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In a bid to respond to the challenges being faced in the installation of flywheel-based electric energy storage systems (EESSs) in customer-side facilities, namely high safety, high energy/power densities and low cost, research work towards the development of a novel, one-body, laminated-rotor flywheel, based on a switched reluctance machine (OBOLAR-Fly SR machine) is presented, where the laminated rotor provides both the energy storage and motor/generator functions. The one-body architecture improves compactness and robustness. Besides, the rotor’s laminated body ensures inherently high safety. From the design perspective, the rotor’s dual purpose causes the traditional electrical machines design aspects, such as power development, cooling, losses, torque ripple, etc., to clash with the typical requirements of a flywheel, namely in-vacuum operation and moment of inertia. This results in six main trade-offs to be addressed during the design process: rotor material, speed ratio, number of drive phases, split ratio, optimal vacuum level, and controller hysteresis band. A 60 kW, 2.2 kWh OBOLAR-Fly SR system is developed with a twofold objective: (1) provide an in-depth description of the six bespoke design trade-offs and give some useful guidelines to tackle them; (2) prove the OBOLAR-Fly concept and compare the prototype’s performance with the current state of the art flywheels. Preliminary experimental results prove the viability of the OBOLAR idea and show its competitiveness in terms of efficiency and power density. On the other hand, a gap in energy density to be filled in future research works is highlighted.

In this work, an in-depth investigation was performed on the properties of the half-bridge current-source (HBCS) bidirectional direct current (DC)-to-DC converter, used to interface two DC-link voltage sources with a high-voltage-rating mismatch. The intended implementation is particularly suitable for the interfacing of a supercapacitor (SC) module and a battery stack in a hybrid storage system (HSS) for automotive applications. It is demonstrated that the use of a synchronous rectification (SR) modulation scheme benefits both the power-stage performance (in terms of efficiency and reliability) and the control-stage performance (in terms of simplicity and versatility). Furthermore, an average model of the converter, valid for every operating condition, is derived and utilized as a tool for the design of the control system. This model includes the effects of parasitic elements (mainly the leakage inductance of the transformer) and of the converter snubbers. A 3 kW prototype of the converter was used for experimental validation of the converter modeling, design, and performance. Finally, a discussion on the control strategy of the converter operation is included.