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2012 Advisory Panel Power Electronics

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

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  1. 2012 Advisory PanelPower Electronics Mark Flynn Center for Electromechanics The University of Texas at Austin 12/4/2012

  2. Outline • Introduction • Recent/current work • Capabilities • Vision for future • Summary

  3. 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

  4. 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

  5. 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

  6. Outline • Introduction • Recent/current work • Capabilities • Vision for future • Summary

  7. 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

  8. Sampling of Recent Power Electronics Projects 60kW Multiphase, Bidirectional DC-DC Converter 1500kW, pk • Algal Cell Lyser 30 kW • Pressure Tolerant Subsea Inverter

  9. Sampling of Recent Power Electronics Projects 2000kW ARCP Soft-Switching Converter 400kW, pk Bidirectional, Solid State Marx Generator 1000 kW DC Inline Fault Generator

  10. Sampling of Recent Power Electronics Projects 2000kW 5.6 kV, 3-Level Inverter 1000’s kW Silicon Carbide Switch Development 200+ kW Motor Controllers

  11. 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

  12. 2 MW ARCP Soft-Switching Converter 10 kW tabletop test-bed converter with advanced ARCP topology 2MW “ARCP” converter (Auxiliary Resonant Commutated Pole)

  13. 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

  14. 60 kW 3-Phase Bidirectional DC-DC Converter

  15. High-Performance Controller VIN 220 – 410 V VOUT 700 – 850 V > 97 % Efficient < 0.2 % ripple

  16. Outline • Introduction • Recent/current work • Capabilities • Vision for future • Summary

  17. Define the CEM Niche • Analysis and Design: Electrical, Thermal, Magnetic, Structural • Solid modeling • Controllers • Fabrication

  18. Detailed Electrical Simulations IGBT Model Diode Model

  19. Thermal Analysis of Complete Systems

  20. Magnetic Analysis • Compute stray inductances

  21. Stress Analysis of Bus Bar • Stress concentrations result in 26 ksi VM stress • Deflection due to load

  22. Solid Modeling Capabilities • Optimize electrical performance • Optimize thermal management • Optimize ergonomics Solid Model Assembly Real World Hardware

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

  24. Verified Pressure Tolerant Controller • Monitors 2 IGBT junction temperatures in real-time • Tested to 4200 psi hydrostatic pressure • 16-bit processor

  25. Outline • Introduction • Recent/current work • Capabilities • Vision for future • Summary

  26. 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

  27. 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

  28. 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.

  29. 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.

  30. 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

  31. 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

  32. 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

  33. 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

  34. Key Challenges – Attracting and Maintaining Sponsors Client Entry

  35. 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

  36. Outline • Introduction • Recent/current work • Capabilities • Vision for future • Summary

  37. 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

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