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2012 Advisory Panel Power Electronics. Mark Flynn Center for Electromechanics The University of Texas at Austin 12/4/2012. Outline. Introduction Recent/current work Capabilities Vision for future Summary. Introduction. Power electronics is multi-disciplinary

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2012 advisory panel power electronics

2012 Advisory PanelPower Electronics

Mark Flynn

Center for Electromechanics

The University of Texas at Austin

12/4/2012

outline
Outline
  • Introduction
  • Recent/current work
  • Capabilities
  • Vision for future
  • Summary
introduction
Introduction
  • Power electronics is multi-disciplinary
    • Semiconductors, circuit theory, electromagnetics, control theory, software, machines, simulation, signal processing, power systems, thermal, structural
  • Power electronics is rapidly developing
  • Success requires
    • Wide breadth of personnel capabilities
    • Equally wide support infrastructure
    • Vision/leadership to invest in strategic development of personnel and infrastructure capabilities
introduction1
Introduction
  • Innovation and customization are what separate power electronics R&D from commercially available solutions
    • Electrical (e.g. power, voltage, topology)
    • Controls (very end user specific)
    • Packaging (e.g. size, cooling, application)
    • Cost
challenge maturing an emergent cem core technology
Challenge – Maturing an Emergent CEM Core Technology
  • CEM excels in power electronics innovation and customization
  • Traditionally power electronics at CEM
    • Ad hoc, supporting role rather than core technology
    • Exception: controllers
  • Recent growth in power-electronics-support of sponsors
    • Smart technologies
    • Higher efficiencies
  • Targeted, concurrent growth of CEM facilities capabilities in P.E.
  • Prompted natural transition of P.E. to Center-wide focus
  • Proper development of P.E. into core technology is key challenge
outline1
Outline
  • Introduction
  • Recent/current work
  • Capabilities
  • Vision for future
  • Summary
what we have done and are doing in the area
What we have done and are doing in the area
  • Sampling of recent power electronics projects
  • Highlighted active projects
    • Silicon Carbide Switch Development
    • 2 MW ARCP Soft Switching Converter
    • 60 kW Bidirectional DC-DC Converter
sampling of recent power electronics projects
Sampling of Recent Power Electronics Projects

60kW

Multiphase, Bidirectional DC-DC

Converter

1500kW, pk

  • Algal Cell Lyser

30 kW

  • Pressure Tolerant Subsea Inverter
sampling of recent power electronics projects1
Sampling of Recent Power Electronics Projects

2000kW

ARCP Soft-Switching Converter

400kW, pk

Bidirectional, Solid State Marx Generator

1000 kW

DC Inline Fault Generator

sampling of recent power electronics projects2
Sampling of Recent Power Electronics Projects

2000kW

5.6 kV, 3-Level Inverter

1000’s

kW

Silicon Carbide Switch Development

200+ kW

Motor Controllers

sic sgto switch development and failure investigation
SiC SGTO Switch Development and Failure Investigation

ARL SGTO Pulse Test Results

Polyimide Damage

EMAP3D Semiconductor Physics Simulations

ANSYS Conduction Current Coupled Simulations

Thermal Imaging Experiments

SiC Device Design Improvements

2 mw arcp soft switching converter
2 MW ARCP Soft-Switching Converter

10 kW tabletop test-bed converter

with advanced ARCP topology

2MW “ARCP” converter

(Auxiliary Resonant Commutated Pole)

soft switching research at cem
Soft-Switching Research at CEM
  • Largest (2MW) ARCP converter in the world, to the best of our knowledge
  • A new, modified technology is under investigation via a 10 kW test prototype
  • The 2MW converter to be upgraded to new technology
  • Full characterization of prototype is expected by Spring 2013
  • Upgrade of 2 MW unit to start in Summer 2013
high performance controller
High-Performance Controller

VIN 220 – 410 V

VOUT 700 – 850 V

> 97 % Efficient

< 0.2 % ripple

outline2
Outline
  • Introduction
  • Recent/current work
  • Capabilities
  • Vision for future
  • Summary
define the cem niche
Define the CEM Niche
  • Analysis and Design: Electrical, Thermal, Magnetic, Structural
  • Solid modeling
  • Controllers
  • Fabrication
detailed electrical simulations
Detailed Electrical Simulations

IGBT Model

Diode Model

magnetic analysis
Magnetic Analysis
  • Compute stray inductances
stress analysis of bus bar
Stress Analysis of Bus Bar
  • Stress concentrations result in 26 ksi VM stress
  • Deflection due to load
solid modeling capabilities
Solid Modeling Capabilities
  • Optimize electrical performance
  • Optimize thermal management
  • Optimize ergonomics

Solid Model Assembly

Real World Hardware

embedded controllers
Embedded Controllers
  • Customized to demand
  • Circuit design, capture
  • PCB layout, assembly
  • SMT, TH soldering
  • Software, controls
  • Numerous licenses to partners

Controller

verified pressure tolerant controller
Verified Pressure Tolerant Controller
  • Monitors 2 IGBT junction temperatures in real-time
  • Tested to 4200 psi hydrostatic pressure
  • 16-bit processor
outline3
Outline
  • Introduction
  • Recent/current work
  • Capabilities
  • Vision for future
  • Summary
how we plan to develop this field
How we Plan to Develop this Field
  • Vision for CEM and power electronics
  • Who might our partners be
  • Near term steps to achieve the vision
  • Key challenges
  • Longer term considerations
vision for cem and power electronics
Vision for CEM and Power Electronics
  • To achieve and maintain a high level of expertise in the design, construction, and operation of all aspects of power electronic assemblies
  • Offer development, integration, and testing of power-electronic/electromechanical systems with world-class competency
who might our partners be
Who Might our Partners be
  • ARL
  • Coda Energy, Inc.
  • Cree
  • EE/ME departments
  • General Electric
  • Giant Magellan Telescope
  • Horstman
  • U.S. Air Force
  • U.S. Navy
  • Vycon, Inc.
near term steps to achieve the vision market vs competencies
Near term Steps to Achieve the Vision – Market vs. Competencies
  • Examine and respond to market demand
    • Understand present market requirements
    • Identify upcoming technologies
    • Maintain forward looking business model
  • Identify desired CEM competencies
    • Basic power electronic topologies: ac/dc, dc/dc, single pulse, dc/ac, etc.
    • Enabling agents: controllers, software, analysis, assembly, etc.
    • Capacity range: power levels: W to MW, voltage range: V to kV, etc.
    • Etc.
near term steps to achieve the vision personnel and facilities
Near term Steps to Achieve the Vision – Personnel and Facilities
  • Match desired competencies to personnel
    • Identify where resources are lacking
    • Develop master plan to invest in training of personnel
    • Establish metrics for on-going personnel development
    • Hire personnel in needed areas as required/have funding
  • Match desired competencies to facility
    • Identify where resources are lacking/aging
    • Develop plan to invest acquiring/maintaining equipment
    • Establish metrics for training personnel on equipment
    • Purchase/upgrade equipment in areas as needed
near term steps to achieve the vision methodology 1 of 2
Near term Steps to Achieve the Vision – Methodology 1 of 2
  • Capture and employ CEM’s intellectual property
    • Designs produced should be recorded and taught to targeted personnel as part of continuing education
    • Develop CEM-standard designs/methods where possible
      • CEM-standard controller is in development
      • No need to re-invent converters for each project
  • Eliminate unnecessary diversity in techniques
    • Wasteful of time and sponsor funds
    • Reduces benefit of Center-wide expertise
  • Eliminate fiefdoms
    • Leverage Center experts
    • Adhere to strategic plan for developing personnel
near term steps to achieve the vision methodology 2 of 2
Near term Steps to Achieve the Vision – Methodology 2 of 2
  • Prepare timeline for execution of vision
    • Compare employee/facility development to plan
    • Commit to investing in personnel and facilities
  • Leverage growth opportunities via projects
    • Match potential employee development opportunities afforded by a given project to the master plan
    • Require projects to grow Center capabilities along the direction of the master plan to the extent possible
key challenges
Key Challenges
  • Internal
    • Tangible and implementable vision required
    • Time/funds for personnel development
    • Eliminate waste/increase Center collaboration
    • Facilities improvements
    • Power electronics not a traditional Center focus
  • External/Marketing
    • Reputation as world class player must be grown
longer term considerations
Longer term Considerations
  • Update and maintain vision according to market demands
  • Commit to personnel and facilities investments
  • Establish and verify metrics regularly
  • Take on projects with a Center-wide focus
    • Center leaders should pursue projects in cooperation to meet the demands of the master plan to achieve the vision desired
    • Each project should permit extraction of some means of advancing the master plan
  • Establish leadership positions to maintain accountability
outline4
Outline
  • Introduction
  • Recent/current work
  • Capabilities
  • Vision for future
  • Summary
summary
Summary
  • Importance of power electronics
    • Sponsors demand ever-capable and efficient solutions
    • CEM seeks to leverage power electronics capabilities
  • Strengths
    • Technical skills: design, analysis, fabrication
    • Intellectual property: internal libraries/designs
    • Facilities: service power, supplies, tools
  • Challenges
    • Managing growth and direction of new department