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Related Experiment Video

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Production of a Strain-Measuring Device with an Improved 3D Printer

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Optoelectronic Strain-Measurement System Demonstrated on Scaled-Down Flywheels.

Matthias Franz Rath^1,2, Christof Birgel², Armin Buchroithner²

¹CD-Laboratory for Measurement Systems for Harsh Operating Conditions, Graz University of Technology, 8010 Graz, Austria.

Sensors (Basel, Switzerland)

|July 13, 2024

Summary

A new contactless optoelectronic system monitors flywheel strain and deformation using optical sensors and a reflective pattern. This enables safer operation and material analysis for kinetic energy storage systems.

Keywords:

contactless strain measurement flywheel laser

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Last Updated: Jun 21, 2025

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Area of Science:

Materials Science
Mechanical Engineering
Sensor Technology

Background:

Safe operation of kinetic energy storage systems relies on monitoring flywheel strain.
Understanding long-term effects in composite materials like carbon-fiber-reinforced plastics requires accurate strain measurement.
Contactless monitoring methods are desirable for high-speed rotating components.

Purpose of the Study:

To investigate an optoelectronic strain-measurement system for contactless deformation and position monitoring of a rotating flywheel.
To evaluate the system's ability to distinguish between flywheel deformation and in-plane displacement.
To assess the system's performance using different rotor materials and scales.

Main Methods:

An optoelectronic system with multiple optical sensors was developed.
A special reflective pattern was applied to the rotor surface for sensor interaction.
The system was tested on a low-speed steel rotor and a scaled-down high-speed PVC plastic rotor.
Deformation measurements were compared against theoretical calculations.

Main Results:

The system successfully performed contactless deformation and position monitoring.
Combining data from multiple sensors allowed differentiation between deformation and displacement.
Testing on a PVC rotor demonstrated feasibility at smaller scales and lower speeds due to higher deformation.
Deformation measurements showed good agreement with calculated values.
Imbalance measurements were successfully derived.

Conclusions:

The developed optoelectronic system provides a viable method for contactless strain and deformation monitoring of flywheels.
The system's ability to distinguish deformation from displacement is crucial for accurate analysis.
The use of PVC rotors facilitates experimental validation at reduced scale and speed.
This technology can enhance the safety and material analysis of kinetic energy storage systems.