FLYWHEEL- PARTS, FUNCTIONS, AND TYPES
1. What is a flywheel?
A flywheel is a mechanical device that uses the conservation of angular momentum to store rotational energy; a form of kinetic energy that is proportional to the product of its moment of inertia and the square of its rotational speed. A flywheel is given high rotating inertia to efficiently offset speed variations. The rotational inertia of a wheel with a hefty rim linked to the central hub by spokes or a web is considerable. This is how many reciprocating engine flywheels are built to smooth the power flow. The energy stored in a flywheel, on the other hand, is dependent on both weight distribution and speed; doubling the speed quadruples the kinetic energy. At the same weight and diameter, a rim-type flywheel will rupture at a significantly lower RPM than a disc wheel. A flywheel can be made of high-strength steel and fashioned as a conical disc, thick in the centre and thin around the rim, for low weight and great energy storage capacity.
2. Parts of Flywheel
Following are the parts of a flywheel:
· Flywheel housing
· Springs
· Planetary wheel
· Axial sliding bearing
· Radial sliding bearing
· Ring gear
· Locking pinhole
· Support disk
· Flywheel sliding shoe, Flywheel cover
1. Flywheel Housing
The flywheel housing is strong and situated on the flywheel’s outside. The flywheel is a rotating component of the engine that powers the alternator.
2. Springs
Parallel two-phase bent springs make up the flywheel. When the engine is operating, the outer arc is tweaked to elevate the spring. The soft outer arc springs are merely included to help with the unpredictability of the resonance frequency range.
3. Planetary Wheel
Many planetary gears are mounted on flywheel carriers to make planetary gears. The meshing with the outer ring gear generates a combined motion consisting of each revolution and rotation of the planetary gear when the flywheel bracket is fastened and rotated.
4. Axial and Radial Sliding Bearing
Axial bearings merely balance weight; radial bearings must correct for imbalanced or parasitic radial forces created by the motor or generator unit.
5. Ring Gear
The outer diameter of the flywheel is fitted with ring gear. A press-fit generated by heating the ring gear is typically used to secure the flywheel. As a result, thermal expansion can be used to arrange it around the flywheel.
6. Support Disc
The flywheel’s two-phase curved springs and other components are supported by the support disc, which is positioned inside the flywheel.
7. Flywheel Sliding Shoe
A convex radial outer section of the skid shoe near to the inner wall of the flywheel is preferred. It is desirable in this industry that it is made to promote slippage and has a low wear rate.
8. Flywheel Cover
Chrome is commonly used for flywheel covers. This chrome-plated flywheel cover keeps dust out of the internal structure of the flywheel, slowing it down.
3. Functions of Flywheel
A flywheel is a large wheel installed on a spinning shaft that helps the engine transmit power to the machine. The flywheel’s inertia cancels out and dampens engine speed changes while also storing extra energy for intermittent usage. Because of the multiple functions listed above, flywheels are employed in practically all types of vehicles. The functions of an automobile engine’s flywheel are as follows:
· Balancing the engine: This is because the piston is offset from the centre of vibration of the crankshaft, causing the g wobble. This is also because each piston ignites at a different angle.The function of the flywheel in this situation is to support less lateral movement. This is achieved due to the heavy weight of the flywheel. The flywheel reduces vibration throughout the engine as the engine is stable and balanced on the mount.
· Starting the engine: The flywheel also aids in the start-up of the engine. The starter motor is connected to the flywheel teeth. This starter is controlled by the car keys, and when the vehicle begins, it rotates the flywheel. The combustion effect keeps the engine spinning when it sand pins. The started motor’s Bendix gear will retract, allowing the flywheel to freely rotate.
· Reducing the load on the drive train: A flywheel can also be used for this purpose. The flywheel also aids in the start-up of the engine. The starter motor is connected to the flywheel teeth. This starter is controlled by the car keys, and when the vehicle begins, it rotates the flywheel. The combustion effect keeps the engine spinning when it is turned on. The started engine’s bendix gear is retracted, allowing the flywheel to freely rotate.
· Speed-reducing: As power builds up, the crankshaft transforms the movement of the piston into a jerky rotary motion. The crankshaft speed is constant and the engine runs smoothly. This is because the mass of the flywheel creates inertia that causes the engine crankshaft to rotate during piston ignition.
· Weight manipulation: The weight of the flywheel determines the output of the engine. Weight depends on the performance of the vehicle. If the flywheel is heavy, the engine may run under load and the engine may stop. Heavy trucks and trailers work well with heavy flywheels, while sports cars and some commercial vehicles make good use of light flywheels.
4. Types
Types of flywheel used in vehicle:
· Solid disc flywheel
· Rimmed flywheel
· High-velocity flywheel
· Low-velocity flywheel
· Single Mass flywheels
· Dual Mass flywheels
1. Solid Disc Flywheel
A solid disc flywheel is one of the different types of flywheels. Used in single-flywheel threshing machines made of cast iron. A flywheel hub and disc are included in the whole disc flywheel. The design calculations for a flywheel with a solid disc are based on a number of parameters. This covers the dimensions of a solid-disc flywheel. In addition, the value of the resulting function is calculated.
2. Rimmed Flywheel
Full-face wheels of the same weight and diameter rupture at substantially lower RPMs than rim-type flywheels. The flywheel is composed of high-strength steel and is designed as a thick central conical disc for low weight and great energy storage capacity.
3. High Velocity Flywheel
High-speed flywheel rates for these sorts of flywheels range from 30,000 to 80,000 rpm. It can also be modified up to 100,000 revolutions per minute. It requires less maintenance because it is equipped with magnetic levitation bearings. It is lighter than a low-speed flywheel, depending on size and capacity. Low-speed flywheels are less expensive than high-speed flywheels.
4. Low Velocity Flywheel
The slow flywheel speed for these types of flywheels is 10000 rpm. High-speed flywheels are bigger and heavier than low-speed flywheels.Regular maintenance is required, and magnetic levitation bearings are not used. Their weight necessitates the use of an unique concrete structure to sustain them. It is less expensive than using a high-speed flywheel.
5. Single Mass flywheels
Single mass flywheels feature no moving parts and are built of a single cast material. They help maintain a steady connection between the engine and the clutch assembly system by facilitating engine rotation. Single-mass flywheels have a considerable deal of torsional rigidity and thermal stability, and they can survive rapid changes in gear and engine speed. One of the most essential qualities of the flywheel variant is its durability. To improve overall reliability and longevity, single mass flywheels are recoated as needed. Their price is also reasonable. Excessive vibration and noise, on the other hand, can be a concern when using these flywheels.
6. Dual Mass flywheels
There are two different flywheels in the dual-mass flywheel. The clutch has one and the crankshaft has the other. The weight capacity (up to 50kg) and monthly capacity of these flywheels are outstanding. Dual-mass flywheels are used in heavy diesel automobiles with manual transmissions (and certain petrol vehicles as well). The flywheel’s robust springs reduce twist peaks and safeguard the transmission.
The dual-mass flywheel features excellent energy storage and transfer options to minimise noise and vibration to a minimum during operation (to the crankshaft). This smooths out the transitions between piston pulses. Dual-mass flywheels increase engine power while lowering fuel consumption. These flywheels, on the other hand, cannot be recoated.
The global flywheel business will be worth slightly under $ 242 million by the end of 2027. In order to keep up with global trends, India’s flywheel industry is fast expanding. Leading flywheel manufacturers in India update their portfolios on a regular basis to ensure that their products continue to deliver exceptional performance and durability. The popularity of these spinning wheels as a form of energy storage has skyrocketed. Buyers should select the “correct” type of flywheel based on their specific requirements.
5. Material Used for Flywheel
The flywheel can be made out of a variety of materials depending on the use. A cast iron flywheel is used on older steam locomotives. Flywheels are used in vehicle engines and are commonly made of cast or nodular iron, steel, or aluminium. Flywheels are also made of high-strength steel. The composite flywheel is intended for use in vehicle energy storage and braking systems. The power of a flywheel is determined by the amount of energy it can store per unit load.
6. Common Problems of Flywheel
Following are the faults that occur when a flywheel is defective:
· Clutch dragging
· Clutch slipping
· Burning smell
· Clutch chatter
· Clutch pedal vibration
1. Clutch Dragging
In this case, the clutch will not fully release. This will result in variable degrees of gear grinding when moving gears. Furthermore, when the car starts from a stop, it may completely fail to shift into first gear. This problem can develop in the flywheel, as well as the bearing or bushing in the flywheel or crankshaft assembly.
2. Clutch Slipping
This problem occurs when the gears change automatically while driving. As a result, the gear may slide. This happens when the clutch fails due to a lack of power being transferred to the wheels. Because of the sliding clutch, the flywheel will eventually disintegrate. The pressure plate may make an abrupt grinding sound. The clutch assembly’s flywheel will heat up in other places. As a result, bending and even cracks will occur.
3. Burning Smell
The clutch generates a burning odour when it wears out. The fault lies with a faulty flywheel or an inexperienced operator. The face of the clutch is made of materials that are supposed to lessen the amount of noise it makes when in use. The face generates too much heat as a result of friction when it is not properly used.
4. Clutch Chatter
This happens when the clutch is having problems engaging. When the clutch catches, it glides along with the flywheel and leaves it repeatedly. There appears to be a stutter or vibration upon release. Clutch noise is frequent when starting from a complete stop in any gear. This failure may be difficult to identify due to a fault in the clutch disc, pressure plate, or release bearings. Components that are broken, deformed, or oil-contaminated are also possible.
5. Clutch Pedal Vibration
You may notice that the clutch pedal or the car floor rattles if the flywheel is damaged. This is because the spring mounts on the flywheel have corroded. Let me explain how the clutch’s vibrations are dampened by the spring mechanism.
7. Applications of Flywheel
The goal of the flywheel is to smooth out an energy source’s power generation. In reciprocating engines, for example, the flywheel is necessary because the active torque from the individual pistons is broken. In most energy storage systems, a flywheel is used to keep the energy in the system as rotational energy. Providing energy at a pace greater than the energy source’s capacity. This is accomplished by gradually accumulating energy in a flywheel. Then immediately releasing it at rates that are faster than the energy source’s capability. It can be used to regulate the adjustment of a mechanical system, gyroscope, or reaction cycle. To store energy, a flywheel is utilized in conjunction with a motorized generator. Flywheels are most commonly found in wind turbines and automobile engines. Used to increase the speed of electric cars and to safeguard major power systems from obstructions. Furthermore, the flywheel is used in advanced locomotive propulsion systems as well as in high-tech transit buses.
8. Advantages and Disadvantages of Flywheel
Advantages
1. The overall cost of the flywheel is less.
2. They have a greater lifespan.
3. By using flywheel can provide you greater storage capacity.
4. It requires less maintenance and has a lesser thermal loss.
5. Flywheel is safe, reliable, and energy-efficient.
6. It is easy to operate and requires high energy density.
Disadvantages
1. The main drawback of the flywheel is that it requires a lot of space.
2. They are quite expensive to manufacture.
3. Building materials always have a limit for.
9. Conclusion
The flywheel is an important part of the engine. Without a flywheel, the engine loses part of the speed that continues the crankshaft speed, so it is needed.
That’s it for the blog!
Keep Learning!
10. References
https://www.theengineerspost.com/flywheel/
https://mechanicaljungle.com/types-of-flywheel/
https://clubtechnical.com/flywheel
https://learnmech.com/flywheel-function-types-advantages-application/