The High Speed Flywheel Test Bench is a comprehensive testing platform designed specifically for flywheel energy storage systems, inertial navigation flywheels, and other products. Its core functions include:

Simulate the entire lifecycle of a flywheel from start up, acceleration, steady state operation to deceleration and shutdown;

Real time collection of speed (up to 60000rpm), torque, vibration frequency, temperature rise rate and other data;

Verify the stability and durability of the flywheel under different power outputs through a load simulation system;

Combining the safety monitoring module to achieve automatic protection for abnormal working conditions such as overspeed, overtemperature, and vibration exceeding limits.

The equipment is widely used in flywheel design verification, performance calibration, reliability testing and other aspects, and is a key bridge connecting laboratory research and development with industrial production.

High precision testing system with high data reliability

Equipped with imported laser speed sensor (accuracy ± 0.1rpm), piezoelectric vibration sensor (sampling rate 1MHz), and infrared temperature monitoring module, the testing error is controlled within 0.5%. Combined with industrial grade data acquisition cards, millisecond level data synchronization storage can be achieved, providing accurate raw data for performance analysis.

Wide coverage of working conditions to meet the needs of multiple scenarios

The speed adjustment range supports continuous adjustment from 500rpm to 60000rpm, with a load power coverage of 0-500kW. It can be adapted to various flywheel products with diameters ranging from 200mm to 1200mm and weights ranging from 50kg to 500kg. Whether it is dynamic response testing of small inertial flywheels or long-term cyclic testing of large energy storage flywheels, they can stably meet the requirements.

Multi layer security protection, strong test safety

Adopting a dual safety design of "physical protection+intelligent monitoring": the outer layer is equipped with a 30mm thick explosion-proof steel plate protective cover and a built-in pressure relief valve; At the system level, it is equipped with real-time fault diagnosis algorithms. When the speed exceeds the limit, the bearing temperature exceeds 80 ℃, or the vibration acceleration is greater than 20g, it can trigger an emergency stop within 0.1 seconds, cut off the power source, and activate the braking device.

Intelligent operation and data analysis

Equipped with independently developed testing software, supporting preset operating parameters, automated execution of testing processes, and data visualization analysis. The software has a built-in flywheel performance evaluation model that can automatically generate speed torque curves, temperature rise characteristic reports, and life prediction charts, significantly reducing the cost of manual data analysis.

New energy storage field

In the development of flywheel energy storage systems, the test bench can simulate scenarios such as grid frequency regulation and backup power supply, and test the charging and discharging efficiency (up to 95%), cycle life (>100000 times), and energy density (>150Wh/kg) of the flywheel, providing data support for flywheel selection and optimization in energy storage power plants.

 Aerospace and Defense

For satellite attitude control flywheels and missile inertial navigation flywheels, the test bench can simulate extreme environments such as vacuum and high and low temperatures (-40 ℃~85 ℃) to verify the stability of flywheels under microgravity and strong impact conditions, ensuring the reliability of aerospace equipment.

Rail Transit and Automotive Industry

In the testing of hybrid electric vehicle flywheel kinetic energy recovery system, it can simulate vehicle acceleration, braking and other working conditions, analyze the energy recovery efficiency and response speed of the flywheel, and help upgrade energy-saving and emission reduction technology.

Universities and research institutions

Provide experimental platforms for the research and development of flywheel materials (such as strength testing of carbon fiber composite materials) and structural optimization (such as rotor dynamic balance design), support multivariate comparative experiments, and accelerate the process of technological innovation.

1. Preliminary preparation

Equipment inspection: Confirm that the protective cover is securely installed, the sensor wiring is not loose, and the cooling system (water-cooled/air-cooled) liquid level or air pressure is normal;

Flywheel installation: Fix the flywheel on the main shaft of the test bench using a dedicated fixture and calibrate it using a dynamic balance meter (residual unbalance should be less than 0.5g · mm);

Parameter preset: Enter parameters such as target speed, test duration, sampling frequency, etc. in the software to save the test plan.

2. Startup operation process

Turn on the main power supply, sequentially start the control module, data acquisition system, and cooling device, and wait for the equipment to complete self inspection (the indicator light shows green);

Click the "Start" button on the software, and the test bench will gradually increase the speed according to the preset program, while monitoring the real-time changes in screen data;

After entering the steady-state operation phase, different operating conditions can be simulated and key parameters can be recorded through the load adjustment knob;

After the test is completed, execute the "slow down and stop" command, and turn off the power of each system after the flywheel is completely stationary.

3. Key points for safe operation

During the experiment, it is strictly prohibited to open the protective cover or touch moving parts. Operators must wear goggles and soundproof earmuffs;

In case of emergency, immediately press the emergency stop button, cut off the main power supply, and troubleshoot before restarting;

Regularly (every 500 hours) replace the lubricating oil of the spindle bearings, clean the sensor probes, and ensure stable equipment performance.