复合材料飞轮的设计分析

复合材料具有重量轻，强度高等优点，是储能飞轮的理想材料。文中对复合材料飞轮的储能能力及其影响因素进行分析，并对两种结构复合材料飞轮－单层与多层等厚度圆环飞轮的应力分布与结构设计进行定量分析与比较。飞轮的储能能力受飞轮转子结构及其飞轮材料强度的影响，飞轮转子内外半径比应根据实际应用要求确定，选择高强度低密度的材料可提高飞轮的轮缘线速度，从而提高飞轮的储能能力，等厚度圆环飞轮的应力分布主要受飞轮转子内外半径比和材料物理特性的影响，对于内外半径比一定的层圆环复合材料飞轮，飞轮的环向应力远大于其径向应力。与单层圆环飞轮相比，多层圆环飞轮的应力分布更为均匀，合理，飞轮的储能能力更大。     

混合复合材料飞轮转子成本优化设计

基于平面应力理论,计算多层过盈装配混合纤维增强复合材料飞轮转子的应力分布;指出多层过盈装配复合材料转子多种可能的失效形式;结合增广Lagrange乘子法、粒子群优化(Particle swarm optimization,PSO)算法和经典梯度算法各自的优点,提出可求解非线性约束问题的且具有全局收敛性和较高计算效率的两阶段增广Lagrange粒子群优化算法(Two-stage augmented Lagrange particle swarm optimization,TS-ALPSO);利用TS-ALPSO优化算法,以多层过盈装配混合复合材料转子的分层半径、层间过盈量和转速为设计变量,研究多层混合复合材料转子的成本优化问题;并分析转子材料价格不变时,材料次序、分层数及过盈量对转子储能性能的影响;揭示出转子单位成本储能最大时,转子分层半径、层间过盈量及转速随转子材料价格变化的规律。     

复合材料储能飞轮转子的设计

当转子的最大环向应力和最大径向应力同时达到它们各自方向上的强度时,可以得到最优内外径比.基于该设计理念对影响飞轮储能密度的复合材料轮缘内外径比λ进行设计,并选用各向异性材料碳纤维环氧树脂复合材料、玻璃纤维环氧树脂复合材料及各向同性材料高强铝合金为飞轮转子材料进行最大边缘线速度及最大单位质量储能的比较,结果表明:碳纤维环氧树脂复合材料所设计的飞轮转子单位质量储能最高,体积最小,边缘线速度最大.     

复合材料储能飞轮挠性结构振动的磁轴承控制

储能密度是储能飞轮的重要指标之一,选用碳纤维、玻璃纤维复合材料的储能飞轮可以有效提高储能密度,同时,选用磁悬浮支承则可以适应真空环境及减少损耗。但是,由此也增加了结构的复杂性,例如,连结飞轮转子中金属部件与复合材料之间的挠性薄壳轮毂具有不同于常规刚体飞轮的动力学模型特性。针对薄壳结构的模态振动特征与陀螺效应控制之间的矛盾,描述一种具有挠性结构储能飞轮的磁轴承控制方法。在模态分析的基础上,利用多通道添加相位整形的控制方法有效抑制了系统中的挠性结构的模态振动。试验结果表明,使用所设计的控制器,转子可平稳通过中心频率为340 Hz的轮毂——心轴挠性模态振动区域,运行转速475 Hz(28 500 r/min),轮缘最大线速度达到450 m/s,并成功实现飞轮的充放电过程。     

两层预应力转子结构复合材料储能飞轮的应力及位移计算

采用预应力结构可使复合材料飞轮的应力、位移分布得到一定改善,从而提高飞轮储能密度。考虑复合材料和预应力结构的特点,建立基于各向异性对称结构理论的计算模型,得到两层预应力转子结构复合材料储能飞轮在工作转速情况下应力和位移的解析公式,对内、外两层飞轮任一点的径向、环向应力及径向位移进行较为全面的仿真分析,并利用所建立的计算模型对飞轮在某一转速时不同的位置对径向应力、环向应力和径向位移的影响进行探讨。结果表明,内层转子径向应力在外侧最大,环向应力在内侧最大;外层转子径向应力和环向应力均在内侧最大。当角速度 从0增加到5 000 rad•s−1时,内、外转子的径向应力、环向应力和径向位移都随之增大。当 =600 rad•s−1,整个飞轮径向应力、环向应力和位移的最大值出现在两层转子的接触面r=0.27 m处。该分析结果可为飞轮的设计制造提供重要的参考。     

复合材料飞轮转子设计

考虑到转子与驱动机构的连接,给出了一种金属轮毂加复合材料轮缘结构飞轮转子的设计方法。分析了转子材料、结构、连接及制作工艺等因素对储能密度的影响,分析结果表明:复合材料轮缘内外径比值α是影响其储能密度的关键,根据轮缘材料选取合理值,对轮毂进行优化可以进一步提高转子的储能密度。分析中所用复合材料及胶粘剂力学常数的准确性是影响仿真结果的主要因素,通过实验对其理论值进行修正可以进一步提高仿真结果的准确性。对实际应用中一个具体飞轮转子进行了设计并制作出了转子,在20 000 r/min转速范围内进行了旋转应力实验,仿真分析与实验结果取得了较好的一致性,证明了本文设计方法的正确性。     

基于ANSYS的复合材料飞轮系统模态分析

储能飞轮系统在工程中应用广泛,由于飞轮系统转速较高,因此对飞轮系统进行模态分析是非常必要的。利用有限元分析软件ANSYS对复合材料飞轮系统进行模态分析,得到了飞轮的固有频率与模态振型,为飞轮系统的结构设计与优化以及振动特性研究提供了有效的依据。     

混合动力汽车用超高强度钢材质飞轮电池转子的优化

分析了目前混合动力汽车常用的储能方式的特点及其存在的问题,指出飞轮电池在混合动力汽车中具有良好的前景。通过对比分析认为在20 000 r/min转速下,超高强度钢飞轮转子相比复合材料飞轮转子有较好的综合性优势。建立了超高强度钢飞轮优化设计的数学模型,利用该模型并借助Matlab计算了飞轮基本参数,进一步基于Abaqus有限元分析软件,优化出储能1 kW.h的飞轮转子的机械结构;优化后的结果满足混合动力汽车应用的要求。     

三维编织复合材料高速飞轮的极限转速

通过对三维编织复合材料圆柱型结构进行应力分析，对三维编织复合材料高速飞轮的极限转速进行了理论推导和数值计算。结果表明，在保证强度的前提下，三维编织复合材料飞轮能够达到很高的极限转速，完全能够满足飞轮电池的储能使用要求。     

Design of composite flywheel rotor

A design method for a flywheel rotor composed of a composite rim and a metal hub is proposed by studying the connection between the rotor and the driving machine. The influence of some factors such as the rotor material, configuration, connection, and fracture techniques on energy density is analyzed. The results show that the ratio of the inner radius to outer radius of the rim is the key factor, and is determined by the rim material. Optimizing the hub can further efficiently improve energy density. The composite flywheel rotor is produced and its rotation stress has been tested at the speed of 20 krpm. The emulation results are consistent with testing results, which proves that the introduced design method is useful. __________ Translated from Optics and Precision Engineering, 2007, 15(6): 852–857 [译自: 光学精密工程]     

Flywheel energy storage—I: Basic concepts

The basic concepts of flywheel energy storage systems are described in the first part of a two part paper. General equations for the charging and discharging characteristics of flywheel systems are developed and energy density formulas for flywheel rotors are discussed. It is shown that a suspended pierced disk flywheel is competitive with the super-flywheel designs currently being suggested in the literature.In Part II the details of a magnetically levitated spokeless ring flywheel design are provided.     

600Wh飞轮转子形状优化设计

介绍了极限转速为15000r/min,储能量为600wh的空心飞轮转子的优化设计方法,根据飞轮储能系统设计要求利用三维软件SolidWorks对飞轮模型进行建模与有限元软件ansys workbench进行仿真分析与优化,首先进行初步建模,然后通过改变其模型轮辐曲线找到更优的飞轮形状并提取其轮辐曲线的结构参数,再通过多目标遗传算法对飞轮转子进行优化设计及研究,以飞轮质量更轻,极转动惯量更大以及应力应变更小为约束条件,提取其飞轮结构几何尺寸为设计变量进行优化,得出一种更优的飞轮结构形式。结果表明,优化后得到的飞轮转子形状较原模型相比性能更佳。     

Finite element analysis of thermal stresses in functionally gradient layered composites

A new composite material has been introduced which has a great potential satisfying successfully the desired functions under severe thermal circumstances. Because of the sharp material discontinuity at the interfaces between different material layers in classical layered composites, thermal and mechanical stress concentration may exist at such interfaces, and which results in undesired failure. The functionally gradient material (FGM), a new concept for future-oriented composite material, has a continuously varying material variation through the thickness of layered composites. And, hence, it can eliminate the defect occurred in classical layered composites. The purpose of this study is to develop a technique for finite element analysis of the thermal characteristics of FGMs, and to investigate the effects of significant governing parameters, a variation function of material composition and a relative thickness of FGM layer inserted between metal and ceramic layers. Through numerous numerical simulations carried out with the developed FEM program, we investigated the thermal characteristics for different concerning parameters. Considerable improvement and parametric dependence on temperature and thermal stress distributions are obtained.     

功能梯度材料飞轮转子优化设计

功能梯度材料(Functionally graded materials,FGMs)是一种材料属性在空间位置上连续变化的新型材料。与均匀材料相比,高速储能飞轮转子采用FGMs可以有效地减少应力集中,充分发挥材料性能,从而改善转子的工作性能。针对飞轮转子轴向厚度相对较厚时平面应力方法误差较大的问题,通过将转子离散为有限个等厚匀质微环的方法,推得变厚度FGMs飞轮转子的三维半解析解——修正平面应力(Modified plane stress,MPS)解,并采用有限元法验证其精确性。应用序列二次规划(Sequential quadratic programming,SQP)优化方法,以飞轮转子的厚度、材料体积分数和转速为设计变量,以最大化转子的储能密度为目标函数,对FGMs飞轮转子的形状和材料分布进行优化设计,并分析材料性能参数对结果的影响。计算结果表明,合理的转子形状与材料分布可以使转子应力分布更加均匀,大大提高飞轮的储能性能。     

变惯量高效微型飞轮的理论与综合

与传统飞轮不同的变惯量飞轮不与机器的主轴固联,这样变速运动的飞轮折算到主轴的等效惯量不是常数,其动能也不是常数。利用变惯量飞轮的动能波动来抵消原机器中惯性和载荷对机器平稳运转的不利影响,从而平稳机器主轴的角速度波动。在起到同样的平稳效果时,变惯量飞轮的惯量比传统的飞轮小许多。给出了变惯量飞轮的原理以及变惯量飞轮的二种结构型,并相应给出二个计算实例。     

飞轮端盖强度的弹塑性设计计算

储能飞轮提高储能密度的关键是提高飞轮转子的线速度 ,为了充分利用端盖材料高强度铝合金的性能 ,强度设计中引入弹塑性设计思想 ,建立了具有几何非线性的有限元弹塑性计算模型 ,提出分段线性化模拟材料非线性的算法。进行了端盖受轴向压力的力学实验 ,和计算结果作了比较。端盖的整体变形和弹塑性计算结果相当符合 ,端盖的破坏载荷大大超过弹性计算的结果。结果表明应用弹塑性计算进行端盖的强度设计是可行的 ,可以明显提高端盖的破坏极限 ,为飞轮端盖的强度设计和结构优化提供了重要方法     

2D shape optimization of leaf-type crossed flexure pivot springs for minimum stress

Leaf-spring crossed flexure pivots are used in an increasingly large number of applications, many of which require the fatigue life and/or the rotational capability of the pivots to be maximized. Since these two qualities are determined by the endurance limit or the yield stress of the leaf-springs’ material, maximizing them will necessarily require reducing the stress levels arising in the aforementioned springs during operation. Partly for the sake of simplicity, partly due to manufacturing constraints, constant thickness leaf-springs have traditionally been used in crossed flexure pivots. However, minimizing stress simply by increasing the length or by decreasing the thickness of the leaf-springs is often not viable, either due to spatial constraints or to the attendant degradation in spring performance. This paper investigates the scope for stress reduction through shape optimization of the leaf-springs. To this end, a procedure combining a linear strain energy formulation, a parametric thickness profile definition and a series of optimization algorithms is employed. The resulting optimized thickness profiles are proven to be not only independent of the angular rotation at which the pivot operates, but also linearly scalable to leaf-springs of any length, minimum thickness and width. Validated using non-linear finite element analysis, the results show very significant reductions in relative maximum stress, of up to as much as 24% in the case of some pivot configurations. The optimized profiles and their corresponding constant thickness counterparts are also compared in terms of stiffness, strain energy and parasitic motion characteristics. It is concluded that shape optimization offers great potential for extending the fatigue life and/or rotational range of crossed flexure pivots.     

复合材料飞轮结构有限元分析与旋转强度试验

飞轮储能技术是一种机械能量储存方式。储能密度是衡量飞轮储能系统优劣的重要参数,如何提升储能密度,是飞轮储能技术研究的重要内容之一。本文运用ANSYS有限元分析软件对复合材料飞轮转子进行有限元分析,得到不同转速下结构应力与应变的分布,计算得到飞轮理论极限转速为950 r/s,飞轮外缘线速度836 m/s。对飞轮进行高速旋转强度、破坏试验。在试验中,利用电涡流传感器测量轮毂侧壁形变,飞轮形变测量值和理论预计值基本一致。试验飞轮边缘最高线速度达到796 m/s,储能密度达到48 Wh/kg。     

Optimization of functionally graded foam-filled conical tubes under axial impact loading

Metallic foams as a filler in thin-walled structures can improve their crashworthiness characteristics. In this article, nonlinear parametric finite element simulations of FGF foam-filled conical tube are developed and the effect of various design parameters such as density grading, number of grading layers and the total mass of FGF tube on resulting mode shapes, specific energy absorption and initial peak load is investigated. Multi design optimization (MDO) technique and the geometrical average method, both are based on FE model are applied to maximize the specific energy absorption and minimize the impact peak force by estimating the best wall thickness and gradient exponential parameter “m” that controls the variation of foam density. The results obtained from the optimizations indicated that functionally graded foam material, with graded density, is a suitable candidate for enhancing the crashworthiness characteristics of the structure compared to uniform density foam.     

基于最终失效强度的层合板结构的鲁棒优化分析

采用有限元方法分析复合材料层合板结构的最终失效强度，并以此对结构进行优化和鲁棒优化分析。层合板结构同时承受面内和面外载荷，每个单层板考虑基体失效和纤维断裂两种失效模式。当某一单层失效后采用比率退化法计算结构新的刚度，然后重新进行结构分析，直到求得结构的最终失效强度。以纤维方向角和层合板厚度作为设计变量，最终失效强度为目标，对结构进行优化。在此基础上，考虑了层合板结构的鲁棒优化分析。