Abstract: Methods and apparatuses are disclosed for incorporating a plurality of independently rotating rotors made from high-strength materials with a high-temperature superconductive (HTS) bearing technology into an open-core flywheel architecture to achieve a desired high energy density in the flywheel energy storage devices and to obtain superior results and performance.

Abstract: Magnets and methods of their manufacture are disclosed for use in flywheel assemblies, such that the magnets comprise oriented fibers, such as, for example, axially-oriented fibers in a flexible rotor magnet composition to predictably allow the magnet to expand dimensionally upon rotation only in a predetermined and predictable fashion while maintaining critical contact with a rotor surface.

Abstract: Apparatuses are disclosed and directed to a substantially cylindrical containment layer, and methods for containment, for a flywheel apparatus comprising a plurality of predictably deformable brackets oriented to contain an impact. The brackets each have a plurality of layers and a surface for absorbing an impact, with the surface providing a glancing angle in the direction of an impact of from about 0.1° to about 5°.

Abstract: Methods and apparatuses are disclosed for incorporating a plurality of independently rotating rotors made from high-strength materials with a high-temperature superconductive (HTS) bearing technology into an open-core flywheel architecture to achieve a desired high energy density in the flywheel energy storage devices and to obtain superior results and performance.

Abstract: Apparatuses are disclosed and directed to a substantially cylindrical containment layer, and methods for containment, for a flywheel apparatus comprising a plurality of predictably deformable brackets oriented to contain an impact. The brackets each have a plurality of layers and a surface for absorbing an impact, with the surface providing a glancing angle in the direction of an impact of from about 0.1° to about 5°.

Abstract: Apparatuses, systems and methods are described for a flywheel system incorporating a rotor made from a high-strength material in an open-core flywheel architecture with a high-temperature superconductive (HTS) bearing technology to achieve the desired high energy density in the flywheel energy storage devices, to obtain superior results and performance, and that eliminates the material growth-matching problem and obviates radial growth and bending mode issues that otherwise occur at various high frequencies and speeds.

Abstract: Magnets and methods of their manufacture are disclosed for use in flywheel assemblies, such that the magnets comprise oriented fibers, such as, for example, axially-oriented fibers in a flexible rotor magnet composition to predictably allow the magnet to expand dimensionally upon rotation only in a predetermined and predictable fashion while maintaining critical contact with a rotor surface.

Abstract: A composite tube is made by applying a mixture of individual reinforcing fibers and a resin onto the interior cylindrical wall of the spinning mandrel.

Abstract: A braking system for a high speed, high load rotor operating in a vacuum and suspended by a magnetic field such as in a flywheel energy storage device includes a pair of calipers disposed on opposed sides of the rotor for actuating a pair of annular friction discs into engagement with opposed sides of the rotor. Each caliper includes a mounting ring on its outer edge and an inner shallow annular groove in which it disposed one of the friction discs. A circulating fluid under pressure is directed into each annular groove for urging each friction disc into engagement with one of the opposed surfaces of the rotor for safely bringing the rotor to a stop such as in an emergency. The circulating fluid removes the heat generated by the braking action, while the controlled pressure applied by the discs also controls the position of the rotor when static such as during initialization.

Abstract: A method of operating a production line comprises the steps of supporting equipment in the production line on a plurality of crawlers comprising at least one rolling track and a structural support for supporting the equipment. A first plurality of lifting magnets coupled to an interior surface of said at least one rolling track is configured to oppose a second plurality of lifting magnets coupled to an exterior surface of said structure support to lift the structural support, such that the structural support floats between and within said at least one rolling track. The magnetic fields experienced by the first and second plurality of lift magnets are adjusted to translate the at least one rolling track, such that the crawlers move along the production line.

Abstract: An apparatus for bearing a tool against a workpiece includes: (a) a pneumatically driven motor unit rotating a drive shaft substantially about a longitudinal drive axis; (b) a process shaft coupled with the drive shaft for rotating the tool substantially about a longitudinal process axis; (c) a flywheel coupled with one shaft of the drive shaft and the process shaft; and (d) at least one urging unit coupled with at least one of the motor unit and the process shaft. The urging unit moves the tool with respect to the workpiece. The flywheel and the one shaft impart inertial rotational energy to the tool after the pneumatic motor achieves a predetermined rotational speed.

Abstract: A method of operating a production line comprises the steps of supporting equipment in the production line on a plurality of crawlers comprising at least one rolling track and a structural support for supporting the equipment. A first plurality of lifting magnets coupled to an interior surface of said at least one rolling track is configured to oppose a second plurality of lifting magnets coupled to an exterior surface of said structure support to lift the structural support, such that the structural support floats between and within said at least one rolling track. The magnetic fields experienced by the first and second plurality of lift magnets are adjusted to translate the at least one rolling track, such that the crawlers move along the production line.

Abstract: An apparatus for bearing a tool against a workpiece includes: (a) a pneumatically driven motor unit rotating a drive shaft substantially about a longitudinal drive axis; (b) a process shaft coupled with the drive shaft for rotating the tool substantially about a longitudinal process axis; (c) a flywheel coupled with one shaft of the drive shaft and the process shaft; and (d) at least one urging unit coupled with at least one of the motor unit and the process shaft. The urging unit moves the tool with respect to the workpiece. The flywheel and the one shaft impart inertial rotational energy to the tool after the pneumatic motor achieves a predetermined rotational speed.

Abstract: Methods and apparatuses to provide improved auxiliary damping for superconducting bearings in superconducting levitation systems are disclosed. In a superconducting bearing, a cryostat housing the superconductors is connected to a ground state with a combination of a damping strip of material, a set of linkage arms to provide vertical support, and spring washers to provide stiffness. Alternately, the superconducting bearing may be supported by a cryostat connected to a ground state by posts constructed from a mesh of fibers, with the damping and stiffness controlled by the fiber composition, size, and mesh geometry.

Abstract: Methods and apparatuses to provide improved auxiliary damping for superconducting bearings in superconducting levitation systems are disclosed. In a superconducting bearing, a cryostat housing the superconductors is connected to a ground state with a combination of a damping strip of material, a set of linkage arms to provide vertical support, and spring washers to provide stiffness. Alternately, the superconducting bearing may be supported by a cryostat connected to a ground state by posts constructed from a mesh of fibers, with the damping and stiffness controlled by the fiber composition, size, and mesh geometry.

Abstract: A braking system for a high speed, high load rotor operating in a vacuum and suspended by a magnetic field such as in a flywheel energy storage device includes a pair of calipers disposed on opposed sides of the rotor for actuating a pair of annular friction discs into engagement with opposed sides of the rotor. Each caliper includes a mounting ring on its outer edge and an inner shallow annular groove in which it disposed one of the friction discs. A circulating fluid under pressure is directed into each annular groove for urging each friction disc into engagement with one of the opposed surfaces of the rotor for safely bringing the rotor to a stop such as in an emergency. The circulating fluid removes the heat generated by the braking action, while the controlled pressure applied by the discs also controls the position of the rotor when static such as during initialization.

Abstract: An equipment-carrying crawler (20) includes a rolling track (44) and a structural support (70). The structural support (70) supports equipment (16). Lifting magnets (72) are coupled to the rolling track (44) and to the structural support (70). The lifting magnets (72) are configured to oppose each other, lift the structural support (70), and aid in the translation of the rolling track (44).

Abstract: An equipment-carrying crawler (20) includes a rolling track (44) and a structural support (70). The structural support (70) supports equipment (16). Lifting magnets (72) are coupled to the rolling track (44) and to the structural support (70). The lifting magnets (72) are configured to oppose each other, lift the structural support (70), and aid in the translation of the rolling track (44).

Abstract: An induction heating system for fabricating a part by heating and forming the part. The induction heating system comprises a smart susceptor that includes a susceptor material that responds to an electromagnetic flux by generating heat and a cavity defined by the susceptor material that is configured to hold the part. An induction coil of the induction heating system is supplied with electrical power so as to generate the electromagnetic flux necessary for the susceptor to generate heat. A temperature controller includes a power supply that supplies electrical power to the induction coil. A controlling element of the temperature controller monitors trends in the electrical power supplied and changes the amount of electrical power being supplied so as to control the temperature of the part during fabrication.

Abstract: An apparatus for thermoplastic welding together by fusion bonding an assembly of composite parts, each having a resin-rich thermoplastic surface layer, along bond lines containing a conductive susceptor includes a weld skate that can be moved along guiding and supporting tooling over the bond line to effect the weld. The skate has an induction work coil and two pressure pads, one on each side of the coil in its direction of motion in operation, for applying pressure to the parts while said induction work coil induces eddy currents in the susceptor to heat the susceptor by resistive heating and melt the thermoplastic surface layers. The skate has bearings projecting from its side into cam grooves machined into the sides of the tooling for guiding and supporting the skate during welding by the induction work coil.