2012 Advisory PanelPower Electronics

Mark FlynnCenter for Electromechanics

The University of Texas at Austin12/4/2012

Outline

• Introduction• Recent/current work• Capabilities• Vision for future• Summary

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

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

• 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

Outline

• Introduction• Recent/current work• Capabilities• Vision for future• Summary

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

Multiphase, Bidirectional DC-DCConverter

Algal Cell Lyser

Pressure Tolerant Subsea Inverter

60 kW

1500 kW, pk

30 kW

Sampling of Recent Power Electronics Projects

ARCP Soft-Switching Converter

Bidirectional, Solid State Marx Generator

DC Inline Fault Generator

2000 kW

400 kW, pk

1000 kW

5.6 kV, 3-Level Inverter

Sampling of Recent Power Electronics Projects

Silicon Carbide Switch Development

Motor Controllers

2000 kW

1000’skW

200+ kW

11

SiC SGTO Switch Development and Failure Investigation

ARL SGTO Pulse Test Results

ANSYS Conduction Current Coupled

Simulations

EMAP3D Semiconductor Physics Simulations

Thermal Imaging Experiments

SiC Device Design Improvements

Polyimide Damage

2MW “ARCP” converter(Auxiliary Resonant Commutated Pole)

10 kW tabletop test-bed converterwith advanced ARCP topology

2 MW ARCP Soft-Switching Converter

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

60 kW 3-Phase Bidirectional DC-DC Converter

High-Performance Controller

200 400 600 800 1000 1200 1400 1600 1800 2000-200

-150

-100

-50

0

50

100

150

Inductance (H)

Cur

rent

(A

)

Max and Min Inductor Current vs. InductanceV

Hi = 750 V, f

s = 3 kHz, P

batt = -40 kW

220

220220

410

410410

220

220220

410

410410

Imax

Imin

VIN 220 – 410 V

VOUT 700 – 850 V

> 97 % Efficient

< 0.2 % ripple

Outline

• Introduction• Recent/current work• Capabilities• Vision for future• Summary

Define the CEM Niche

• Analysis and Design: Electrical, Thermal, Magnetic, Structural

• Solid modeling• Controllers• Fabrication

Detailed Electrical Simulations

IGBT Model

Diode Model

Thermal Analysis of Complete Systems

Magnetic Analysis

Compute stray inductances

Stress Analysis of Bus Bar

Stress concentrations result in 26 ksi VM stress Deflection due to load

Solid Modeling Capabilities

• Optimize electrical performance• Optimize thermal management• Optimize ergonomics

Solid Model Assembly Real World Hardware

Embedded Controllers

Controller

• Customized to demand• Circuit design, capture• PCB layout, assembly• SMT, TH soldering• Software, controls• Numerous licenses to

partners

Verified Pressure Tolerant Controller

• Monitors 2 IGBT junction temperatures in real-time

• Tested to 4200 psi hydrostatic pressure

• 16-bit processor

Outline

• Introduction• Recent/current work• Capabilities• Vision for future• Summary

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

• 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

• 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

• 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

• 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

• 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

• 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

• 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

Key Challenges – Attracting and Maintaining Sponsors

Expertise

ReputationPresentation Client Entry

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

Outline

• Introduction• Recent/current work• Capabilities• Vision for future• 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