High Speed flywheel and test rig design for rural energy storage

There is considerable growth in the renewable energy sector to contribute to sustainable development, environmental conservation and most importantly to provide affordable energy to isolated rural communities of sub-Saharan Africa. Renewable energy sources such as solar and wind require energy storage since the source of energy is intermittent. Electrochemical batteries especially from lead acid are commonly used to store energy in Solar Home Systems (SHS) for rural electrification in sub-Saharan Africa. Disadvantages such as low efficiencies, low life cycle costs, high maintenance, comparatively short life and serious environmental and human toxicity effects exist. Since recycling is not widespread, replacement costs are high, as are the resultant environmental damage and health hazards from lead and sulphuric acid. In this thesis, an electromechanical flywheel energy storage device is proposed as an alternative to a lead acid battery in order to increase efficiency, life expectancy, increased high depth of discharge, low life cycle cost and elimination of adverse environmental effects. Due to income and service skill constraints in rural areas, the proposed, high speed flywheel systems (for long time energy storage) will require the use of low cost configurations and topologies, special considerations on the flywheel rotor profile design, robust electrical machines, simple power electronics and a low cost bearing set. Low loss magnetic bearings are also possible but were limited by time while also making their maintenance complex especially in rural areas. Conventional high strength composite materials used in flywheel rotor manufacture for high speed operation are expensive. Therefore there is a need to develop techniques to profile the rotor shape so as to improve on material usage and exhibit lower mechanical stresses. A robust electrical machine topology for high speed operation and a simple drive system are investigated to ensure simple assembly, low cost and low maintenance. vii The various flywheel components were designed using analytical and numerical methods. Two techniques were used to develop two optimal profiles for the flywheel rotor structure. Partial differential equations and analytical solutions were employed to develop the profiles. Analytical equations were used to design the electrical machine, drive, bearing system and other accessories. The final electromechanical battery prototype consisted of a composite flywheel rotor made from E-glass fibre materials, double rotor Axial Flux Permanent Magnet (AFPM) machine and a drive system using Brushless DC (BLDC) mode of operation. The system was designed for 300Wh of energy storage for the delivery of 100W and 500W of power and an operating speed range of 8,000 rpm-25,000 rpm. The design and development of the flywheel energy storage system and test rig using locally available materials was investigated. Experiments were conducted for speeds up to 6,000 rpm. The electromechanical battery was able to store a maximum of 77Wh of energy. The shortfall of the system to meet its design specifications was investigated and found to have been caused by vibrations resulting from prototyping issues. A thermal model was developed to predict the temperature rise in the system which showed a good correlation with the experimental results

Resilient and Real-time Control for the Optimum Management of Hybrid Energy Storage Systems with Distributed Dynamic Demands

A continuous increase in demands from the utility grid and traction applications have steered public attention toward the integration of energy storage (ES) and hybrid ES (HESS) solutions. Modern technologies are no longer limited to batteries, but can include supercapacitors (SC) and flywheel electromechanical ES well. However, insufficient control and algorithms to monitor these devices can result in a wide range of operational issues. A modern day control platform must have a deep understanding of the source. In this dissertation, specialized modular Energy Storage Management Controllers (ESMC) were developed to interface with a variety of ES devices. The EMSC provides the capability to individually monitor and control a wide range of different ES, enabling the extraction of an ES module within a series array to charge or conduct maintenance, while remaining storage can still function to serve a demand. Enhancements and testing of the ESMC are explored in not only interfacing of multiple ES and HESS, but also as a platform to improve management algorithms. There is an imperative need to provide a bridge between the depth of the electrochemical physics of the battery and the power engineering sector, a feat which was accomplished over the course of this work. First, the ESMC was tested on a lead acid battery array to verify its capabilities. Next, physics-based models of lead acid and lithium ion batteries lead to the improvement of both online battery management and established multiple metrics to assess their lifetime, or state of health. Three unique HESS were then tested and evaluated for different applications and purposes. First, a hybrid battery and SC HESS was designed and tested for shipboard power systems. Next, a lithium ion battery and SC HESS was utilized for an electric vehicle application, with the goal to reduce cycling on the battery. Finally, a lead acid battery and flywheel ES HESS was analyzed for how the inclusion of a battery can provide a dramatic improvement in the power quality versus flywheel ES alone

Digital Control of Power Converters and Drives for Hybrid Traction and Wireless Charging

In the last years environmental issues and constant increase of fuel and energy cost have been incentivizing the development of low emission and high efficiency systems, either in traction field or in distributed generation systems from renewable energy sources. In the automotive industry, alternative solutions to the standard internal combustion engine (ICE) adopted in the conventional vehicles have been developed, i.e. fuel cell electric vehicles (FCEVs), hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEV) or pure electric vehicles (EVs), also referred as battery powered electric vehicles (BEV). Both academic and industry researchers all over the world are still facing several technical development areas concerning HEV components, system topologies, power converters and control strategies. Efficiency, lifetime, stability and volume issues have moved the attention on a number of bidirectional conversion solutions, both for the energy transfer to/from the storage element and to/from the electric machine side. Moreover, along with the fast growing interest in EVs and PHEVs, wireless charging, as a new way of charging batteries, has drawn the attention of researchers, car manufacturers, and customers recently. Compared to conductive power transfer (usually plug-in), wireless power transfer (WPT) is more convenient, weather proof, and electric shock protected. However, there is still more research work needs to be done to optimize efficiency, cost, increase misalignment tolerance, and reduce size of the WPT chargers. The proposed dissertation describes the work from 2012 to 2014, during the PhD course at the Electric Drives Laboratory of the University of Udine and during my six months visiting scholarship at the University of Michigan in Dearborn. The topics studied are related to power conversion and digital control of converters and drives suitable for hybrid/electric traction, generation from renewable energy sources and wireless charging applications. From the theoretical point of view, multilevel and multiphase DC/AC and DC/DC converters are discussed here, focusing on design issues, optimization (especially from the efficiency point-of-view) and advantages. Some novel modulation algorithms for the neutral-point clamped three-level inverter are presented here as well as a new multiphase proposal for a three-level buck converter. In addition, a new active torque damping technique in order to reduce torque oscillations in internal combustion engines is proposed here. Mainly, two practical implementations are considered in this dissertation, i.e. an original two-stage bi-directional converter for mild hybrid traction and a wireless charger for electric vehicles fast charge

Power delivery mechanisms for asynchronous loads in energy harvesting systems

PhD ThesisFor systems depending on methods, a fundamental contradiction in the power delivery chain has existed between conventional to supply it. DC/DC conversion (e.g.) has therefore been an integral part of such systems to resolve this contradiction. be made tolerant to a much wider range of Vdd variance. This may open up opportunities for much more energy efficient methods of power delivery. performance of different power delivery mechanisms driving both asynchronous and synchronous loads directly from a harvester source bypassing bulky energy method, which employs a energy from a EH circuit depending on load and source conditions, is developed. through comprehensive comparative analysis. Based on the novel CBB power delivery method, an asynchronous controller is circuits to work with tasks. The successful asynchronous control design drives a case study that is meant to explore relations between power path and task path. To deal with different tasks with variable harvested power, systems may have a range of operation conditions and thus dynamically call for CBB or SCC type power set of capacitors to form CBB or SCC is implemented with economic system size. This work presents an unconventional way of designing a compact-size, quick- circuit overcome large voltage variation in EH systems and implement smart power management for harsh EH environment. The power delivery mechanisms (SCC, employed to help asynchronous- logic-based chip testing and micro-scale EH system demonstrations

Critical Aspects of Electric Motor Drive Controllers and Mitigation of Torque Ripple - Review

Electric vehicles (EVs) are playing a vital role in sustainable transportation. It is estimated that by 2030, Battery EVs will become mainstream for passenger car transportation. Even though EVs are gaining interest in sustainable transportation, the future of EV power transmission is facing vital concerns and open research challenges. Considering the case of torque ripple mitigation and improved reliability control techniques in motors, many motor drive control algorithms fail to provide efficient control. To efficiently address this issue, control techniques such as Field Orientation Control (FOC), Direct Torque Control (DTC), Model Predictive Control (MPC), Sliding Mode Control (SMC), and Intelligent Control (IC) techniques are used in the motor drive control algorithms. This literature survey exclusively compares the various advanced control techniques for conventionally used EV motors such as Permanent Magnet Synchronous Motor (PMSM), Brushless Direct Current Motor (BLDC), Switched Reluctance Motor (SRM), and Induction Motors (IM). Furthermore, this paper discusses the EV-motors history, types of EVmotors, EV-motor drives powertrain mathematical modelling, and design procedure of EV-motors. The hardware results have also been compared with different control techniques for BLDC and SRM hub motors. Future direction towards the design of EV by critical selection of motors and their control techniques to minimize the torque ripple and other research opportunities to enhance the performance of EVs are also presented.publishedVersio

Measurements, Models, Systems and Design

531 s.

Reduced-order modeling of power electronics components and systems

This dissertation addresses the seemingly inevitable compromise between modeling fidelity and simulation speed in power electronics. Higher-order effects are considered at the component and system levels. Order-reduction techniques are applied to provide insight into accurate, computationally efficient component-level (via reduced-order physics-based model) and system-level simulations (via multiresolution simulation). Proposed high-order models, verified with hardware measurements, are, in turn, used to verify the accuracy of final reduced-order models for both small- and large-signal excitations. At the component level, dynamic high-fidelity magnetic equivalent circuits are introduced for laminated and solid magnetic cores. Automated linear and nonlinear order-reduction techniques are introduced for linear magnetic systems, saturated systems, systems with relative motion, and multiple-winding systems, to extract the desired essential system dynamics. Finite-element models of magnetic components incorporating relative motion are set forth and then reduced. At the system level, a framework for multiresolution simulation of switching converters is developed. Multiresolution simulation provides an alternative method to analyze power converters by providing an appropriate amount of detail based on the time scale and phenomenon being considered. A detailed full-order converter model is built based upon high-order component models and accurate switching transitions. Efficient order-reduction techniques are used to extract several lower-order models for the desired resolution of the simulation. This simulation framework is extended to higher-order converters, converters with nonlinear elements, and closed-loop systems. The resulting rapid-to-integrate component models and flexible simulation frameworks could form the computational core of future virtual prototyping design and analysis environments for energy processing units