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Journal of Composite Materials
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0021998306061324v1
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Design and Spin Test of a Hybrid Composite Flywheel Rotor with a Split Type Hub

Sung K. Ha

Center of Innovative Design Optimization Technology Department of Mechanical Engineering, Hanyang University #1271, Sa1-dong, Ansan, Kyunggi-do 425-791, Korea;sungha{at}hanyang.ac.kr

Myung H. Kim

Center of Innovative Design Optimization Technology Department of Mechanical Engineering, Hanyang University #1271, Sa1-dong, Ansan, Kyunggi-do 425-791, Korea

Sang C. Han

Tae-Hyun Sung

Power System Laboratory, Korea Electric Power Research Institute #103-16 Munji-dong, Yusong-gu, Taejon, Korea

A study is conducted on lowering the radial tensile stresses and increasing the performance of the fiber wound composite flywheel rotor by applying pressure on the inner surface of the rotor using a split type hub that spreads in the radial direction due to the centrifugal force. A conventional solid or ring type hub in most cases produces tensile stresses within the rotor, possibly causing delamination and eventually lowering the maximum speed of the rotor. The relationship between the stresses of the rotor and the thickness of the hub is derived and applied to the single and hybrid rotors. A hybrid composite rotor of 180 mm inner diameter and 340 mm outer diameter is designed and fabricated, which reaches only the strength ratio of 0.58 at the maximum rotating speed of 40,000 rpm. A spin test was conducted to show the improved performance of the rotor with the split type hub by measuring the mechanical strains from the rotor. The radial and circumferential strains at four different locations are measured up to 30,000 rpm using a wireless telemetry system, and they are in good agreement with the analytical calculations. The rotor has survived a spin test of up to 40,000 rpm, which corresponds to the usable energy of at least 500 W h with the safety factor of 1.7.

Key Words: hybrid composites • flywheel rotor • split hub • spin test • telemetry

This version was published on December 1, 2006

Journal of Composite Materials, Vol. 40, No. 23, 2113-2130 (2006)
DOI: 10.1177/0021998306061324
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This article has been cited by other articles:


Home page
 Journal of Reinforced Plastics and CompositesHome page
S. K. Ha, H. H. Han, and Y. H. Han
Design and Manufacture of a Composite Flywheel Press-Fit Multi-Rim Rotor
Journal of Reinforced Plastics and Composites, June 1, 2008; 27(9): 953 - 965.
[Abstract] [PDF]