source in a composite energy source, has multiple functions, and particularly can be used for controlling the gesture of a vehicle body, such as anti-rolling and rolling of a small 4-wheel vehicle, stabilizing and stabilizing of a small ship body, realizing self-balancing of front and rear 2-wheel vehicles, standing and falling, realizing high-moment quick response gesture control of a novel 2-wheel electric vehicle, aviation and spacecraft and the like.

Background

In the energy storage application field, a flywheel rotor is driven by an electric/power generation reversible motor as a motor to rotate at a high speed, and electric energy is stored in the form of inertial mechanical rotational kinetic energy, namely 'charging'; in contrast, the flywheel rotor rotating at a high speed drives the motor/generator to act as a generator to generate electricity, and converts the inertial mechanical rotational kinetic energy of the flywheel rotor into electric energy to supply the electric energy to an external load, namely 'discharging', and the device is called a Flywheel Energy Storage System (FESS), or simply called a flywheel battery. The research of such physical batteries working according to this principle has been long history, and a great deal of patent technology and literature has been published, which shows that continuous research and improvement have been pursued. The technology has been successfully applied to some fields, such as spacecraft energy, suppression and compensation of fluctuation peak values of a power grid, electric energy storage of wind power and solar power generation, fixed UPS (uninterruptible power supply), electromagnetic gun and track ejection, high-power lasers, high-power supplies of cranes and cranes, and the like.

Although the flywheel battery has high specific energy, high specific power and no pollution and CO ₂ The discharge, insensitivity to the environmental temperature, high energy conversion efficiency, high charge and discharge speed, long service life and the like, but there are few cases where it can be applied to small ground vehicles or surface vessels. For years, the technology has been tried in the F1 formula car, mainly used for recovering and utilizing braking energy, but has not been applied to the case of the like products which are produced in the largest quantity, namely commercial passenger cars/saloons. One example of the prior art is found in WO2007132241 (A1).

In terms of attitude control, attitude control techniques of Control Moment Gyroscopes (CMGs), momentum Wheels (MW) and reaction flywheels (RW) made by gyroscopic effects of flywheel rotors in high-speed rotation have achieved numerous achievements with rapid advances in microelectronics and computers, electromagnetic levitation and new materials of superconductivity and high strength, and have been successfully applied to certain fields, mainly spacecraft such as satellites, airships; recently, applications have also begun to be explored in the field of walking/mobile robots. But are still rarely used in other fields, particularly in small cars, which are currently one of the major vehicles for humans. Although some patent techniques have been disclosed, few examples of applications have been found in mass production. Reference examples applicable in the prior art are found in US3373832 (1968), and US2013233100, CN105365914 etc. for self balancing of front and rear two-wheelers.

The main reason for the failure of the flywheel battery and gyro attitude control technology to be widely applied is that: the cost of obtaining high specific energy for energy storage or attitude control according to the prior art is too high to make it difficult to use in consumer products requiring relatively low prices.

According to the physical equation of flywheel rotor energy storage: e=0.5 jω ² For a commonly used annular flywheel rotor: j=mr ² Therefore, there are:

E＝0.5mr ² ω ² (1)

wherein the mechanical rotational kinetic energy (J or Wh) of the E-flywheel rotor, the moment of inertia (kg.m) ² ) The mass (kg) of the m-flywheel rotor, the inertia radius (m) of the r-flywheel rotor, and the angular speed (rad/s) of the ω -flywheel rotor rotation. Here, the inertia radius r= [0.5 (R ₀ ² +R _i ² )] ^1/2 Wherein: r is R ₀ For the outer radius of the flywheel rotor, R _i Is the inner radius of the flywheel rotor.

It is therefore clear from the above principle that m, r are large and ω are high to obtain high stored energy, but E increases in proportion to the square of r, ω, so that increasing both will generally be more efficient than increasing m. The previous technical progress route is to develop along the track, so that the working rotation speed of the flywheel rotor is higher and higher to obtain high specific energy (wh/kg), and the highest rotation speed is reported to be more than 200,000 r/min. However, in order to enable the flywheel rotor to rotate at a high speed or an ultra-high speed, the flywheel rotor is limited by various factors.

As a rotary support of the flywheel rotor, the common mechanical bearing has too large loss due to the centrifugal force and friction force of high-speed rotation at an ultra-high rotation speed and can not be used, and usually only an active electromagnetic suspension bearing or a superconductive magnetic suspension bearing with complex structure and control and high price can be used.

The use of high rotational speeds for high energy storage or high attitude control torque results in corresponding operating environment requirements for the flywheel rotor assembly-high vacuum is required, otherwise the rotor rotation in air will create high wind resistance and wind losses. And wind resistance is proportional to the square of the movement speed of the flywheel rotor rim relative to the air, i.e. the linear speed, will increase exponentially, resulting in high driving power consumption.

The problems associated with this are also: the manufacturing of a fully sealed structure required to maintain a high vacuum for a long period of time will also significantly increase the long-term maintenance costs during the lifetime; in order to avoid the evaporation of the grease of the mechanical bearing in the vacuum chamber, an active electromagnetic suspension bearing with complex structure and high cost is usually used, and the whole motor/generator needs to be completely installed in the vacuum chamber, otherwise, a special transmission device, namely magnetic coupling transmission, a magnetic gear and the like are needed to transmit motion and energy, so that the cost is high, and the limitation of torque and power exists. Because of vacuum, the stator and windings of the motor can not radiate heat through air convection, and because of possible air leakage in long-term use of the high vacuum chamber, a vacuum pump and the like are added to maintain the vacuum degree in the chamber. In addition, the various leads of the motor, including the high-power leads, must also be introduced and extracted through the hermetic enclosure without leakage, which significantly increases the complexity of the device, not only with high manufacturing costs, but also with difficulty in maintenance, which is generally difficult to guarantee for civil vehicle or ship mounted devices.

Importantly, at ultra-high rotational speeds, the rotor is subjected to significant centrifugal forces due to its own rotating mass, and must be designed and manufactured using materials that have ultra-high strength and enable high mass specific energy, such as high strength carbon fibers or the like, that are wound with epoxy resin to form a composite. To reduce the cost, the current popular structure is a multi-layer ring with strength level gradually decreasing from outside to inside along the radial direction, and the rings are pressed and connected with each other by interference to form a sandwich-like sandwich structure. However, the price of the material is still expensive at present, often tens or hundreds times that of steel, so the material is usually used for aerospace and military industry, and is still difficult to use in mass-produced civil products. Only a small number of products in high-grade civil products are applied at present, such as thin shell type automobile bodies of high-grade automobile parts, bumpers and the like.

On the other hand, the rotor outer radius R _O The increase in (c) would mean an increase in the volume of the device, which would also be severely limited by the otherwise limited cabin, body space in a small car or walking/mobile robot.

When simultaneously increasing R _O And omega, allowable stress [ sigma ] of rotor material]Is strictly limited, its edge linear velocity (v=r _o ω) cannot be too high. Otherwise, once the flywheel rotor bursts, breaks and flies out or falls off, serious safety and even casualties can be caused. Although expensive rotors made entirely of high strength carbon fiber composites may fly out in the form of flocs when broken, carbon fibers are inherent in anisotropic materials-too low radial tensile strength and weak radial crimp strength between them can also result in peeling off of the whole ring, the risk of which remains not completely eliminated. Therefore, only the flywheel rotor rotating at the ultra-high speed can obtain high kinetic energy, but the danger caused by the damage is strong, so that the safety protection of the flywheel rotor is enhanced, and the flywheel battery and the gyro attitude control flywheel device are important matters in design, manufacture, application and popularization, and the like, and the high safety guarantee is provided for users.

In addition, the existing processing is usually manufactured by adopting a process of winding and curing a material mixed by high-strength carbon fiber and epoxy resin, so that the raw materials are expensive, the required thickness is required to be achieved by layering and curing for many times, the curing speed is very slow, the production period is too long, the production efficiency is very low, and the requirement of extremely large-scale continuous high-speed automatic production in the civil product field is difficult to meet, so that the manufacturing cost is very high. Therefore, the flywheel battery material and the processing cost are high, and the production efficiency is low, which is also an important reason for limiting the large-area popularization and application of the flywheel battery.

The high energy and high energy storage density and the high gyroscopic moment of the flywheel rotor in the prior art are usually obtained on the premise that the flywheel rotor can operate at an ultrahigh rotating speed, otherwise, the flywheel rotor is difficult to reach. The carbon fiber composite material has the characteristic of high mass ratio strength, so that the carbon fiber composite material can exert the advantages of the carbon fiber composite material when the carbon fiber composite material is used for a flywheel rotor.

However, for lower speeds below 20,000r/min, the combined advantages are more pronounced with the use of high strength steel rotors than with the use of carbon fiber composite rotors, as seen by the development and practice of flywheel batteries in hybrid and electric racing vehicles. According to the performance parameters of vehicle-mounted flywheel battery products of the company of Flybridsystems and the like, the working rotation speed is mostly distributed below 60,000 r/min. However, since the mass specific energy of the product is mostly only 5-6wh/kg and mostly less than 10-12wh/kg, the energy storage application is too low compared with the power battery, and therefore, the energy storage application is mainly used as the power battery for a kinetic energy recovery system (KRS) and providing starting and accelerating power. In this regard, well-known vehicle enterprises such as Wolwa, baojie, audi and the like have been studied intensively in the past, and some products have been used for the formula F1 car since 2009. Unfortunately, there has been no report to date that can be applied to commercial automobiles on the market.

The us flywheel systems company (AFS) was earlier in 1992 pushing out a conceptual prototype car AFS20, which was a fully flywheel battery powered electric vehicle, driven by 20 flywheel batteries, but since then no information has been released to date that has been applied in the market.

Because the flywheel energy storage system limits the rotation speed of the flywheel rotor, the energy carried by the flywheel energy storage system is very small under the limit of certain cost, and the mass specific energy is only 1/40-1/50 of the lithium ion power battery widely used by the electric automobile at present, so that the flywheel battery cannot be used as a main energy storage power supply.

In view of motor/generator research used in vehicle flywheel rotors, the charge and discharge of a flywheel energy storage system and the transmission and exchange of energy with an automobile are finished by relying on a motor, so that research on a high-performance motor is also another key of vehicle flywheel technology.

The gyroscopic effect of the flywheel rotor is successfully applied to a 2-wheel motorcycle to realize balanced and upright concept vehicle examples which are not easy to crash, such as a 2-wheel electric vehicle with Lit motors (2011) in the United states, a 2-wheel electric motor with intelligent cloud in China (2014), a German BMW electric motor (2017) and the like, but no report on mass production and marketing is available at present.

The flywheel rotor has problems in its gyroscopic effect for attitude control of the hull of a small vehicle, similar to the flywheel battery application described above: the high cost and safety problems and the need for miniaturization are also major difficulties to be thoroughly solved.

The electric vehicle has the strong advantages of green environmental protection and energy conservation, and gradually replaces the fuel oil vehicle to become one of the main vehicles of the 21 st century human beings, because the electric vehicle can be used as a small-sized convenient vehicle for individuals and families. However, whether it be an internal combustion locomotive or an electric vehicle, there is a significant conflict in that it is difficult to obtain both excellent power performance and ultra-long range at the same time: the power required for starting and accelerating is far greater than the power required for constant speed running, usually several times or more than ten times that of constant speed running, which results in that the power of an engine or a driving motor of a common car is usually up to several tens to hundreds kilowatts (kW), and luxury cars or sports cars are even up to hundreds of kilowatts or even nearly Megawatts (MW).

For electric vehicles with limited energy sources, the solution of the contradiction is more difficult: in order to obtain excellent power performance and long one-time charging range, a high-power driving motor and a high-capacity battery capable of being charged and discharged with high current are required to be used correspondingly, so that the volume of the battery and the weight of the whole vehicle are greatly increased, and the high cost and the high energy consumption are caused to be uneconomical. Currently, high-performance electrochemical energy storage batteries (such as ternary lithium batteries) are commonly used as energy sources for electric vehicles, and the purchase cost of the batteries of the high-performance electrochemical energy storage batteries is a major part of the manufacturing cost of the whole electric vehicle, and is generally close to 1/3-1/2 or higher, so that the manufacturing cost of the pure electric vehicle is far higher than that of a fuel vehicle with the same size level. However, compared with the fuel oil vehicle, the power performance of the fuel oil vehicle is quite different except that the one-time charging driving range is too short and the charging time is too long, and the fuel oil vehicle becomes a great obstacle for application, popularization and popularization in the future.

In terms of range, the limited energy capacity of the vehicle battery is a major factor in determining the range length of one charge of the electric vehicle. To ensure that as long a range as possible is achieved with limited battery capacity, a more powerful motor and its drive control system cannot be used, otherwise the limited energy of the battery will be quickly exhausted. Therefore, the vehicle is limited to obtain better power performance, especially highest speed, acceleration, climbing and load carrying performance, which is the most difficult contradiction of the current new energy vehicles.

In view of the increasing environmental pollution and the increasing imminence of exhaustion of petroleum resources, the yield of electric vehicles is rapidly increasing worldwide. However, the specific energy (wh/kg) which is a key parameter of the lithium battery as a main energy source of the current electric automobile is still very slow along with the improvement of the development and improvement process: according to statistics, in the 7 years 2011-2018, the lithium ion battery which is the only energy source currently available for the pure electric automobile has the specific energy of about 245wh/kg, but the annual average growth rate is still very low and is only 4.3%, which certainly becomes the main bottleneck of the electric automobile industry for rapidly growing in future development.

In order to obtain ultra-long driving range and excellent power performance at the same time, if the prior art is based, the vehicle must be as a luxury electric car: only a larger capacity battery can be used together with a more powerful drive motor along with its control system. For example, in order to obtain the highest speed of more than 250km/h, the primary charging driving mileage of 500-1000km and the ideal power performance of 3-5s of hundred km acceleration time, the maximum power of the motor and the driving control system is 400-600kW, and the lithium battery capacity is 100-200kWh; this will further lead to a significant increase in overall vehicle cost and weight, making the vehicle expensive, and also greatly limiting the rapid popularization and promotion of commercial applications of electric vehicles.

The light ground small-sized vehicles belong to the civil field, but the one-time charging driving range of most popular electric vehicles sold in the market at present is only about 150-200 km, and the charging range is too short compared with the fuel oil vehicles, and the charging time is too long even if the electric vehicles can be charged rapidly, so that the electric vehicles become the biggest doubt when consumers select to make decisions in purchasing vehicles. The primary factor considered by most electric automobile buyers is the length of one-time charging driving mileage, and under the current condition that the construction speed and the distribution density of the charging piles are not matched, for example, the electric anchoring is not carried out in the middle of a vehicle, the vehicle owner can be trapped into the biggest embarrassment.

The second is that electric vehicles are expected to have excellent power performance as fuel vehicles, especially the required maximum speed and shorter hundred kilometer acceleration time, so that high trip efficiency can be achieved. Of course, driving safety and comfort, good value or low price are also important factors for making purchasing and using decisions.

The performance of the existing power battery, namely the lithium ion battery mainly based on the electrochemical energy storage principle at present, is still not good enough to solve the contradiction, and is still not an ideal power source of the electric automobile in the future. The main defects of the vehicle-mounted power lithium battery at present are as follows: the specific power is too low, the charging and discharging can not be carried out with large current, the times of charging and discharging are limited, the cycle service life is short (only 500-2000 times), and the environment is still not completely friendly; the electric energy is not easy to control in the use process: the voltage of the single battery is low (only 3.2/3.7V), namely, high-power high-voltage power supply is often required to be connected in series by hundreds of sections or more, and the Battery Management System (BMS) is complex and has low reliability due to the fact that the battery management system must be charged and discharged in an equalizing manner; in addition, the electrolyte is currently non-aqueous, and there is still a risk of ignition and combustion. In addition, the cost is still high, the manufacturing cost is high, and the specific energy is still small, so that the development and growth speed of the electric vehicle industry is limited. The driving motor of the electric automobile generates large starting current at the moment of starting due to zero rotating speed and no counter electromotive force balance, and if the driving motor is not limited, the power battery of the electric automobile is greatly damaged. The maximum discharge current determined according to the capacity of the vehicle-mounted battery is limited as starting current, so that the maximum discharge current is in great contradiction with the guarantee of the power performance such as the acceleration performance of the whole vehicle, otherwise, the capacity of the vehicle-mounted battery can only be increased, but a series of problems such as overweight of the whole vehicle and over-high manufacturing cost can occur.

Commercial electric cars are often used in large numbers for driving under urban cycle conditions (e.g., NEDC conditions) that require frequent start, acceleration and deceleration or parking, and the difference between the value of the primary charging range and the constant speed driving condition is often reduced by about 15% -30%. In order to reduce the selling price of the whole vehicle and enlarge sales volume, manufacturers often use small-capacity batteries and correspondingly select a driving motor with smaller power to reduce cost, so that the power performance of the motor is quite different from that of a similar fuel automobile with an engine with larger displacement or power. In addition, the energy consumed by braking accounts for about 50% of the total driving energy in the running process of the automobile, and if the braking energy is effectively recovered, the running distance of the electric automobile can be prolonged by more than 10% -30%.

The power required for constant speed running of existing small vehicles, in particular cars, whether fuel or electric vehicles, at economical vehicle speeds (e.g. 50/60 km/h) is very small compared to the maximum power required for starting acceleration or climbing. From the power load diagram of the car, it can be seen that: the power requirement of a car in steady operation is typically only 1/4 or less of the peak power. If a short-time power energy storage system capable of outputting high power is introduced into an electric automobile to work in parallel with an electrochemical energy storage system, the contradiction can be perfectly solved.

In general, electric vehicles such as electric vehicles are required to have a balance between cost, driving range and power performance. However, it is often difficult to choose between the capacity of the vehicle battery and the maximum driving power, and the root cause is that: current electrochemical energy storage cells cannot be charged or discharged with high power (i.e., high current), which would otherwise lead to early battery failure or a significant reduction in their useful life. The limitation of the limited capacity of the vehicle-mounted battery to the maximum allowable discharge current directly constrains the power of the maximum driving motor and the driving control system of the whole vehicle which are allowed to be used, and further determines the upper limit of the improvement of the power performance of the whole vehicle.

The flywheel battery can output or store short-time high-power energy with small volume, and the specific power of the flywheel battery can be as high as 1-5kW/kg or even higher, which is about 5-25 times that of the current power lithium battery. For example, the combination of a power battery and a lithium battery as a power auxiliary battery is certainly an ideal solution for the design of new energy automobiles and other electric vehicles and ships in the future, and some research papers have been published in this respect.

The flywheel energy storage is particularly suitable for pure electric or hybrid power vehicle systems, and the high-power charging and discharging capacity of the flywheel energy storage is far better than that of an electrochemical energy storage power battery, so that the requirements of high peak power during vehicle starting, acceleration, climbing and heavy load can be effectively met. During acceleration in typical urban driving cycle conditions, the flywheel battery may provide the vehicle with the required brief amount of high power; during deceleration coasting or braking, the short-time high-power energy generated by the motion inertia of the vehicle body can be absorbed by the flywheel battery system rapidly, and is rarely limited by the maximum allowable charge and discharge current due to limited capacity like a power battery. The flywheel power battery is also obviously superior to the super capacitor used on the short-distance large-scale bus at present in terms of volume and cost.

The international automobile association (FIA) is a world automobile movement administration and a world advanced automobile movement organization, and it has been clearly shown in 10 months 2009 that flywheel batteries will be strongly supported in the future. To achieve high power performance, the pure electric vehicle needs to combine a high-power motor with a high-power energy short-time release and conversion technology of a flywheel battery. The new energy such as lithium ion power battery has higher specific energy, namely the current single battery reaches 200-300wh/kg, but is limited by the fact that the battery cannot be charged and discharged with large current, and the battery has the advantages of being mainly used for guaranteeing the long driving range required by the uniform driving working condition in future. The situation that the existing electric automobile is powered by an electrochemical energy storage power battery is changed, the combined power supply of the two is selected to be a composite new energy, the advantages are complementary, the best balance between the whole automobile performance and the cost can be obtained, and therefore the electric automobile can be one of the optimal overall design schemes at present, and the electric automobile is also a development trend and direction of industry in a certain period in the future.

Along with the continuous increase of the quantity of the global automobiles, the quantity of traffic accidents is rapidly increased, and traffic accident casualties and vehicle body damage become a large social problem in the global scope. According to the statistics of world health organization, about 120 tens of thousands of people die each year from traffic accidents and car accidents. The automobile side-turning is a serious traffic accident which can happen rapidly and has fatal danger, the degree of the hazard is second to that of collision, the automobile side-turning is the second place, the life and property safety of human beings is extremely threatened, and serious disasters are brought. According to the statistics of traffic accidents in some countries, the proportion of rollover accidents in traffic accidents is not high, but the mortality rate is up to 30%. When a vehicle turns over, a driver often cannot take effective measures, and the damage of the turning over accident is fatal, so that the turning over of the vehicle has become a worldwide attention to safety problem.

The safety of luxury sedan and sedan sports car is high, and the car is not easy to turn over, mainly because the car body is relatively heavy or the gravity center is low, in particular the structure is firm-the strength and the rigidity are high: the chassis and the vehicle body are manufactured by high-strength steel materials with high proportion, so that the probability of turning over and damaging the chassis and the vehicle body when collision occurs is small. However, the energy consumption is necessarily very high when the vehicle body is overweight and runs at a high speed, and an engine or a driving motor with very high power is required to be used for ensuring high power performance, so that high oil consumption, high emission or high electricity consumption is caused, and a sharp contradiction is clearly formed between the high oil consumption, the high emission or the high electricity consumption and the energy-saving and environment-friendly time requirements. And a large number of ordinary cars without luxury car features are main bodies of road traffic, so how to ensure the driving safety and prevent rollover and rolling is obviously one of the most important innovative research subjects.

The factors causing the rollover of the automobile are many, particularly sideslip and curve jerk, and the main types are Trip-over (Trip-over), flip-over (Flip-over), fall-over (Fall-over) and the like. According to the statistics of the related aspects, about 95% of rollover accidents are "tripping rollover", and only 5% are rapid turning rollover on roads. However, the proportion of the rolling accidents gradually increases along with the gradual reduction of the proportion of the front collision and the side collision accidents, and the characteristic of large accidents is often presented. In view of importance and hazard, various large vehicle enterprises in the world usually pay great attention to research on vehicle rollover early warning, namely, vehicle body postures and operating parameters such as a camber angle, an angular velocity, a lateral acceleration, a steering angle and the like are monitored in real time based on a dynamic model of vehicle operation, and the transverse Load Transfer Rate (LTR) or the lateral acceleration and the like are calculated according to an early warning and control algorithm to predict. When the roll is predicted to be about to reach the limit working condition, alarm information is sent in advance so as to remind a driver to pay attention and prepare in advance, and corresponding measures are taken to avoid accidents.

Although the alarm can be sent out before the occurrence of the potential traffic accident to improve the active safety of the automobile for preventing the rollover, the active safety of the automobile in the real sense cannot be calculated if a direct effective means for resisting the rollover is not available. If the technology is used for controlling the attitude of the spacecraft, effective resisting moment opposite to the rollover direction can be directly generated to prevent the rollover, particularly when the gravity center of the vehicle body does not cross the plumb line of the grounding point of the tire in the rollover or exceeds the angle but is not large, the occurrence of serious traffic accidents of rollover and rollover can be prevented, and the method has great significance in guaranteeing the personal and property safety of passengers and reducing the damage of the vehicle body obviously.

Reaction flywheels (RWs) have found widespread successful use in the field of satellites, spacecraft, etc. as key components for attitude adjustment. A reaction flywheel is arranged in the object, and the counter moment obtained by driving the reaction flywheel can effectively control the motion gesture of the object. When the object with larger mass is changed in a rapid large-angle posture, the object generally needs a large counter moment to prevent the object, and based on the principle, a physical foundation for realizing active safety of the automobile for preventing rollover can be formed. The development trend of new energy electric vehicles is to use new materials to realize light weight so as to be more environment-friendly and energy-saving, but obviously, the improvement of anti-rollover capability in collision is more difficult to solve. Therefore, the anti-rollover realization of active safety is also important for the realization of light-weight development of the new energy electric automobile.

Along with the continuous development of world economy, the continuous improvement of human living standard and the increasing acceleration of urban process, more and more road vehicles, traffic jam and difficult parking/storage become worldwide difficult problems.

Two-wheeled vehicles, particularly bicycles, are the most efficient vehicles invented by humans. Compared with 4-wheel vehicles, the motorcycle has the important advantages of small occupied area, small volume, small running resistance, low power consumption and low manufacturing cost like a bicycle. However, the biggest disadvantage of such front and rear two-wheeled vehicles (also called monorail vehicles) or electric vehicles thereof is that the vehicles do not have closed carriages, and cannot keep out wind and rain or keep out sun and keep out cold. The root cause is as follows: the vehicle has no self-balancing function before running at low speed or stopping, can not keep upright, and also has to rely on a driver to separate the legs, contact with the ground with feet or put down the support for supporting so as to ensure that the vehicle body does not overturn.

The largest number of personal and family vehicles, namely 4-wheel sedans, are used in all countries of the world, and the most time use state is that only 1-2 passengers or only drivers own, which is certainly a great waste. In case that a considerable part of the existing 4-wheel automobiles can be transformed into two-wheel electric automobiles with self-balancing functions, the trouble of road traffic jam and difficult parking can be relieved clearly, and the automobile is more environment-friendly and energy-saving.

In recent years, a novel self-balancing two-wheeled electric vehicle derived from the birth of an electric motorcycle clearly shows a strong vitality peculiar to a new colleague. The vehicle body has the advantages of small volume, small occupied area, low cost and low energy consumption, has the important safety advantage that the vehicle body can not turn over when being collided, and plays an important role in solving the modern urban traffic problems such as energy conservation, environmental protection, road traffic safety, traffic jams, parking/parking difficulties and the like. If the attitude control technology based on flywheel gyroscopic effect is used for small electric vehicles, ships and the like, the high safety, the low cost and the mass production can be realized rapidly, and the method has important commercial value and social benefit. Unfortunately, although the earliest emerging prototype cars have been 7 years ago, mass production and market entry have not been realized, essentially in the concept car stage.

The physical essence of flywheel energy storage and flywheel attitude control are based on the principle that a high-speed flywheel rotor has high rotational kinetic energy. In order to obtain high mechanical kinetic energy, it is more effective to increase the rotation radius r and the rotation angular velocity ω in addition to the rotation mass m of the flywheel rotor. However, as mentioned above, in practical applications, these parameters are limited in many ways, and in particular, the rotational angular velocity ω of the flywheel rotor is limited by the material strength, and in-vehicle applications also have many limiting requirements for the weight and volume space of the flywheel device, the allowable installation location, and the like.

Many factors can lead to failure of catastrophic results when the flywheel rotor is operating at very high rotational speeds. For example, cracks and propagation due to manufacturing and material defects, bearing failure or external impacts, etc. during flywheel manufacturing. Once the rotor bursts, the huge kinetic energy of the high energy fragments flying out under the centrifugal force will pose a significant safety threat to surrounding equipment and personnel. Therefore, the maximum barriers of flywheel rotor technology application popularization, such as difficult manufacture, high manufacturing cost and large potential safety hazard in the prior art, must be thoroughly overcome from the aspects of safe and reliable use and good economy.

Thus, in the application fields of small vehicles and ships, the greatest challenges of technologies and applications faced by developers of flywheel energy storage and attitude control systems are still safe in practice. Internationally, the steam alliance (FIA) and its fleets are also the primary task of safety as a Kinetic Energy Recovery System (KERS), although this problem has not been addressed significantly directly in the relevant research papers. Particularly, the problem of suppressing the burst of the high-speed flywheel rotor must be avoided to the greatest extent by the greatest effort, or fragments thereof can be effectively prevented from flying out even if the burst occurs, so as to ensure the personal safety of personnel around the flywheel rotor and avoid the damage of peripheral equipment.

The flywheel safety problem must first be solved and tested in a design and test stage to ensure that the flywheel system produced later has sufficient safety to be used by the user without fail, and it is often necessary to design a complete protection measure that almost completely prevents the flywheel rotor from flying out after bursting. In terms of fracture mechanics, it is desirable to not only prevent ductile fracture but also brittle fracture, and to try to reduce the incidence of other various associated failures that lead to bursting.

The specificity of application of flywheel rotors in the field of small vehicles and ships is also that: the running environment of the automobile is very bad, and vibration on different road surfaces, starting, accelerating, decelerating and steering of the automobile, road conditions and the like can all influence the running of the vehicle-mounted flywheel rotor. The gyroscopic effect of the high-speed energy storage flywheel battery is that the flywheel rotor generates additional gyroscopic precession moment on constraint due to the change of the flywheel shaft direction when the automobile runs, and the additional gyroscopic precession moment also causes excessive additional pressure on mechanical parts such as bearings, so that the parts are possibly damaged or the service life is reduced. Moreover, gyroscopic effects may also be a possible source of new vibration noise for the system. Therefore, it must be fully considered in design. The gyroscopic effect of the flywheel rotor is the basic physical principle that can be utilized for attitude control, and any adverse effect on the motion control and stability of vehicles and ships must be prevented so as to avoid traffic accidents. These are the main problems to be solved by the present invention.

Disclosure of Invention

Aiming at the defects of the prior art, the invention provides the energy storage attitude control dual-purpose concentric reverse double flywheel electromechanical device which has the advantages of high safety, multiple functions, low cost, small volume, compact structure, simple installation, no interference to the movement and operation of the body of the small-sized vehicle and ship and multiple purposes, and can provide high-power energy storage, rapid charge and discharge and large reaction moment output.

The invention solves the problems in the prior art by adopting the technical scheme that: the concentric reverse double flywheel electromechanical device with the electromechanical integrated structure is formed by adopting a pair of flywheel rotor assemblies with identical or nearly identical structures, shapes, sizes, materials, manufacturing processes and functions, arranging the flywheel rotor assemblies concentrically along the mirror symmetry and the axis of the bottom surface of the flywheel rotor assemblies, and connecting, combining, fastening and sealing the two bottom plates. In addition, the anti-burst and anti-flying-out structure of the flywheel rotor component adopts a 4-weight safety protection structure, and particularly, the anti-burst and anti-flying-out structure also has an effective new measure of preventing the flying-out of fragments, namely energy absorption and speed reduction. And measures.

Further, both flywheel rotor assemblies are mounted in respective assembly housings, both flywheel rotor assemblies having a complete function as either a stand-alone stored energy (FESS) or a reaction flywheel (RW). The two flywheel rotor components are mutually connected by a flange at the lower edge of a shell bottom plate with a radial symmetrical structure, then the two components are kept accurately concentric by positioning annular or partial annular keys or pins, and the two components are connected and fixed into an electromechanical device which has the functions of an integral seal, mirror symmetry, concentricity, compact structure, easy installation, high-power energy storage, physical battery and high-torque attitude control function executor by using fasteners such as screws, rubber seals or sealing silicone rubber and the like.

Further, the working principle of the electromechanical device is as follows: the energy storage or attitude control functions can be respectively executed by being matched with an external motor/generator driving control system to work in a time-sharing way. When used as a flywheel energy storage battery, the motor/generator and an external driving controller thereof absorb external short-time high-power energy and rapidly increase the angular speed of a flywheel rotor; or vice versa: a short-time high-power energy output conversion, i.e. a fast discharge of the high-speed flywheel rotor, to an external load is produced by an external DC-DC reversible converter. When used as a reaction flywheel (RW) for attitude control, the output of the short-time high-value reaction torque is generated by the principle that the motor/generator and its drive controller rapidly change the angular acceleration/deceleration of the flywheel rotor, i.e., acceleration or braking. The two flywheel rotors are driven by motor/generator subassemblies with the same structure and parameters respectively, and based on the mirror symmetry relationship of the connecting planes of the bottom plates of the two flywheel rotor assemblies, when the flywheel rotors rotate at the same rotating speed (namely, the same absolute value angular speed), the rotation directions of the flywheel rotors are completely opposite from the whole device, namely, opposite rotation is formed, so that the angular momentum of the device and the precession moment generated by the gyroscopic effect are completely counteracted.

Further, both flywheel rotor assemblies include identical or nearly identical numbers and configurations of parts, including flywheel rotor and motor/generator subassemblies, flywheel rotor, housing and end caps, center post, guard and energy absorption rings, and sensors, fasteners, positioners, seals, etc. The flywheel rotor subassembly is press fit onto the rotor shaft and rotatably mounted within the housing of the assembly via the main bearing support along with the motor rotor of the motor/generator subassembly. In the case of an outer rotor motor, the rotor of the motor/generator subassembly is integral with the flywheel rotor subassembly. The motor/generator subassembly is integrally mounted within and concentric with the cavity in the lower central portion of the flywheel rotor subassembly, resulting in a compact overall assembly having a minimum axial length. The stator component of the motor is also concentric with the flywheel rotor and the motor rotor. In the case of an inner rotor motor, the stator and rotor of the motor/generator subassembly are all mounted within a larger diameter central column member, and the motor rotor is mounted on the central shaft and directly connected to the flywheel rotor subassembly.

Further, the flywheel rotor subassembly comprises a flywheel rotor component, a bearing cover component, a rotor upper end cover, a rotor lower end cover, a magnetic steel baffle, various fasteners, a protection reinforcing layer and the like.

Further, the motor/generator is a high-speed three-phase permanent magnet brushless motor, a synchronous motor, or a reluctance motor. For a three-phase permanent magnet brushless motor or a synchronous motor, the electromagnetic topology of the motor is a concentrated winding structure with fewer poles and fractional slots. The number of tooth grooves is z=3i, i=2, 3, … 6, and the number of poles is 2p=2j, j=1, 2, …; the combination of slot pole numbers is preferably Z/2p=3/2, 6/4, 6/8, 9/6, 9/8, 9/10, 12/4, 12/8, 12/10, 18/4; the winding is of a single winding structure per tooth, and the minimum winding coil circumference, the shortest end length and the low internal resistance can be obtained. The motor comprises a rotor, a stator, a winding part of the stator, a position sensor, a lead wire, a wiring terminal and the like; the stator core and winding parts of the motor are pressed and fixed on the central column part in the center of the bottom plate of the shell by inner holes or outer circles and key positioning. When the motor is of an outer rotor type, the stator winding part is pressed on the outer circle thereof; when the motor is of an inner rotor type, the stator winding part is press-fitted in the inner hole thereof. The magnetic pole number 2 P=2 has the advantages that an integral magnetizing rotor is used, dynamic balance is facilitated, the alternating frequency of a magnetic field and current is the lowest, and the high-frequency eddy current has small iron loss; the advantage of the pole count 2p=4 is that the winding end is short, the span is small, and the copper loss is small, but the alternating frequency of the magnetic field and the current of the pole count 2p=4 is 1 time higher than that of the magnetic field and the current of the pole count 2p=2, so the high-frequency iron loss is larger.

Further, the center post member includes a center post, a center shaft, a main bearing, a wave spring washer, a lock nut, etc., and is positioned and fixed in the center of the housing floor with fasteners as a positioning and mounting basis for the flywheel rotor and motor/generator subassembly. The center post is hollow and rotatably supports the flywheel rotor subassembly by a center shaft and a main bearing.

Further, the shield and energy absorbing ring member includes an outer ring, an energy absorbing stub pin or screw, an energy absorbing layer, and an inner ring. Once the flywheel rotor bursts and fragments fly out, the inner ring is broken firstly and collides with the energy absorption short shaft pin or the screw; this collision process is a transient process of conservation of energy and exchange of momentum: the most of the kinetic energy is converted into bending deformation energy of the short shaft pin or the protruding part of the screw to be absorbed, and the small part of the kinetic energy is dissipated in the form of sound energy, heat energy and other energy. The process begins with the crushed mass coming into contact with the short pin or screw being impacted and the deformation will be from small to maximum, and then the two bodies spring back apart, each continuing to move until eventually stopped.

Further, the housing part comprises a housing, an end cover, a bearing cover part, an electric connector of a motor outgoing line, a connecting fastener, a sealing piece, or an air pumping/charging nozzle, an air valve, a water cooling pipeline and the like. The bearing cap component is provided with a protective bearing, a spring retainer, or a 1/2 permanent magnet bearing.

Further, the sensor includes: flywheel rotation speed sensor, motor rotor position sensor, electromechanical device inclination angle or multiaxial micromechanical acceleration/gyroscopic sensor, acoustic sensor or acoustic emission sensor for detecting overall operation vibration noise, vibration sensor, eddy current/proximity sensor for detecting flywheel rotor displacement, temperature sensor for detecting bearing and motor stator temperature, etc., each being placed at proper position of component. Leads of each sensor are led out through the lower part of the bottom plate and connected with an external control circuit through an electric connector. The device has abnormal safety control, mainly triggered by the signals of an acoustic sensor or acoustic emission and vibration/displacement sensor arranged on the shell, and once the sensor detects abnormal sound or vibration, especially high decibel impact sound, in the interior, the flywheel rotor is rapidly decelerated by an external central control unit, the power supply is cut off, and the power supply to the motor/generator is stopped. Some vehicles are equipped with rollover protection systems (RMI), electronic rollover protection systems (ERM), electronic braking force distribution systems (EBD), vehicle dynamic control systems (VDC), etc., for ensuring vehicle stability in extreme situations, and for ensuring driver and passenger safety. In these systems, if the sensor signal used is the same as or available to the device, the same sensor may not be located on the device and the signal may be taken from the system for control or alarm.

Further, the double flywheel electromechanical device is mainly used as a high power source in a vehicle-mounted and ship-mounted composite energy source and also used as a gesture control device, and the power of the device is as follows: p=mr ² Omega epsilon, in order to obtain high power, only the flywheel rotor mass m and angular acceleration epsilon (rad/s) can be increased, while R, omega are defined, epsilon being determined by the output torque of the flywheel rotor motor/generator, so that the mass m value can only be increased with limited rotor size, i.e. m=ρpi (R) _o ² -R _i ² ) l. Where ρ is the material density, l is the flywheel rotor axial length (cm), and the remaining parameters are as defined above.

Further, the flywheel rotor body of the flywheel rotor component is a circular ring, the internal-external diameter ratio is more than or equal to 0.6, the flywheel rotor body is made of high-strength and high-toughness isotropic materials such as alloy steel or stainless steel, and the contribution rate of the moment of inertia of the flywheel rotor component compared with that of a solid disc can reach 87% under the condition that the materials are homogeneous. Depending on the choice of materials, the flywheel rotor body material has a yield strength of preferably σ _s The design stress safety coefficient of the flywheel rotor is more than or equal to 800-1100MPa and is more than or equal to 2; the hollow of the central portion of the ring is for receiving the motor/generator subassembly.

Further, in order to effectively improve the value m under the condition that the volume size of the flywheel rotor, particularly the rotation radius Ro thereof, is limited, and simultaneously, the use stress safety of the flywheel rotor can be ensured, a proper number of holes or concentric grooves are uniformly distributed along the circumference on the position of the inertia radius r of the flywheel main body, and round bars made of high-specific-gravity alloy are pressed into the holes in an interference fit manner; when concentric groove structures are used, an interference fit can be used to press a ring made of high specific gravity alloy into the groove. When the size of the ring is larger, the ring can be split and pressed in. The material of the round rod or the round ring of the high specific gravity alloy pressed by the flywheel rotor component is tungsten or tungsten alloy; the main body can also be of a groove-free structure, and each inner ring is sequentially pressed into each outer ring in sequence by interference fit to form a 3-ring sandwich structure. For low cost applications, lead filling may also be used in the grooves; but for unmanned vehicles, ships or application occasions with good radiation protection, the round rod or the round ring material can also use depleted uranium.

Further, the flywheel main body of the flywheel rotor component can also be made by stamping high-strength and high-toughness cold-rolled alloy steel/stainless steel thin plates, and is integrated by stacking, buckling, riveting and pressing, and round holes which are uniformly punched on the circumference of the flywheel main body penetrate rivets or screws through the upper end cover and the lower end cover of the flywheel rotor subassembly, and are riveted or fastened into a whole. The thickness of the thin plate can be 0.8-1.2mm, and the plate is overlapped and buckled into a round shape without material fracture and larger stress concentration. Due to the flaking of the flywheel rotor, the flying objects in case of bursting are mostly thin fragments, the momentum, energy and hazard of the fragments are much smaller, and the flywheel rotor is easy to absorb and dissipate energy.

Further, the flywheel main body part of the flywheel rotor part is clamped by the upper end cover and the lower end cover in the axial direction; the two sides of the cylindrical surface of the circular ring main body of the flywheel rotor component are connected and fixed with the two end covers by rivets or fasteners. After the flywheel rotor main body is firmly connected with the upper end cover and the lower end cover, the whole shape of the flywheel rotor main body forms a hollow structure of a bell jar (U) shape, and the functions of the spoke and the hub of the flywheel rotor main body are outwards changed without the spoke and the hollow structure: the upper end cap will have the functions of a hub and spoke. The flywheel rotor has only a large hole in the center of the lower end cap, and a hollow portion is provided for receiving the motor/generator subassembly, thereby enabling a compact, flattened configuration and a significant reduction in the axial length of the subassembly. The inner part of the upper end cover close to the center is concentrically connected and fixed with the rotor bracket through a fastener; when the motor is an outer rotor, a motor rotor component with magnetic steel is pressed or cast into the rotor bracket; a small hole in the center of the upper end cover is pressed into the main bearing at the center shaft, is rotatably fixed on the center post, is pressed with the step part of the center shaft, and is pressed and fastened by the lock nut and the spring washer; the connection of the rim of the flywheel rotor subassembly and the wheel hub, the wheel hub and the flywheel shaft is press fit of a keyless structure, so that good dynamic balance is ensured when the flywheel rotor rotates.

Further, the upper and lower end caps of the flywheel rotor member are made of a high strength, high fracture toughness aluminum alloy, preferably having a yield strength sigma _s More than or equal to 450-500MPa. Concentric circular flanges are formed in the centers of the outer surfaces of the upper end cover and the lower end cover; the outer edge diameters of the two end covers are the same and are 5-10mm larger than the outer diameter of the flywheel rotor main body. The edge part of the end cover can also be made of alloy steel, and then is connected and fixed with the central part of the aluminum alloy end cover by a fastener to form a whole. The corners of the outer edges of the upper end cover and the lower end cover are all made into circular arcs, and the radius r of the circular arc is more than or equal to 5mm. And after the flywheel rotor part is assembled with the end covers, the flywheel rotor part is wound with filament carbon fiber epoxy resin composite material in the circumferential direction in a shallow annular groove gap formed by the upper end cover, the lower end cover and the outer cylindrical surface of the flywheel main body by applying pretension until the annular groove gap is just filled or slightly higher than the annular groove gap by 0.3-0.5mm, and is solidified and reinforced, so that the flywheel rotor part is used as a first circumferential protection layer for preventing the rotor from bursting.

And then, on the outer surface of the cylindrical whole formed by the upper end cover and the lower end cover together, winding the flywheel rotor component by using a long-filament carbon fiber epoxy resin composite material along the arc of the edge corner of the end cover along the outward direction of the chord and pretensioning along the flange in the middle of the outer surface of the upper end cover and the lower end cover, continuously winding the flywheel rotor component along the new chord direction until the edge of the end cover is at another arc after the fiber is turned around the flange by about 120 degrees after encountering the flange, then turning the flywheel rotor component along the axial direction again until the arc of the edge corner of the other end cover is encountered, and continuously winding. The flywheel rotor subassembly is wound continuously along different new chords and turns each time to the chords which are approximately tangential to the flange in the middle of the outer surface of the end cover, so that the operation is repeated and circulated, the outer surface of the whole flywheel rotor subassembly is completely coated, and the flywheel rotor subassembly is solidified and reinforced after reaching a uniform thickness of about 1-3mm, so that the flywheel rotor subassembly is used as a second radial protection layer for preventing the flywheel rotor from bursting. The two protective layers form dual anti-burst protective layer reinforcement of the inner circumference and the outer circumference/axial direction of the flywheel rotor subassembly.

Further, the flywheel rotor subassembly is driven to rotate via the motor/generator subassembly, with the flywheel outer diameter dimension being limited by the linear speed of the outer rim to not more than 240m/s.

Further, the dynamic balance accuracy of the flywheel rotor assembly as a whole together with the flywheel rotor subassembly of the motor rotor is of the order G0.4-G1.0.

Further, the motor/generator is a high-power input-output type motor belonging to a short-time operation system S2 or a load and rotation speed non-periodically changing operation system S9, and the operation time under high power is usually 4 to 13S, and the maximum continuous operation time is usually not more than 41S. The motor is arranged in a sealed shell, and the maximum output power of the motor used as the flywheel power battery for storing energy can be 5-21 times of the rated power in continuous operation. The rotating speed of the motor is at the low end of the rotating speed range of common flywheel battery similar products, and the highest rotating speed is not more than 20000r/min. The rotational speed of each flywheel rotor subassembly can be regulated and controlled by an internal motor/generator through an external motor controller, can change steering, reverse or same direction, and can synchronously or asynchronously regulate the angular acceleration and deceleration or keep constant speed of the double flywheels.

Further, the motor may be an outer rotor or an inner rotor structure, and may be a radial or axial magnetic field. The stator core of the motor is positioned by a key and pressed into and fixed on a central column of the bottom plate of the shell. Because the iron loss of the motor is proportional to the 1.3-1.5 th power of the alternating frequency of the magnetic field, the motor iron core preferably uses a high-permeability, high-frequency and low-loss thin silicon steel sheet lamination combination to reduce the eddy current loss at high rotation speed. For the device, the stator iron core is manufactured by punching, stacking, buckling and riveting high-frequency low-loss silicon steel sheets with the thickness of 0.2-0.35mm and then compacting; the stator core can also be an iron core pressed by integral SMC (Soft Magnetic Composite) powder metallurgy, or can also be manufactured by winding and splicing an amorphous iron-based alloy with smaller high-frequency loss; or may be designed as coreless structures. The motor winding is of a single winding structure. In order to reduce the increase of high-frequency loss caused by the high-frequency skin effect, the flat oxygen-free copper belt with the insulating layer is wound in a single sheet or a plurality of layers in a stacked manner, and the insulating layer is PI preferentially; the windings may also be wound from a plurality of insulated enamelled copper wires. The thickness of the flat oxygen-free copper strip is preferably 0.5-0.7mm. When the winding adopts a flat oxygen-free copper belt, the lead connection between the windings on the adjacent teeth is lap welding, and the winding is coated with insulation treatment after welding. The outgoing lines of the motor windings and the rotor position sensor are led out at a proper position of the lower part of the bottom plate of the shell. The magnetic steel material of the motor rotor is neodymium iron boron or samarium cobalt with high temperature resistance level, when the number of poles is in a topological state with a small number of poles, for example 2p=2 and 4, the magnetic steel can still be composed of a plurality of magnets, and a Halbach array type magnetic steel structure can be used; the electromagnetic topology of the slot pole count is preferably selected to be a fractional slot concentrated winding configuration to achieve short winding circumference and end length and reduce copper losses.

Further, a magnetic steel cylinder of the motor rotor member is made of a soft ferromagnetic material and is used as a yoke. When the motor is of an outer rotor type, the motor is installed and pressed into or cast into a rotor bracket cavity on the flywheel rotor end cover; permanent magnet steel is arranged and glued on the inner surface of a rotor magnetic yoke, and the magnet steel structure can be arranged in an NS way with alternating polarities, but can also be arranged in NNSS way in blocks or can also be an interpolation type (IPM): however, in this case, the magnetic yoke may be the same as the motor stator, i.e. instead of being laminated with silicon steel sheets, each magnetic fly is formed by two flat magnetic steels with the same polarity arranged in V shape, and the two ends of each magnetic steel are provided with air magnetic isolation bridges on the magnetic yoke to prevent larger magnetic leakage.

Further, the center post is made of high-strength aluminum alloy with good thermal conductivity; the central shaft is a solid or hollow shaft with short steps, and the material of the central shaft can be high-strength medium carbon alloy steel or stainless steel.

Further, the main bearing of the bearing component is an angular contact composite bearing of small-diameter silicon nitride ceramic dense beads and stainless steel inner and outer rings; for the use in the occasion of frequent severe jolting, double bearings can be symmetrically used back to back in pairs, or a protection bearing is additionally arranged to increase the safety; the protection bearing is a ball bearing with larger outer ring diameter and width; the main bearing and the protection bearing are both lubricated by grease, and a gap of about 0.08-0.11mm can be reserved between the outer ring of the protection bearing and the hole of the bearing seat.

Further, the housing parts include a housing, an end cap, a bearing cap part, a protective reinforcement layer, an electrical connector, a coupling fastener, a seal or also an air pump/charging nozzle, a water cooling pipeline, etc.; the bearing cap component is provided with a protective bearing or also with another 1/2 of a permanent magnet bearing.

Further, the outer ring of the protection and energy absorption ring component is a high-toughness steel cylinder, the inner ring is a thin-wall cylinder made of non-high-toughness engineering plastic, and the inner ring and the outer ring are concentric.

Further, the outer ring of the protection and energy absorption ring component is uniformly provided with a certain number of step through holes along the radial direction and the axial direction on the ring wall, a short step steel shaft pin for absorbing impact energy is pressed in the holes, or a screw thread is tapped in the ring wall hole and then screwed by a steel short screw, and a spring pad or a connection part is coated with anti-loosening anaerobic adhesive and the like to prevent loosening. Each short step shaft pin or screw is made of an annealed steel rod, protrudes out of the inner surface of the outer ring for a certain length and forms an array; the outer diameter of the inner ring cylinder is basically the same as the diameter of an inscribed circle formed by the protruding heads of the short step shaft pins or the short screws, and the inner ring cylinder is connected and kept concentric. The two ends of the inner ring and the outer ring can be sealed into a whole by end cover sealing heads. The space between the inner ring and the outer ring can be filled with flexible energy-absorbing materials before the end cover of the shell is sealed, and the energy-absorbing materials can be intelligent collision protection gel and the like. The short step shaft pins or screws are used for preventing fragments flying out of the flywheel in case of burst from collision, absorbing energy and decelerating, and the protection and energy absorbing ring is used as a third protection layer for preventing the rotor from burst and flying out.

Further, the outer shell and the end cover are made of high-strength metal materials such as alloy steel or aluminum alloy, and the outer surface of the end cover is provided with reinforcing ribs. The outer part of the cylinder wall of the shell can be wound with a thin layer of filament carbon fiber epoxy resin composite material for reinforcement, and the thickness of the carbon fiber layer can be 3-8mm, so that the carbon fiber layer can be used as a fourth radial protection layer for preventing the rotor from bursting and flying out. When the shell and the end cover are made of high-strength aluminum alloy, high-toughness alloy steel or stainless steel sheets can be added and paved on the inner surfaces of the shell and the end cover to serve as protection plates, and carbon fiber cloth is glued and coated outside the plates to serve as an axial reinforcing protection layer.

Further, the shell is of a full-sealing structure, and the contact surface or the spigot of each end face is provided with an O-shaped rubber sealing ring or silicon rubber for filling sealing. After the shell is sealed, the vacuum is not pumped, but the common industrial gas can be filled: hydrogen or helium. After assembly and initial testing, the interior of the housing can be evacuated of air through a suction nozzle with a small air valve, and then the interior is filled with hydrogen or helium and the cavity is sealed, with the pressure of the air being about 1 atmosphere (atm) slightly above ambient pressure. About 11% nitrogen may be mixed in when helium is filled. Because the internal space of the shell is limited, the amount of the gas to be filled is small. The two gases, hydrogen or helium, are chosen because their gas density is only 1/14 or 1/7 of the gas density, respectively. The wind resistance is proportional to the gas density, so the wind resistance loss is greatly reduced in proportion to the density. In addition, the wind resistance is lower at low speed because the wind resistance is proportional to the square of the rotating speed. As a result of the combined action of the two factors, it is completely unnecessary to draw a vacuum. Other benefits of such a selection are: the heat conductivity coefficients of the two gases are 6.7 times and 5.6 times higher than that of air respectively, so that the heat dissipation is better than that of air, the defects of no vacuum state and difficult heat dissipation due to convection are overcome, and the reduction of the overall temperature rise is very beneficial to improving the working reliability of the device.

Further, the flange (namely the combination of the two flywheel rotor assembly bottom plates) in the upper middle part of the device shell is also provided with a mounting hole, and the mounting hole can be connected and fixed with a bracket on the vehicle bottom plate and the ship bottom plate by using a fastener. The mounting bracket can be directly fixed on the upper surface or the bottom surface of the bottom plate of the vehicle and the hull. However, the device is mounted and fixed so that only about half of its height is exposed to the surface of the base plate, whether the device is mounted horizontally or vertically.

Further, for the application of large torque, the mounting flanges can also be respectively arranged at the outer ends of the end covers of the two flywheel rotor assemblies, and the flanges at the two ends of the assemblies are respectively connected with the bottom plates or the frames of the vehicles and the ships and the brackets on the keels to form a fixing structure with double brackets at the two ends.

Further, the present electromechanical device, when dedicated solely for flywheel power cell energy storage, may have both flywheel rotor shafts mounted perpendicular to the ground, or may also be mounted horizontally to the ground. The motor/generator and the drive controller are regulated and controlled to synchronously rotate reversely at the same rotating speed; preferred flywheel rotors have an aspect ratio of less than 1. When the device is used as attitude control, for example, for preventing the vehicle body from turning over, stabilizing the hull, or for keeping the upright self-balance of the front and rear two-wheelers, the two flywheel rotor shafts are horizontally arranged at the center of the vehicle body and the hull along the longitudinal axis direction of the vehicle and the hull, and the angular acceleration or the angular deceleration of the flywheel rotor can be regulated and controlled by the motor/generator driving controller under the condition that the absolute values are equal and the absolute values are synchronously increased and decreased, and the rotation direction of the flywheel rotor shafts can be changed if necessary or also to flexibly form the reaction moment of the required direction.

Further, when the flywheel rotor assembly works vertically, in order to reduce the axial load of the main bearing and prolong the service life of the main bearing, the permanent magnet bearing of the upper flywheel rotor assembly can be a tension magnetic bearing, and the permanent magnet bearing of the lower flywheel rotor assembly can be a thrust magnetic bearing. The permanent magnetic bearing is a pair of permanent magnetic concentric rings with the same size, opposite axial directions and small interval, but the upper half ring of the upper tension bearing can be omitted, and the upper half ring can be replaced by soft ferromagnetic materials. The permanent magnet bearing is also unnecessary when the rotor mass is small relative to the load allowed to be carried by the bearing, and can meet the service life specified by the bearing standard.

Further, when the flywheel rotor subassembly works horizontally, the permanent magnet bearing is a pair of permanent magnet rings with different diameters, the outer diameter of the small ring is smaller than the inner diameter of the large ring, a gap is reserved between the outer circular surface of the small ring and the inner circular surface of the large ring, and the two surfaces are magnetized to form the homopolar concentric thrust magnetic bearing.

Furthermore, the device realizes multiple functions of one machine, and performs function conversion according to a time-sharing working mode. In normal operation, the device is preset in a flywheel power battery mode; when the gesture control function is needed, the working mode of the flywheel power battery is stopped. The reactive flywheel (RW) function is used as an executing mechanism, and the gesture control of the vehicle body and the dual task requirement of the flywheel battery type power energy source can be simultaneously realized by adopting a simple control algorithm.

Further, when the device is used as a flywheel power battery, the two flywheels are rapidly charged to the highest rotating speed, so that the vehicle can be rapidly discharged to provide short-time high power for the vehicle drive control system when the vehicle is started, accelerated or climbed and other high loads, and the power performance of the whole vehicle can be greatly improved; when the vehicle decelerates, slides and brakes, the two flywheels are firstly in a state of being discharged to a low rotation speed, and can be rapidly charged to efficiently retract the inertial kinetic energy of the vehicle body; while a short-time high-current charge is acceptable in emergency braking. The charge and discharge control is carried out by an external reversible DC-DC buck-boost converter and a flywheel motor drive controller, or can be matched with an external super capacitor and an electrochemical energy storage battery, or can be matched with an external functional device such as a vehicle-mounted kinetic energy motor (MGU-K) and the like to work so as to flexibly adapt to the requirements of the required charge or discharge state. When the vehicle and boat are started Guan Suoguan and stopped, the electric energy stored in the super capacitor can be gradually boosted by means of the DC-DC with the variable boosting ratio and then is completely turned off after being stored in the power battery. The boost and charge circuit of the device may also be powered by an external small capacity auxiliary battery during this period. Because the rotating speeds of the two flywheels are synchronous and rise and fall at the same speed, the angular momentum and gyroscopic moment effect of the device can be completely counteracted.

When the device is used as attitude control, such as rollover, rolling or rolling resistance, the device works in a reaction flywheel (RW) mode, the attitude control law and the control law of the flywheel are designed, for example, the two flywheels are preset at the position of 1/2 of the highest rotating speed, after receiving a signal for applying the reaction force moment, the device can synchronously and rapidly rise and fall in the same direction or different directions according to a given direction, the acceleration and deceleration increase and decrease are carried out at an angle with the given absolute value, and the interference of the external moment on the movement of a vehicle body and a ship is counteracted, balanced or reduced by using the output reaction moment.

Compared with the existing flywheel battery and attitude control technology for vehicles and ships, the invention has the beneficial effects that:

(1) High safety

a. The invention provides 4-fold safety protection, which is based on the principle of fracture mechanics, and takes into consideration the danger that a machine part made of high-strength materials can be broken in brittle state in which the stress is far lower than the yield strength, in order to prevent flywheel rotors from flying out in case of bursting, the invention only uses a small amount of thin-layer high-strength or ultra-high-strength filament carbon fiber epoxy resin composite materials for wrapping protection: circumferential and radial/axial protection reinforcement of the flywheel rotor component body; circumferential and end face axial protection reinforcement is carried out on the outer cylindrical surface of a container of the flywheel rotor, namely the outer shell of the device; the shell is also particularly pressed with a protective and energy absorbing ring component, namely, the novel energy absorbing material is utilized to absorb energy by bending deformation of a short shaft pin or a screw array or flexible energy absorbing material is added, so that a perfect and reliable protective measure is formed that a flywheel rotor is difficult to fly out in case of burst due to effective energy absorption and deceleration of fragments, a user can be relieved, a foundation is laid for large-scale safe application of a flywheel technology in civil and vehicle-mounted products, and the novel energy absorbing flywheel device has important significance in preventing rollover, rolling and rolling of 4-wheel electric vehicles, improving power performance, efficiently recovering braking energy, prolonging one-time charging driving range and realizing popularization of 2-wheel electric vehicles in future.

b. Contrast safety-the flywheel rotor selects a lower operating speed and limits the highest linear speed of the flywheel rotor outer rim. The design stress has high safety coefficient due to the fact that the scheme of working at high or ultra-high rotation speed is not used and the combination of the high-strength isotropic material capable of obtaining high safety coefficient and the reinforcing structure is used. The safety of the above-mentioned parameter references is high in view of their wide safety application, and their low values in already established industrial rotor products, such as motorized spindles and high-speed motors of numerically controlled machine tools.

c. The device is reasonably arranged at the bottom plate in the center of the vehicle-body, has low gravity center, and has extremely low probability of being collided and damaged even if collision occurs, so that the doubt of users on use safety can be eliminated, and the device creates a prospect that the device can be widely popularized and applied in civil products.

d. Compared with the single flywheel power battery in the prior art, the gyro precession effect of the device is completely counteracted when the single flywheel power battery is used as a power battery, so that the device has no interference on the operation of a moving vehicle body or the risk of losing control and accidents caused by the interference on the operation of the moving vehicle body in complex road conditions.

e. The device has abnormal safety control, once the acoustic emission and vibration/displacement sensor arranged on the shell detects that abnormal sound, especially high decibel impact sound, vibration or abnormal displacement occurs in the interior, the device rapidly alarms through the external central control unit and rapidly decelerates the flywheel rotor, then cuts off the power supply, and stops supplying power to the motor/generator.

f. The flywheel rotor of the device adopts high-strength alloy steel as a main body material, but the rotational inertia or the energy storage energy of the flywheel rotor is improved by increasing the mass m of the flywheel rotor, so that the material density is increased under the condition of limited radius size, and the high-specific gravity material is adopted. However, the high specific gravity material generally has insufficient strength, so that the method of inserting the high specific gravity alloy into the high strength alloy steel is adopted, and the equivalent mass of the flywheel rotor is remarkably improved without increasing the volume of the flywheel rotor. Because the high specific gravity alloy is surrounded and protected by the peripheral high strength alloy steel, the high specific gravity alloy is not limited by low strength, so that the safety can be ensured, and the design freedom degree is increased.

(2) Low cost

a. The cost of the device can be greatly reduced compared with the existing product, and the main materials are cheaper materials, so the device has the price of only a fraction or even a tenth of that of the similar products, is easy to manufacture, and can easily achieve the aim of low cost.

b. Because the working rotation speed of the flywheel rotor belongs to the low rotation speed area of the like product, the rim linear speed still belongs to the sonic speed range, and hydrogen or helium with much smaller air density is filled in the flywheel rotor, so that the wind resistance and wind loss are very small, a vacuum-level sealed shell and structure are not needed, and a vacuum pump is not needed to be purchased and troublesome subsequent use and maintenance are not needed.

c. Compared with the prior art of vehicle-mounted attitude control, the similar technology uses a control moment gyro (CM), so that a frame, a frame bearing, a precession motor controller and the like are needed. In addition, because the control moment gyro is of a single flywheel structure, the influence of the gyro precession moment on the position change of the vehicle body and the movement manipulation of the vehicle can be eliminated by using two flywheels to reversely rotate in parallel, so that the control moment gyro has large volume and occupied area, heavy weight and obviously increased manufacturing cost. The invention adopts the reversing double flywheel with single structure and the reaction flywheel technology with the simplest structure, and does not use double frames and frame bearings, a precession motor, an electric control device and the like, thereby having simple control, fewer structural parts, high reliability and greatly reducing the purchase and manufacturing cost.

d. Low work with the deviceFor rotation speed, use is made of boron nitride (Si) which is much cheaper and simpler than electromagnetic suspension bearings, superconductive suspension bearings ₃ N ₄ ) The ceramic-metal inner and outer ring composite bearing can also be added in the flywheel rotor component, and the permanent magnet bearing with extremely simple structure and low cost can be used, which is only used for reducing the load of the main bearing and prolonging the service life of the main bearing, but does not obviously increase the cost. Therefore, compared with similar products, the cost is obviously reduced.

(3) Multifunctional, multipurpose

The prior art is usually single-purpose, or used as energy storage, or used as attitude control. In view of the inertia and gyroscopic effect of the flywheel rotor of the base of both purposes, the invention can realize one machine for multiple purposes in consideration of time-sharing work. The system can not only greatly improve the power performance of the whole vehicle, realize the efficient recovery and regeneration of braking energy and prolong the one-time charging driving range or reduce the used battery capacity based on the function of a power battery, but also be used for preventing rollover and rolling of a small automobile and preventing ship rollover and stabilizing of a small ship based on the function of attitude control, and has great significance for reducing the casualty rate and property loss of road traffic accidents. In addition, the attitude control function is used for the front and rear two-wheel vehicles, can realize standing and self-balancing, can realize the popularization of the two-wheel electric vehicles with low cost, small occupied area and low energy consumption, and has obvious significance for relieving the worldwide traffic problem of road traffic jam and difficult vehicle storage.

(4) Compact structure, small volume, convenient placement

Because of the limited space inside the vehicle and the ship, the size of the internal facilities is much more strict than the weight of the internal facilities, and the installation position of the internal facilities is more strict.

a. The weight of the electromechanical device is usually small compared with the weight of the small-sized vehicles and ships, for example, for the application of a common electric car, the weight of the electromechanical device is usually about less than 1/20-1/40 or even less than the preparation quality of the electromechanical device, so that the electromechanical device does not form the problem of remarkable weight increase, and the overall performance and the product value can be greatly improved due to the advantages realized by the electromechanical device.

b. The flywheel rotor is made into a hollow bell shape, and the flywheel rotor is an assemblyIs of flattened design, which considers that the inner diameter and the outer diameter ratio of the ring of the flywheel main body made of isotropic materials are R _i /R _o At =0.6, the ratio of the values of the moment of inertia to the solid disk, i.e. the contribution to the moment of inertia, has reached 87%. And the motor/generator is completely placed in the hollow portion (R _i ＝0.6R _o ) The internal structure is compact, the axial dimension is short, and the volume of the device is small.

c. Because the high specific gravity alloy is added into the flywheel body, the equivalent density and the rotational inertia of the flywheel body can be obviously increased compared with those of the flywheel without the high specific gravity alloy, and the flywheel can also realize small-volume and high-power storage kinetic energy or high attitude control moment output and has higher mass or volume power density.

d. In particular, the invention combines two identical or nearly identical flywheel rotor components in mirror symmetry and concentricity, and the same motor drive controller is used for synchronous speed regulation to form synchronous reverse rotation at the same speed outside, thus the adverse effects of the angular momentum and the gyro precession moment effect can be completely eliminated, the volume is small, the occupied space is small, the occupied area can be reduced by at least 1/2, and the installation and the control are simpler. The similar products are mainly characterized in that two single flywheel rotor assemblies are arranged in parallel, the occupied area is large, and the part connected with each other between two assembly mounting bottom plates is likely to be affected by the moment of a large precession gyro and generate large vibration noise when the flywheel central shaft changes direction along with a vehicle body, such as steering and vehicle body tilting, or under the condition that the two flywheel rotors are out of step, and the strength problem is also likely to occur.

e. According to the design of the invention, the installation of the device on the bottom plate is that the flange in the middle of the shell is fixed on the bracket in the center of the bottom plate of the vehicle and the ship, so that the installation is simple, and the longitudinal height in the carriage and the cabin is little increased because half of the device can be projected out of the surface of the bottom plate, the reasonable and effective utilization of the internal space of the vehicle and the ship is not influenced, and the device is easy to be overall and reasonably arranged. Due to the design of minimum volume, the occupied area of the bottom plate is small, and the layout of the energy storage battery on the chassis is not greatly influenced when the energy storage battery is used for an electric vehicle.

(5) High output power, large attitude control moment, high efficiency and low power consumption

The device adopts a new design of a motor/generator which is a high-power input/output type motor working in a short-time, load and rotation speed aperiodic change working mode and is used as a flywheel rotor, so that the device can work under high current and can obtain very high angular acceleration, and the device can be used as a high-power battery, can obtain large attitude control moment output and has one of the key characteristics of small volume and high performance. The permanent magnet brushless or synchronous motor with fewer poles, concentrated fractional slots, and flattened winding conductors can make the perimeter and end parts of the winding short, copper loss and iron loss small, high-frequency loss low, so the efficiency is high, and the total power consumption is low.

(6) High productivity, easy mass automatic production and popularization

The device is mainly manufactured by a high-efficiency mature production process, namely mechanical processing, and has the advantages of short processing period and high processing efficiency, and the device is a precondition that the products can realize mass production and popularization and application.

(7) Extending driving range or reducing vehicle-mounted capacity of energy storage battery and prolonging service life of power battery

a. When the device is used as a high-power battery of an electric automobile, the device can form a composite energy source with a conventional lithium battery and the like, and the primary charging driving range (for example, under NEDC working condition) of the cycle working condition method can be close to the mileage value under the economic speed per hour (for example, 50/60 km/h), so that the device can be prolonged by about 15-30%. The instantaneous high power required for vehicle start and acceleration is provided by a high power battery, while the electrochemical energy storage lithium battery is mainly used for the energy required under the uniform-speed driving condition. The instantaneous high power required by the vehicle during starting and accelerating is high, but the total energy is very small, for example, a common car runs under the urban circulation working condition, and the typical high power required during starting and accelerating is only about 200-300 wh.

b. The electric automobile in the prior art cannot be too large due to the limitation of the capacity and the charge-discharge current of the vehicle-mounted electrochemical energy storage battery. The energy storage battery has small capacity, large internal resistance and line impedance, and large energy consumption in the frequent starting, accelerating and decelerating processes of the circulation working condition method. And is wasted because efficient recovery and regeneration of large braking energy cannot be directly achieved. The device is limited less, has small internal resistance and can bear large current, so that the device can realize high-efficiency recovery of energy during braking, sliding and downhill, and the flywheel battery can save energy and save more than 25 percent of oil. The impact of high charge and discharge current on the power battery can be reduced, so that the cycle service life of the power battery can be obviously prolonged.

c. If the length of the primary charging driving mileage is unchanged under the comprehensive working condition of the existing vehicle, the total capacity of the battery used at present can be reduced by about 15-30% after the device is used, and the manufacturing cost of the whole vehicle can be obviously reduced under the condition that the price of the lithium battery is still high and the cost of a battery system is about 1/3-1/2 or more than the cost of the whole vehicle at present, and the device has an important role in popularizing and applying new energy electric vehicles. In addition, if the total capacity of the battery in use is unchanged, the one-time charging driving range can be prolonged by about 15-30%.

(8) High dynamic performance

The existing new energy electric automobile is limited in capacity of a vehicle-mounted battery due to price restriction. But it is difficult to obtain better power performance without using a high-power motor and a high-capacity energy storage battery. Short hundred kilometers of acceleration time, faster maximum speed, larger climbing and carrying capacity, which can be realized only on luxury cars and sports cars which can use high-power and high-torque motors/engines and high-capacity energy storage batteries, but the price is very high, so that the motor can be purchased by the vast majority of users. The device provided by the invention is combined with the existing electrochemical energy storage battery, so that the power performance of the ordinary car can be greatly improved under the condition that the capacity of the vehicle-mounted battery is not increased and the cost is only slightly increased, and even under the condition that the energy consumption is hardly increased (only a few percent of the energy of the vehicle-mounted battery is |), the level of the marking parameters of the saloon car and the sports car can be expected to be obtained, and the commodity and the use value of the ordinary car can be obviously improved.

Drawings

Fig. 1 is a schematic longitudinal sectional view of a flywheel rotor assembly according to the present invention.

Fig. 2 is a top view of the flywheel rotor assembly of the present invention.

FIG. 3 is an exterior elevation view of the present device of the present invention assembled from a pair of flywheel rotor assemblies, positioned horizontally.

Fig. 4 is an external side view of the present device of the present invention assembled from a pair of flywheel rotor assemblies, positioned horizontally.

Fig. 5 is an exterior elevation view of the present device of the present invention assembled from a pair of flywheel rotor assemblies, positioned vertically.

FIG. 6 is an external top view of the present device of the present invention assembled from a pair of flywheel rotor assemblies, positioned vertically.

Fig. 7 is a schematic view of the structure of the flywheel rotor body of the flywheel rotor member pressed into the high specific gravity alloy rod.

Fig. 8 is a schematic front view of the path, direction and sequence of filaments during radial protection, chordwise winding of a flywheel rotor subassembly with a filament carbon fiber composite.

Fig. 9 is a schematic side view of the path, direction and sequence of filaments during radial protection, axial winding of a flywheel rotor subassembly with a filament carbon fiber composite.

Fig. 10 is a schematic view of the tooth structure of the 9-slot 6-pole stator and rotor components of the outer rotor motor/generator subassembly.

Fig. 11 is a schematic view of the tooth structure of the 6 slot 4 pole stator and rotor components of the outer rotor motor/generator subassembly.

The numbers in the figures are: 1 outer shell, 2 outer ring, 3 short shaft pin, 4 energy absorbing layer, 5 inner ring, 6 end cover, 7 flywheel rotor main body, 8 high specific gravity alloy bar, 9 flywheel rotor lower end cover, 10 flywheel rotor upper end cover, 11 permanent magnet bearing cover, 12 permanent magnet bearing A,13 permanent magnet bearing B,14 bearing cover, 15 wave-shaped elastic washer, 16 protective bearing, 17 big lock nut, 18 wave-shaped elastic washer, 19 central shaft, 20 ceramic angular contact main bearing A,21 central column, 22 stator core, 23

The assembly comprises a winding, a 24-wave-shaped elastic washer, a 25-ceramic angular contact main bearing B, a 26-small lock nut, a 27-circumferential protection layer, a 28-part circular ring or full circular ring-shaped positioning key, a 29-motor rotor baffle, a 30-motor rotor support, a 31-magnet steel cylinder, 32-magnet steel, a 33-stator winding outgoing line, a 34-base plate/end cover protection plate, a 35-base plate/end cover protection reinforcing layer, a 36-rotor circumferential protection layer, a 37-rotor radial protection layer, a 38-winding wiring terminal, a 39-junction box, a 40-mounting hole, a 41-mounting direction mark, a 42-stator iron core key, a 43-rivet, a 44-component housing-base plate assembly mounting flange, a 45-general flywheel rotor component, a 46-flywheel rotor upper component, a 47-flywheel-rotor lower component A and a flywheel-rotor component assembly mounting bottom surface.

Detailed Description

Specific embodiments of the present invention are further described below with reference to the accompanying drawings. The invention can make various designs with different parameters and specifications according to the structural principle of the invention for different use objects and use environments. Here, only the energy storage attitude control dual-purpose concentric reverse double flywheel electromechanical device applicable to the electric car is used as some embodiments of the device.

Embodiment one: as shown in fig. 1, the flywheel rotor assembly is fully functional as a free-standing flywheel energy storage or reaction flywheel (RW). The flywheel rotor assembly comprises a flywheel rotor and motor/generator subassembly, and main components such as a flywheel rotor, a shell, an end cover, a central column, a protection and energy absorption ring and parts such as a sensor, a fastener, a positioning piece, a sealing piece and the like.

Referring to fig. 3 and 4 and fig. 5 and 6, the present electromechanical device is comprised of a pair of identical flywheel rotor assemblies 00 or nearly identical flywheel rotor assemblies 01 and 02. The two flywheel rotor components are symmetrically arranged and combined along the bottom surface A of the shell 1 in a mirror image way, left and right or up and down or concentric with the center line. The bottom plate A surface of the shell 1 of the assembly is of a semi-symmetrical structure along the center line on the surface, the two assemblies are mutually connected into a whole through a flange 44 at the lower edge of the bottom plate of the shell 1, the two assemblies are kept accurately concentric through positioning of a part circular ring or full circular ring positioning key 28 or a pin and the like, and the two assemblies are connected, fixed and combined through a fastener, a rubber sealing piece and the like to form a concentric double flywheel electromechanical device of an integral sealing and electromechanical integrated structure;

The two flywheel rotor subassemblies of the two flywheel rotor assemblies are respectively connected, driven or driven by motor/generator subassemblies with the same structure, parameters and performances; based on the mirror symmetry relation of the bottom plate connecting planes A of the two flywheel rotor components, when the two flywheel rotor components are driven by respective motors through the same external driving controller, the angular momentum and gyroscopic precession effect of the device are completely counteracted because the flywheel rotor can be controlled, synchronously lifted with the same steering and rotating speed and form opposite rotation with the steering completely opposite through mirror image.

Fig. 3 and 4 show the device consisting of a pair of identical flywheel rotor assemblies 00, which is suitable for horizontal installation of flywheel rotor shafts, can be used as a flywheel power battery, can be used as a reaction flywheel (RW), namely a gesture control actuator, and can also work according to time sharing and have two functions.

Fig. 5 and 6 show the present device consisting of a pair of almost identical flywheel rotor assemblies 01 and 02, suitable for vertical mounting of the flywheel rotor shaft, mainly solely for use as a flywheel power cell.

Assemblies 01 and 02 differ from 00 only in the construction of their permanent magnet bearings. The flywheel rotor shafts of the assemblies 01 and 02 are vertically arranged, so that the permanent magnet bearings of the assembly 01 are parallel suction bearings, and the permanent magnet bearings of the assembly 02 are required to be parallel thrust bearings with the same polarity because the mirror image positions are reversed. As shown in fig. 3 and 4, when the two components are horizontally arranged, the components can be 00 with identical structures, the permanent magnet bearing can be a pair of permanent magnet rings with different diameters, the outer diameter of the small ring is smaller than the inner diameter of the large ring, and the outer surface of the small ring and the inner surface of the large ring have the same polarity and have gaps, so that the permanent magnet bearing is a thrust permanent magnet bearing. This is also a prior art and is not shown. However, when the flywheel rotor mass is small, no matter the assembly is 00, or 01 or 02, the permanent magnet bearing pair can be omitted.

Referring to fig. 1, the flywheel rotor subassembly includes a flywheel rotor member, a permanent magnet bearing cover member, a rotor upper end cover 10, a lower end cover 9, a motor rotor barrier 29, rivets 43, fasteners such as screws, a rotor circumferential protective layer 36 of the flywheel rotor subassembly, a rotor radial protective layer 37, and the like.

The flywheel rotor member includes: flywheel rotor body 7, high specific gravity alloy rod 8.

The permanent magnet bearing cap member includes: permanent magnet bearing cover 11, permanent magnet bearing A12.

The motor/generator subassembly includes a motor stator component and a motor rotor component.

The motor stator component includes a motor stator core 22, stator windings 23, stator winding lead wires 33, and stator core keys 42.

The motor rotor component comprises a magnetic steel cylinder 31 and a magnetic steel 32.

The housing and end cap member include: bearing cap components, housing 1, end cap 6, housing circumferential protective layer 27, partial or full annular locating key 28, base plate/end cap protective plate 34, and base plate/end cap protective reinforcement layer 35, or also pump/inflator nozzles (not shown), etc.

The bearing cap member includes: permanent magnet bearing B13, bearing cap 14, wave-shaped elastic washer 15, protection bearing 16.

The center post assembly includes: the large lock nut 17, the wave elastic washer 18, the central shaft 19, the ceramic angular contact main bearing A20, the central column 21, the wave elastic washer 24, the ceramic angular contact main bearing B25 and the small lock nut 26.

The shield and energy absorbing ring member includes: an outer ring 2, a stud 3, an energy absorbing layer 4, an inner ring 5.

The sensor comprises: a motor rotor speed and position sensor; inclination angle or multiaxial micromechanical acceleration/gyro sensor, acoustic emission sensor for detecting operation vibration noise, vibration sensor, eddy current sensor for detecting flywheel rotor position/displacement, temperature sensor for detecting bearing and motor stator temperature, etc., each being placed at proper position of component. Or the existing available sensors of the vehicle and the ship can be used for reducing the types and the quantity of the electromechanical device which is required to be equipped. The abnormal safety control of the device is mainly triggered by the signals of an acoustic emission and vibration/displacement sensor arranged on the shell, and once the sensor detects abnormal sounds, particularly high decibel impact sounds or abnormal displacement and vibration, the flywheel rotor is rapidly decelerated and the power supply is cut off through an external central control unit, so that the power supply to the motor/generator is stopped.

As shown in FIG. 4, the flywheel rotor body 7 is a circular ring with an internal/external diameter ratio Ri/Ro of 0.6 or more. The diameter and the highest rotating speed of the flywheel rotor main body 7 are limited to be not more than 240m/s by the highest linear speed at the outer rim of the flywheel, and the design stress safety coefficient is more than or equal to 2.

The flywheel rotor body 7 is manufactured from a high strength, high toughness isotropic material such as alloy steel or stainless steel forgings. The available materials are numerous, for example: 40CrNiMoA,4340, 45CrNiMoVA,18Ni-250,0Cr13Ni8Mo2Al,25Cr2Ni4MoV, 17-7PH, M250, 300M, etc. can be determined according to the actual required technical performance and target cost of the device. The yield strength sigma of the preferred material _s The elongation delta is more than or equal to 11 percent and is more than or equal to 900MPa, and certain requirements on the fracture toughness of the material are also required.

Referring to fig. 7, a proper number of holes are uniformly formed along the circumference at the position of the inertia radius r of the flywheel main body 7, and round bars 8 made of tungsten alloy with high specific gravity are pressed into the holes with interference fit, and tungsten alloy materials are available, such as 93W-4.9Ni-2.1Fe, WG8, etc.

Referring to fig. 1, the rotor upper and lower end caps 10, 9 of the flywheel rotor subassembly are made of a high strength aluminum alloy, many of which can be used, such as 7075, 7050, 7055, 7a55, 7150, 7475, etc., preferably with a yield strength σ _0.2 More than or equal to 500MPa, and the elongation delta is more than or equal to 11 percent.

Referring to fig. 1 and 7, the flywheel main body 7 is clamped by upper and lower end covers 10, 9 in the axial direction, and the inner and outer joints of the inner and outer rims of the flywheel rotor main body 7 and the upper and lower end covers 10, 9 are in interference press fit. Both sides of the cylindrical surface of the flywheel main body 7 are connected and riveted with the both end covers 10, 9 by rivets 43. After being firmly connected with the upper end cover and the lower end cover through riveting, the whole shape forms a hollow structure of a bell-jar inverted U shape, and the upper end cover 10 has the functions of a hub and a spoke.

A permanent magnet bearing cap member is screwed with a fastener at the center of the upper surface of the upper end cap 10 of the flywheel rotor subassembly. The central aperture of the upper end cap 10 of the flywheel rotor subassembly is used to rotatably mount and secure the flywheel rotor subassembly to the central shaft 19 of the central post member. The connection between the upper end cover 10 of the flywheel rotor subassembly and the flywheel central shaft 19 is a press fit of a keyless structure, so as to ensure good dynamic balance when the flywheel rotor rotates.

The rotor support 30 is secured by a fastener screw connection to concentric grooves in the lower inner surface of the upper end cap 10 of the flywheel rotor subassembly. And a magnetic steel cylinder 31 of the motor rotor member with magnetic steel 32 is pressed or cast into the inner surface of the rotor bracket 30. A magnetic steel baffle 29 is fixed below the rotor bracket 30 by screws, and the material of the magnetic steel baffle is non-magnetic metal, such as aluminum alloy.

The center of the lower end cap 9 of the flywheel rotor subassembly has only a large hole, and the hollow portion thereof can be used for completely accommodating the whole of the motor/generator subassembly, so that the device can be compact and flattened, and the axial length of the subassembly is obviously reduced.

Circular flanges with the same diameter and concentricity are manufactured at the central part of the outer surfaces of the upper end cover 10 and the lower end cover 9, and the outer diameters of the two end covers are the same and are 5-10mm larger than the outer diameter of the flywheel rotor main body 7. The outer edge angles of the two circular arc-shaped grooves are all made into circular arcs, and the radius r of the circular arc is more than or equal to 5mm.

After the flywheel rotor component is assembled with the upper end cover 10 and the lower end cover 9, filament carbon fiber epoxy resin composite materials are wound in the circumferential direction in shallow annular concave groove gaps formed on the outer circumferential surfaces of the upper end cover 10 and the lower end cover 9 and the flywheel rotor main body 7 by applying pretension until the flywheel rotor component is just filled or slightly higher than 0.5mm, and the flywheel rotor component is solidified and reinforced, so that the flywheel rotor is used as a first circumferential protective layer for preventing the flywheel rotor from bursting and flying out;

referring to fig. 8 and 9, concentric circular flanges are formed on the outer surfaces of the upper and lower end caps near the center for winding the filament carbon fiber composite material as a second radial protection layer for preventing the rotor from bursting.

The winding method comprises the following steps: the outer surface of the flywheel rotor sub-assembly is wound by using a long-filament carbon fiber epoxy resin composite material along the arc of the edge corner of the upper end cover 10 and the lower end cover 9 to a chord direction which is approximately tangential to the flange in the middle of the outer surface of the upper end cover 10 and the lower end cover 9, the winding is continuously wound to the other arc on the edge of the upper end cover 10 and the lower end cover 9 along the new chord direction by about 120 degrees after encountering the flange, the winding is then turned to the axial direction again until the arc of the edge of the other end cover is encountered, and the winding is continuously wound to the chord direction which is approximately tangential to the flange in the middle of the outer surface of the other end cover along the different new chord directions; the two surfaces of the upper end cover and the lower end cover are circularly operated repeatedly, and the whole flywheel rotor subassembly is completely coated except the outer surface of the flange and is solidified and reinforced after reaching a uniform thickness of about 1-3mm, so that a second radial and axial reinforcing protective layer for preventing the flywheel rotor main body 7 from bursting and flying out is formed. The numbers, sequences and arrows on the lines in fig. 8, 9 schematically indicate the sequence, position and direction of filament carbon fiber winding; the solid line indicates the position of carbon fiber wire wrapping on the visible side of the end cap and the dotted line indicates the position of carbon fiber wire wrapping on the invisible side of the back end cap.

The two protective layers form a double anti-burst fly-out protective reinforcement for the inner circumferential layer 27, the outer radial, axial layer 37 of the flywheel rotor component.

The overall dynamic balance accuracy of the flywheel rotor subassembly along with the motor rotor components should be of the order G0.4-G1.0.

The motor/generator subassembly of the embodiment shown in fig. 1 is a 3-phase permanent magnet brushless motor with an outer rotor radial field structure, and the windings are wye-connected.

The motor is a high-power input-output type motor which is made of short-time operation, and the maximum output power of the motor is 5-21 times of the rated power of the flywheel power battery during continuous operation; its maximum continuous working time is usually not more than 41s.

The motor/generator stator core 22 of the embodiment of fig. 10 has a slot number z=9 and a rotor pole number 2p=6, whereas the stator core 22 of the other embodiment of fig. 11 has a slot number z=6 and a rotor pole number 2p=4. Since the electromagnetic topology of the slot pole number is a fractional slot concentrated winding structure, the shortest coil circumference and end length can be obtained, and the copper loss (impedance loss) is small. Because the number of the magnetic poles of the rotor is small, the frequency of magnetic force lines of the stator and the winding is low when the magnetic poles cut the stator and the winding during rotation, so that the iron loss is low and the motor efficiency is high.

Referring to fig. 1, a magnetic steel drum 31 of a motor rotor part is shown as 10 ^# Steel is used as the yoke. The magnetic steel cylinder 31 is pressed or cast into the flywheel rotor upper end cap 10The fixed rotor support 30 is in the cavity.

Referring to fig. 1, 10 and 11, the magnetic steel 32 of the motor rotor is made of high-temperature-resistant grade neodymium iron boron NdFeB, such as N35UH or N40UH, and consists of a plurality of magnets. Permanent magnet steel 32 is arranged and glued on the inner surface of rotor magnetic steel cylinder 31, and the magnetic steel structure is of NS arrangement with alternating polarity, and radial magnetization or parallel magnetization can be adopted. .

Referring to fig. 1, 10 and 11, the magnetic steel 32 of the motor rotor is made of high-temperature-resistant grade neodymium iron boron NdFeB, such as N35UH or N40UH, and consists of a plurality of magnets. Permanent magnet steel 32 is arranged and glued on the inner surface of rotor magnetic steel cylinder 31, and the magnetic steel structure is of NS arrangement with alternating polarity, and radial magnetization or parallel magnetization can be adopted.

The motor stator core is manufactured by punching, stacking, buckling and riveting high-frequency low-loss silicon steel sheets with the thickness of 0.2 and then compacting. The brand of the silicon steel sheet is 20JNEH1200. The motor stator core 22 and the winding members are positioned by the key 42 and pressed and fixed to the outer circumference of the center post 21 of the bottom plate of the housing 1.

The motor stator winding 23 is a single on-tooth winding. In order to reduce the increase of loss caused by the high-frequency skin effect, a flat oxygen-free copper belt with a Polyimide (PI) insulating layer is wound in a single sheet or a plurality of layers, the lead connection between adjacent slot windings is lap welding, and insulating treatment is coated after welding. The thickness of the flat oxygen-free copper strip can be 0.3-0.7mm.

The lead-out wires 33 of the motor stator winding 23 and the lead-out wires of the rotor position sensor (which are positioned at the outer edge of the stator core and are not shown in the conventional technology) are led out from openings at proper positions at the lower part of the bottom plate of the housing 1.

The center post component is positioned in the center of the bottom plate of the housing 1 and secured with a fastener screw and serves as the basis for the positioning and installation of the flywheel rotor subassembly and motor/generator subassembly.

The center post 21 is hollow. The central shaft 19 is fitted into the hollow portion of the central column 21 via the main bearings 20, 25 and the wave washer 24 and is axially positioned on the central column 21, thereby rotatably supporting the flywheel rotor subassembly by the central shaft 19. The main bearing 25 is locked and fixed at the lower end of the central shaft 19 by a small lock nut 26 and a spring washer. The main bearing 20 is integrally locked and fixed with the flywheel rotor subassembly at the upper end by a large lock nut 17 and a wave-shaped elastic washer 18.

The central shaft 19 is a stepped shaft, and the material of the stepped shaft is medium carbon alloy steel, such as 35CrMo,38CrMoAl,40Cr, 40CrNiMoA, etc. The fit between the central bore of the flywheel rotor subassembly upper end cap 10 and the shaft 19 is a keyless interference press fit.

The main bearings 20, 25 are stainless steel inner and outer rings of silicon nitride (Si ₃ N ₄ ) Ceramic angular contact composite bearings. Ceramic bearings can generally operate in a range of speeds below 75,000r/min, but are dependent on their speed characteristics D _m n value (D) _m The pitch diameter of the bearing is mm; n is working rotation speed, r/min), lubricating grease, D _m n＝(2-3)x10 ⁶ mm.r/min。

The small hole in the center of the upper end cover 10 of the flywheel rotor subassembly is pressed into the upper end of the central shaft 19 and is pressed on the inner ring of the bearing 20, and then is pressed by the large locking nut 17 through the wave-shaped elastic washer 18, so that the axial positioning and fixing of the flywheel rotor subassembly are completed. The lower end of the central shaft 19 is then spring-washer-pressed against the inner ring of the lower main bearing 25 by means of a small lock nut 26 to complete the rotatable fixation on the central column 21.

The shell 1 and the end cover 6 are also made of high-strength metal material aluminum alloy, the outside of the cylindrical wall of the end cover 6 with the reinforcing rib shell 1 is wound with a carbon fiber epoxy resin composite material thin layer 27 for reinforcement, the thickness of the carbon fiber layer is 3mm, and the carbon fiber layer is used as a fourth circumferential protection layer for preventing the rotor from bursting and flying out. The inner bottom surfaces of the end cover 6 and the shell 1 are additionally paved with high-toughness alloy steel or stainless steel plates as protective plates 34, and carbon fiber cloth 35 is glued outside the plates as an axial reinforcing protective layer. Optional carbon fibers such as: t300, T700, T800, etc.

The protection and energy absorption ring part 2-5 is pressed into the shell 1, the outer ring 2 is a high-toughness steel cylinder, and the inner ring 5 is a thin-wall cylinder made of non-high-toughness engineering plastics; the inner ring and the outer ring are separated by an energy absorption layer 4 formed by a short shaft pin 3 or a screw extending part, and the protection and energy absorption ring part is used as a third protection layer for preventing the flywheel rotor from bursting and flying out and absorbing energy of flying high-energy fragments.

Formation of the energy absorbing layer 4: the outer annular wall of the outer ring 2 is uniformly provided with a certain number of step through holes along the radial direction and the axial direction, a short step-shaped shaft pin 3 is pressed in the holes, or threads are tapped in the through holes of the annular wall, a spring cushion is added, and then a short screw is screwed in, or a loose-proof anaerobic adhesive is coated at the threaded connection part to prevent the loose of the short step-shaped shaft pin. Each stub pin 3 or screw is of annealed steel and protrudes a certain length from the inner surface of the outer ring-forming an array. The stud pin 3 or the protruding part of the screw may be bent and deformed when being impacted by a strong force. The outer diameter of the cylinder of the inner ring 5 is substantially the same as the diameter of the inscribed circle formed by the protruding heads of the respective stub pins 3 or screws, so that the inner and outer rings 5, 2 remain concentric.

The two ends of the outer ring 2 and the inner ring 5 can be fixed into a whole by end cover sealing heads. The voids within the energy absorbing layer 4 may also be filled with an energy absorbing material, such as a smart crash barrier gel.

The protection and energy absorbing ring member of the present device absorbs energy mainly in the form of bending deformation of the stud pin 3 or screw extension structure. The burst fragments of the flywheel rotor collide with the energy absorption short shaft pin 3 or the screw after flying out, most of the kinetic energy of the burst fragments is quickly converted into bending deformation energy, and the small part of the kinetic energy is dissipated in other energy forms such as acoustic energy, heat energy and the like.

The material of the outer ring 2 of the protection and energy absorption protection ring is a high-toughness steel material, such as 40Cr; the material of the short shaft pin or the screw can be A3 or 20 in an annealed state ^# -45 ^# Steel; the inner cylinder is made of general engineering plastics such as PS, non-high impact ABS; the shield and energy absorbing ring member acts as a third radial shield against rotor burst fragments from flying out.

Referring to fig. 3-6, two flywheel rotor assemblies (00, or 01 and 02) are mounted in respective housings 1. The pair of flywheel rotor components 00 or 01 and 02 with almost identical structures, shapes, sizes, materials, manufacturing processes and functions are arranged along the mirror symmetry of the bottom surface A of the shell 1, the axial center line is concentrically arranged, the two components are kept accurately concentric by positioning through a part or full-circular positioning key 28, a pin and the like, and the two components are connected, fixed and combined together through fasteners such as screws, rubber sealing parts and the like, so that the concentric reverse double flywheel electromechanical device which is integrally sealed, mirror symmetry and concentricity, compact in structure, electromechanical integration structure, easy to install and has high-power energy storage and physical battery and reaction flywheel (RW) large-moment attitude control function actuator is formed.

When the two flywheel rotor subassemblies 00 or 01 and 02 are combined with the shell 1, the contact surface or the groove at the spigot of the end face A is sealed by O-shaped rubber sealing rings or filling sealing silicone rubber (not shown). After the assembly and the initial measurement are completed, helium or hydrogen can be filled into the shell of the device, and the pressure is about 1 atmosphere (atm) slightly higher than the ambient pressure; when helium is filled, about 11% nitrogen may be mixed.

The device works in time to complete its function conversion: in normal operation, the assembly is placed in a flywheel power battery mode; when the attitude control function is started, stopping the working mode of the flywheel power battery;

external other matching system architecture profiles: the lithium ion power battery pack is used for guaranteeing the range length requirement of low-speed uniform-speed running. In addition, a super capacitor module which is basically the same as the energy storage energy of the device and a DC-DC charging boosting current limiting circuit can be additionally arranged, so that the charging buffer of the battery can be realized in a short time.

When the electromechanical device is used as a flywheel power battery function, the two flywheel rotor subassemblies are firstly charged to the highest rotating speed, so that short-time high-power electric energy is provided for a driving motor and a control system of the vehicle through rapid discharge when the vehicle starts, accelerates or climbs a slope and other high loads. When the rotating speed of the flywheel rotor sub-assembly reaches the highest rotating speed, stopping charging the two flywheel rotor sub-assemblies; when the speed of rotation of the two flywheel rotor subassemblies is detected to drop to a certain proportion, for example-10%, it can be recharged with an external power source to remain in the vicinity of the highest speed.

When the vehicle is decelerating, sliding, descending and braking, the vehicle is charged, the inertial kinetic energy of the vehicle body can be efficiently recovered through the electric energy reversely converted by the driving motor/generator and the like of the vehicle body, and the short-time high-current charging energy storage which can be converted into the output of the generator by the driving motor is realized during emergency braking: the charging and discharging are carried out by a reversible DC-DC buck-boost converter and a flywheel motor controller outside the electromechanical device, and the rotating speeds of the two flywheels are synchronous and rise and fall at the same speed, so that the gyroscopic moment effect is completely counteracted.

When the electromechanical device is used as a gesture control function, the electromechanical device works in a reaction flywheel (RW) mode: the two flywheels can be preset to 1/2 of the highest rotating speed; when receiving the applied reaction force moment signal, the device synchronously operates at a given and absolute equal angle and deceleration in a given direction, namely inversely increasing and decreasing the rotating speed, so that the total output generated by the device in the given direction is equal to the reaction moment of 2 times of a single flywheel rotor assembly.

In the first embodiment of the device, main parameters are as follows: flywheel rotor main body outer diameter phi 245mm, thickness 52, equivalent density of flywheel rotor after inserting 18 diameter phi 25mm tungsten alloy bars: ρ=11.22 g/cm ³ This is almost the same as the density of lead, increasing the material density by 44% compared to an all steel rotor. The total moment of inertia of the concentric inverted dual flywheel device is: 0.35kg m ² When the maximum rotation speed of the rotor is 15000r/min, the maximum energy storage E=228 Wh of the double rotors. The device has the following volume: 20L and 110kw peak power can meet the power enhancement requirement of most cars and realize the anti-rollover safety function. The whole can realize the invention aims of high safety, low cost, small volume, high performance and easy installation.

Embodiment two: the main body 7 of the flywheel rotor is made of high-strength and high-toughness cold-rolled alloy steel sheets by punching, and is integrated by stacking, buckling, riveting and pressing or bonding by adhesives such as epoxy resin; the concentric small round holes punched uniformly on the circumference are riveted by penetrating rivets 43 through the upper end cover 10 and the lower end cover 9 of the flywheel rotor or are firmly integrated with the upper end cover and the lower end cover by fasteners. The thickness of the thin plates can be 0.8-1.2mm, and the overlapped buckles among the thin plates are round rivets without material breakage and larger stress concentration. The other structures, parameters and features are the same as those of the first embodiment, and the implementation effects are the same. But because the structure is a thin plate, in case the rotor bursts, fragments can fly out in small pieces with low kinetic energy, and the safety is better.

The related content which is not described in the above mode can be realized by taking or referencing the existing technology. The foregoing description is only a part of a specific embodiment of the invention and is in no way limiting.

It is necessary to explain that: such or other readily variable modifications, such as equivalents, or obvious variations thereof, may be made by those skilled in the art in light of the present disclosure. Any modification, equivalent replacement, improvement, etc. made within the principle of the present invention should be included in the protection scope of the present invention.

Claims

1. An energy-storage attitude-control dual-purpose concentric-inversion double-flywheel electromechanical device is composed of a pair of flywheel rotor components, and is characterized in that:

a pair of identical (45 and 45) or nearly identical flywheel rotor assemblies (46 and 47) mirror-image side-to-side or up-and-down symmetric along the bottom surface A of the housing (1) and concentric with the center line; the two components are mutually connected into a whole by a flange (44) at the lower edge of the bottom plate of the shell (1), the two components are kept accurately concentric by positioning by a partial circular ring or full circular ring positioning key (28) or a pin, and the two components are connected and fixedly combined together by a fastener and a rubber sealing piece to form a concentric double flywheel electromechanical device with an integral sealing and electromechanical integrated structure;

the two flywheel rotor subassemblies of the two flywheel rotor assemblies (45 and 45, or 46 and 47) are respectively connected and driven by two motor/generator subassemblies with identical structures, parameters and performances, or conversely, the two flywheel rotor subassemblies drive the rotor of the motor/generator subassemblies to rotate;

The motor/generator subassembly of the electromechanical device is a permanent magnet brushless motor, a synchronous motor or a reluctance motor, and is a high-power input-output type reversible motor which works according to short-time intermittent working and is of an outer rotor type or an inner rotor type; the working high rotating speed is not more than 20,000r/min; when the device is used as a flywheel battery, the device can generate absorption or output of short-time and pulse high-power electric energy by rapid charge and discharge of a high-speed flywheel, namely along with rapid change of the angular speed of a flywheel rotor; the torque control device is used for generating short-time high-torque output by using a reaction flywheel (RW) principle that the angle acceleration and deceleration of a flywheel rotor are quickly changed by short-time pulse high-power electric energy during attitude control;

each flywheel rotor assembly includes a flywheel rotor and motor/generator subassembly, a housing and end cap, a guard and energy absorbing ring, a center post member, and a sensor, fastener, seal, and positioning member;

the central hole of the flywheel rotor subassembly is pressed on the central shaft (19) of the central column part in interference fit, and is installed in the shell (1) together with the motor/generator subassembly through the main bearings (20, 25) to form a whole; the stator of the motor/generator subassembly is integrally received within and concentric with the cavity in the center of the flywheel rotor subassembly;

The flywheel rotor sub-assembly comprises flywheel rotor components (7, 8), upper and lower end covers (10, 9), permanent magnet bearing cover components (11, 12), a motor rotor bracket (30), a motor rotor baffle (29), fasteners and rotor protection reinforcing layers (36, 37);

the flywheel rotor main body (7) of the flywheel rotor part is made of high-strength and high-toughness alloy steel or stainless steel, a proper number of holes or concentric grooves are uniformly formed in the position of the inertia radius of the flywheel rotor main body along the circumference, and the holes or grooves are pressed into high-specific-gravity alloy rods (8) or circular rings in an interference fit manner; or the flywheel rotor main body (7) is of a multi-ring structure without grooves: the inner rings are sequentially pressed into the outer rings in sequence by interference fit to form a sandwich structure with 3 rings as a whole, and a high specific gravity alloy ring is arranged in the middle;

the flywheel rotor main body (7) of the flywheel rotor part is clamped by upper and lower end covers (10, 9) in the axial direction, and the joint parts of the inner and outer rims and the upper and lower end covers (10, 9) are in interference press fit; the two sides of the cylindrical surface are connected with the upper end covers (10) and the lower end covers (9) at the two ends by rivets (43) or other fasteners and are fixed into a firm whole;

after the components of the flywheel rotor subassembly are firmly connected, the whole hollow structure of the bell-jar inverted U shape is formed, and the functions of the spoke and the hub are externalized, wherein the hollow structure is hollow without the spoke: the upper end cover (10) has the functions of a hub and a spoke, and after being pressed at the step of the central hole and the central shaft (19), the upper end cover is pressed and fixed by a large locking nut (17) and a wave spring washer (16); the center of the lower end cover (9) is only provided with a big hole; the hollow portion of the flywheel rotor subassembly for receiving and housing the motor/generator subassembly;

When the motor/generator subassembly is of an outer rotor type, the upper end cover (10) is concentrically connected and fixed with the rotor bracket (30) near the center through a fastener; the rotor parts (31, 32) of the motor are pressed or cast into the inner holes of the rotor bracket (30) in an interference fit; a motor rotor baffle (29) is fixed below the motor rotor bracket (30) by a fastener and is used for supporting or limiting the axial movement of rotor components (31, 32) of the motor; when the flywheel rotor subassembly and the motor/generator subassembly are assembled, the rotor and stator components of the motor are aligned with each other by axial center lines and have gaps between the radial directions;

the flywheel rotor subassembly is driven to rotate by the motor/generator subassembly, the internal-external diameter ratio of the flywheel rotor main body (7) is more than or equal to 0.6, the design stress safety coefficient is more than or equal to 2, and the highest linear speed at the outer rim of the flywheel rotor main body (7) is not more than 240m/s; the dynamic balance precision of the flywheel rotor or the rotor component of the motor is G0.4-G1.0 level;

the shell part comprises a shell (1), an end cover (6), bearing cover parts (13-16), protective reinforcing layers (34, 35), an electric connector, a connecting fastener, a sealing piece, an air pumping/charging nozzle and a water cooling pipeline; the bearing cover part comprises a bearing cover (14), a protective bearing (16), a wave-shaped elastic washer (15), a spring retainer and the other half magnetic ring of the permanent magnet bearing (13);

The protection and energy absorption ring component (2-5) is pressed into the shell (1) and comprises an outer ring (2), an energy absorption layer (4) and an inner ring (5); the outer ring (2) is a high-toughness steel cylinder, and the inner ring (5) is a thin-wall cylinder made of non-high-toughness engineering plastics; the space between the inner ring and the outer ring is an energy absorption layer (4) formed by a short shaft pin (3) or an extension part of a screw, and the protection and energy absorption ring component is used as a third protection layer for preventing the flywheel rotor from bursting and flying out, so that energy can be absorbed to flying-out high-energy fragments;

formation of the energy absorbing layer (4): a certain number of step through holes are uniformly distributed on the outer annular wall of the outer ring (2) along the radial direction and the axial direction, short step shaft pins (3) are pressed in the holes, or threads are tapped in the through holes of the annular wall, a locking spring cushion is added, then a short screw is screwed in, or locking anaerobic adhesive is coated at the connecting part of the locking anaerobic adhesive; each short shaft pin (3) or screw is made of annealed steel and protrudes out of the inner surface of the outer ring for a certain length to form an array, and can be bent and deformed when being impacted by strong force; the outer diameter of the cylinder of the inner ring (5) is basically the same as the diameter of an inscribed circle formed by the extension of the head of each short step-shaped shaft pin (3) or screw, so that the inner ring (5) and the outer ring (2) are basically concentric; the two ends of the inner ring and the outer ring (5, 2) can be fixed into a whole by end cover sealing heads; the energy absorbing layer (4) is filled with an energy absorbing material: intelligent collision protection gel;

The bottom plates of the shells of the two flywheel rotor assemblies are also used as combined mounting flanges (44), and the edges of the two flywheel rotor assemblies are also provided with mounting holes for the assemblies to be connected with the bottom plates or frames of the vehicles and the ships used and the brackets on the keels in a mounting way and be fixed; for the application of large torque, the mounting flange or the mounting flange can be respectively arranged at the outer ends of the end covers (6) of the two flywheel rotor assemblies, and the flanges are additionally manufactured on the two end covers (6) of the electromechanical device and are respectively connected with the bottom plates or the frames of the vehicles and the ships and the brackets on the keels so as to form two-end fixation; the mounting bracket can be fixed on the upper side or the lower side of the bottom plate of the vehicle and the hull, and only half of the height of the device is exposed on the bottom plate after the device is mounted and fixed.

2. The energy storage attitude control dual-purpose concentric reverse rotation double flywheel electromechanical device according to claim 1, characterized in that: the device works in a time-sharing way, and is changed or switched by an external control system to complete the function conversion; during normal operation, the assembly is set into a flywheel power battery operating mode; when the attitude control function is started, the working mode of the flywheel power battery is stopped, and vice versa;

when the electromechanical device is used as a flywheel power battery function, the charging and discharging are performed by a flywheel motor controller and a reversible DC-DC buck-boost converter of the electromechanical device, and the rotating speeds of the two flywheels are synchronously and reversely raised and lowered at the same speed so as to form the charging and discharging without a gyro precession moment effect;

When the electromechanical device is used as a gesture control function, the electromechanical device works in a reaction flywheel (RW) mode: the two flywheel rotor assemblies can be preset to 1/2 of the highest rotation speed; when receiving the torque signal of the applied reaction force, the motor synchronously increases and decreases the rotation speed at a given angle and deceleration in a given direction, namely, in opposite directions; or when both flywheel components are at the lowest rotating speed, the device synchronously runs in a given direction with given angular acceleration and in the same direction in the given direction, and the device is used for generating reaction moment with the total output equal to 2 times of that of a single flywheel rotor component.

3. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the material of the high specific gravity alloy round bar (8) or the round ring pressed on the flywheel rotor main body (7) of the flywheel rotor component is tungsten or tungsten alloy, lead or depleted uranium.

4. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the main body (7) of the flywheel rotor component is made by stamping a high-strength and high-toughness cold-rolled alloy steel sheet, and is integrated by stacking, buckling, riveting and pressing or bonding and curing by an epoxy resin adhesive;

The concentric small round holes punched uniformly on the circumference are riveted or screwed by rivets (43) penetrated by the upper end cover and the lower end cover of the flywheel rotor so as to form a firm whole with the upper end cover and the lower end cover; the thickness of the thin plate is 0.8-1.2mm; the overlapped buckles among the thin plates are round primary-secondary rivets without material rupture and stress concentration.

5. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the upper end cover (10) and the lower end cover (9) of the flywheel rotor component are integrally made of high-strength aluminum alloy, and the edge diameter of the end covers (10, 9) is 5-10mm larger than the diameter of the flywheel rotor main body (7); the upper end cover (10) can also be made into a two-body combined structure, at the moment, the edge part of the upper end cover (10) and the inner diameter and the outer diameter of the lower end cover (9) correspond to each other and can be made of high-toughness alloy steel, and the edge part of the alloy steel end cover (10) and the central part of the aluminum alloy end cover are connected and combined into a whole by interference fit through a fastener;

the outer edges of the upper end cover (10) and the lower end cover (9) are all made into circular arcs, and the radius r of the circular arcs is more than or equal to 5mm; after the flywheel rotor main body (7) is assembled with the end covers (10, 9), the flywheel rotor main body (7) is wound with filament carbon fiber epoxy resin composite materials along the circumferential direction in shallow annular grooves formed on the surfaces of the upper end cover (10, 9) and the outer ring of the flywheel rotor main body (7) until the grooves are just filled or slightly higher than 0.5mm, and the grooves are solidified and reinforced, so that the flywheel rotor is used as a circumferential first protective layer for preventing the flywheel rotor from bursting and flying out;

Then, winding the outer surface of the flywheel rotor sub-assembly in the chord-wise direction tangential to the flanges in the middle of the outer surfaces of the upper end cover (10) and the lower end cover (9) along the arc corner of the edge corner of the end cover (10, 9) by using a filament carbon fiber epoxy resin composite material; after encountering the flange, the steering wheel is continuously turned for 120 degrees and is directly wound to the other arc corner on the edges of the upper end cover (10) and the lower end cover (9) along the new chord direction; then winding turns to be along the axial direction again until the arc corner of the upper edge of the other end cover is encountered, and winding and turning are continued to be carried out on the surface of the other end cover along different new chords to the chord-wise outward direction tangential to the flange in the middle of the outer surface of the end cover; the method is repeated, the two sides of the end cover are circularly operated, the outer surface of the flange is completely coated by the whole flywheel rotor subassembly, and the thickness is uniform and is about 1-3mm, and then the flywheel rotor subassembly is solidified and reinforced, so that a radial and axial reinforced second protective layer for preventing the flywheel rotor main body (7) from bursting and flying out is formed;

pretension is always applied to the winding of the 2 protective layers by the filament carbon fiber epoxy resin composite material; the two protective layers form a dual protection reinforcement against burst-out of the flywheel rotor part in the inner circumferential and outer radial directions.

6. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the bearings used by the device comprise main bearings (20, 25), protective bearings (16) and permanent magnet bearing pairs (12, 13); the main bearings (20, 25) are composite angular contact bearings of small-diameter silicon nitride ceramic dense beads and stainless steel inner and outer rings; for the use or doubling in the occasion of frequent severe jolting, namely double bearings are symmetrically used in pairs back to back; or a protective bearing (16) is added to increase the safety: the protection bearing (16) is a ball bearing which has an inner ring and an outer ring with larger diameter and width than the main bearings (20, 25) and can bear larger load; the main bearings (20, 25) and the protection bearing (16) are both grease lubricated; a gap of 0.08-0.11mm can be reserved between the outer diameter of the protection bearing (16) and the inner diameter of the bearing hole of the permanent magnet/protection bearing cover (14);

the permanent magnet bearing used in the device mainly reduces the load of the main bearing and prolongs the service life;

when the flywheel rotor assembly of the device works vertically, the permanent magnet bearing pair (12, 13) of the upper flywheel rotor assembly is a tension magnetic bearing with opposite faces having different magnetic polarities and attracting each other; the pairs of permanent magnet bearings (12, 13) when used as the lower flywheel rotor assembly then become thrust magnetic bearings of the same opposite magnetic polarity, repulsive; the permanent magnet bearing pairs (12, 13) can be permanent magnet concentric rings with the same shape and size and opposite axial directions; when the upper tension bearing is made, 1/2 of the permanent magnet bearing pair (12, 13) namely one ring can be replaced by soft ferromagnetic materials;

When the flywheel rotor assembly of the device works horizontally, the permanent magnet bearing can be a pair of permanent magnet rings with different diameters, the outer diameter of the small ring is smaller than the inner diameter of the large ring, the outer surface of the small ring and the inner surface of the large ring are homopolar and a gap is reserved between the small ring and the large ring, and the small ring is a concentric thrust permanent magnet bearing; the permanent magnet bearing pair may be dispensed with when the weight of the rotor subassembly relative to the allowable load of the main bearings (20, 25) is such that the service life defined by the bearing standard is met.

7. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the motor/generator subassembly includes rotor components (31, 32), stator component cores and windings (22, 23), position sensors and leads, terminals; when the device is used as a flywheel power battery, the maximum peak power of the motor/generator subassembly is 5-21 times of rated power during continuous operation; the longest continuous working time is not more than 41s;

when the motor/generator subassembly is a permanent magnet brushless motor or a synchronous motor, the motor/generator subassembly is a three-phase Y-connection, and the magnetic field is a radial magnetic field;

when the motor/generator subassembly is of the outer rotor type, its motor stator parts (22, 23) are fixed to the outer circle of the central column (21) of the housing base plate with a key or interference fit; the stator iron core (22) is punched, buckled, riveted and pressed by high-permeability high-frequency low-loss silicon steel sheets with the thickness of 0.2-0.35 mm; or an iron core pressed by integral SMC (Soft Magnetic Composite) powder metallurgy, or is wound and manufactured by an amorphous iron core, or can also be of a coreless structure;

The rotor parts (31, 32) of the motor are then mounted on a rotor support (30) of the flywheel-rotor subassembly: the magnetic steel cylinder (31) of the rotor component is used as a magnetic yoke, and the rotor permanent magnetic steel (32) is arranged, sucked and glued on the inner circular surface of the magnetic steel cylinder (namely the rotor magnetic yoke); the rotor magnet steel (32) may also be of the insert type: in this case, the magnetic steel cylinder magnetic yoke and the stator core (22) can be made of silicon steel sheets in a superposition way, but each magnetic pole is formed by two pieces of homopolar magnetic steel arranged in a V shape, and air magnetism isolating bridges are arranged at the two ends of each magnetic steel on the magnetic yoke so as to reduce magnetic leakage;

the magnetic steel (32) of the rotor is made of high-temperature resistant neodymium iron boron or samarium cobalt; when a small number of poles is used: 2 p=2, 4, or using Halbach array magnetizing structures;

the electromagnetic topology of the pole number of the motor is a fractional slot concentrated winding, the tooth slot number Z is Z=3i, i=2, 3, … 6, and the magnetic pole number 2P is 2P=2j, j=1, 2, …; the combination Z/2p of the slot pole numbers is Z/2p=3/2, 6/4, 6/8, 9/6, 9/8, 9/10, 12/4, 12/8, 12/10, 18/4;

the stator winding (23) is of a structure with a single winding on each stator tooth, and is formed by winding a single sheet or a plurality of sheets of flat oxygen-free copper strips with Polyimide (PI) insulating layers in a multi-layer and stacked manner, or by winding a plurality of thin insulating enamelled round copper wires (litz wires) in parallel, wherein the thickness of the flat oxygen-free copper strips is preferably 0.3-0.7mm; when a flat oxygen-free copper belt is adopted as a winding (23), the connection between adjacent slot windings is lap welding, and insulation treatment is carried out after the connection; the outgoing line (33) of the motor winding and the outgoing line of the rotor position sensor are led out at a proper position of the lower part of the bottom plate of the shell (1);

When the motor/generator subassembly is of the inner rotor type, then the motor stator and rotor components are all disposed concentrically within the center post component;

when the motor/generator subassembly is of the outer rotor type, its motor stator components are all concentrically disposed outside the center post component; the central column part comprises a central column (21), a central shaft (19), main bearings (20, 25), large and small locking nuts (17, 26) and wave-shaped elastic washers (18, 24), and is positioned, installed in the center of a bottom plate inside the shell (1) and fixed by a fastener.

8. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the shell (1) and the end cover (6) are made of alloy steel or aluminum alloy of metal materials;

the outer part of the cylinder wall of the shell can be applied with a prestress winding filament carbon fiber epoxy resin composite material thin layer for re-reinforcement, and the thickness can be 3-8mm, so that a fourth radial protective layer for preventing the flywheel rotor from bursting and flying out is formed;

when the shell (1) and the end cover (6) are made of high-strength aluminum alloy, high-toughness alloy steel or stainless steel thin plates are paved on the inner surfaces of the shell (1) and the end cover (6) as protective plates (34), carbon fiber cloth is glued outside the plates, and the combination is used as an axial reinforcing protective layer (35) for preventing the flywheel rotor from bursting out;

When the output torque is large, the outer surfaces of the end covers (6) at the two ends of the device shell can be also provided with reinforcing ribs;

when the electromechanical device is only specially used as a flywheel power battery, two rotor shafts can be arranged perpendicular to the ground of a vehicle and ship bottom plate or parallel to the ground of the bottom plate, and the rotation speed and linkage control of the electromechanical device can be adjusted by 2 motor controllers outside the electromechanical device so as to enable the electromechanical device to synchronously and reversely rotate at the same rotation speed;

when the local electrical device is dedicated or is used as the attitude control: in order to prevent the vehicle body from turning over and the hull from rolling, or to keep the front and rear two-wheel vehicle to realize the vertical self-balance, the rotor central shafts (19) of the two flywheels can be horizontally arranged along the central longitudinal axis direction of the vehicle and the hull, and the angular acceleration or the angular deceleration of the two-wheel vehicle can be respectively and synchronously regulated and controlled by 2 motor controllers outside the device so as to form the reaction flywheel control torque in the required direction.

9. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the shells (1) of the two flywheel rotor assemblies are combined and connected to form a full-sealing structure, and O-shaped sealing rings or sealing silicon rubber is filled in grooves at the contact surfaces or the rabbets of the end surfaces;

After the assembly and the initial measurement are completed, helium or hydrogen can be filled in the shell (1), and the gas pressure is about 1 atmosphere (atm) slightly higher than the ambient pressure; when helium is filled, about 11% nitrogen may be mixed.

10. The dual-purpose concentric reverse rotation dual-flywheel electromechanical device for energy storage and attitude control according to claim 1, wherein: the sensor comprises a motor rotor rotating speed and a position sensor; an inclination angle or multiaxial micromechanical acceleration/gyroscopic sensor, an acoustic emission sensor for detecting operation vibration noise, a vibration sensor, an eddy current sensor for detecting the position/displacement of a flywheel rotor, and a temperature sensor for detecting the temperature of a bearing and a motor stator; each sensor is positioned at an appropriate location of the assembly; however, when the vehicle and the ship have the same function and the sensors are suitable, the same sensors or the output signals thereof are utilized as much as possible so as to reduce the types or the quantity of the sensors which are required to be equipped by the self-electric device as much as possible;

safety control of faults or anomalies of the device: the device is mainly triggered by acoustic emission and vibration/displacement sensor signals arranged on a shell (1), and once the sensor detects that abnormal high decibel impact sound or displacement occurs in the sensor, a flywheel rotor is rapidly decelerated and a power supply is cut off through an external central control unit of the device, and power supply to a motor/generator is stopped.