Cost optimization of a hybrid composite flywheel rotor with a split-type hub using combined analytical/numerical models

A procedure to find the optimal design of a flywheel with a split-type hub is presented. Since cost plays a decisive role in stationary flywheel energy storage applications, a trade-off between energy and cost is required. Applying a scaling technique, the multi-objective design problem is reduced to the maximization of the energy-per-cost ratio as the single objective. Both an analytical and a finite element model were studied. The latter was found to be more than three orders of magnitude more computationally expensive than the analytical model, while the analytical model can only be regarded as a coarse approximation. Multifidelity approaches were examined to reduce the computational expense while retaining the high accuracy and large modeling depth of the finite element model. Using a surrogate-based optimization strategy, the computational cost was reduced to only one third in comparison to using only the finite element model. A nonlinear interior-point method was employed to find the optimal rim thicknesses and rotational speed. The benefits of the split-type hub architecture were demonstrated.