Power Conditioning Research at ARL Adelphi

T.F. Podlesak

A.G. Stewart

Presented at the DARPA/EPRI Megawatt Review

Monterey, CA

12-13 January 1999Approved for Public Release: Distribution is Unlimited

Outline

• Overall Power Conditioning Program Plan

• Matrix Converter Vehicle Program – Needs

– Current Technology Shortfalls

– Proposed Solutions and Objectives

– Teaming

• Facility Update

• Large Semiconductor Research

Compact Power

ConditioningAC - DC - Pulsed

Compact Power

ConditioningAC - DC - Pulsed

FutureCombat Systems

Technology Base R&D Enabled Technology System Applications

98 99 00 01 02 03 04 05 06 -25

CERDEC

ARDEC

MICOMHard SwitchingHard Switching

Soft SwitchingSoft Switching

Mobile Electric Power

High-Power Radars

Hybrid SwitchingHybrid Switching

Algorithm Development

High-Energy Conv.High-Energy Conv.

Circuit TopologiesCircuit Topologies

High-Temp. Conv.High-Temp. Conv.

Matrix Converters

PEBB SwitchesPEBB Switches

High Voltage Dev.High Voltage Dev.

Wide Bandgap Dev.Wide Bandgap Dev.

Switch Technology

Large Area DevicesLarge Area Devices

RF / DEW

UAVs, Robotic Systems

Hybrid Electric Vehicles

FSV FCS

Reactive Armor

EML / ETC Gun

Smart Munitions

AAN

TARDEC

ARL Power Conditioning Roadmap

ARL Power Conditioning Program Architecture

Mission Tech-Base Program

High-risk, generic, enabling technology

Laboratory demonstrations: IGBTs(10-100 kW matrix converter) MCTs

PEBBs

Partnering with Academia:Visiting Scholars - Nottingham University

Wide bandgap program liaison: TPAsFOCsSTOs

Customer Programs

FOCUS : Matrix Converter Applicationsand Integration

FOCUS : Matrix Converter Technology R&D

DARPA / TARDECElectric Vehicle Programs

Industry & Academia Partnering Projects

FOCUS : Device Characterization/Design Development

• Novel Switch R&D • Training Opportunities• Simulation and Modeling • Marketing Support

Foreign Technology• IGBT/IGCT Switches• Fast Dynistor Switch• Fast Turn-on Thyristor

IAT EM Gun

Parallel 125-mmThyristor Evaluation

BRAC

High-power Dyna-mometer Controller

A

C

B

Application of matrix converter to electric vehicle drive

• PEBB• M113 & HMMWV test beds

Joint program by Rockwell, ARL, Nottingham University, Berkeley Research Associates, and SPCO

Army ResearchLaboratory

• Highly Compact, high power converters are a critical part of electric propulsion and on-board power generation systems for Electric Combat Vehicles (ECV)

• Size reduction paramount for ECV - interior space under armor at high premium• ECV electric propulsion drives (and over 45% of other applications) require truly

inherent line regeneration capability for braking and steering• Overall system operates in a harsh environment at elevated temperatures

Critical Need for High Power Density Converters

• Electric actuation systems for MEA• HPD power converters for EHA, PGS• Low weight, compact motor drives• High temperature electronics

Dual needs for MEA & MES

All-Electric D rive Train• H ig her en gine efficien cy• Increased ran ge• Im proved log istics

Active Su spension

EM / ETC Gu n• Increased ran ge/lethal ity• D eeper m ag azine

Active A rm o r• R edu ced weigh t• Increased protectio n

DEW A pp licatio ns• H ig h/m edium pow er laser• H ig h po w er m icr ow ave

Ad vanced Senso rs• N arrow/wid eband EM• N BC• T herm al/ IR

Co un term easu res

P ower Elec tron ics A pp lica tio ns for Arm y M iss ion s

• All previously proposed converters for ECVs are DC link type large reactive filter components

• C and L are largest components; produce heat, but not real power– Electrolytic caps have shortest lifetime and limited temperature range

Not suitable for harsh environment, high temperature operation– Poor braking capability due to low performance, bulky & heavy

regeneration system – Premature failures of motor winding and device caused by hard-

switching and high dv/dt stresses – Poor PF, harmonics negatively impact fuel efficiency & on-board pwr– High EMI and switching losses

• Added large volume, weight by low frequency excitation (60 Hz) of motor system and conventional cooling

• Overall volume, weight, lifetime and perf unacceptable for future DoD sys

Current Technology Shortfalls

• Highly compact, low weight, high power matrix converters

• 400 Hz motor and 4-quadrant HF drive system with variable frequency input.

• New cooling technology

Proposed Technology Solutions

Power conditioning and propulsion systemfor future combat vehicles and tanks

High Speed

Generator

High

FrequencyGenerator

Propulsion

Weapon

High VAC

480/277 VAC

28 VDC

e.g. 270 VDC

Hf

Xfmr

MatrixConverter

MatrixConverter

MatrixConverter

MatrixConverter

MatrixConverter

Suspension

Actuation

Protection

Vetronics

NBC

Loader

Automotive

Active Armor

Main Armament

Active Suspension

Advanced SensorsDEW Applications

Countermeasures

Electric Drive

• Highly compact and low weight matrix converters– Eliminate large reactive elements– Eliminates bulky & heavy front-end rectifiers by inherent

regeneration – Eliminate temperature sensitive electrolytic components, elevate

operating temperature, extend system lifetime – 60-75% reduction in volume – 50% weight reduction– Much improved braking and steering– Improve fuel efficiency, clean power, low EMI

• 400 Hz motor & drive system further reduces size and weight• New cooling technology

– Using available vehicle fluid (engine cooling water, lubricatingoil or fuel) eliminates bulky dedicated cooling system.

Proposed Technology Solutions

Program Objectives• Develop revolutionary AC-AC power converter that is highly-

compact, low-weight, and modular for DoD systems

– Achieve 60-75% volume reduction

– Achieve 50% weight reduction

– Improve regeneration for braking, steering

– Increase operating temperature range

• 200-225ºC (electronics controller)

• 90-100°C (motor and power).

– Extend the system lifetime

• Demonstrate AC-AC converter for high power regulation, power conditioning and motor control (5, 25, 100, 150 HP) on a HMMWV and an M-113 vehicle

• Experimentally verify performance of AC-AC converter for HMMWV and M-113 vehicle missions.

Management PlanRockwell Team:• Rockwell Science Center • Collins Avionics & Communications • Oak Ridge National Laboratory• Boeing North American.

ARL Team:• Army Research Laboratory• Nottingham University• Berkeley Research Associates, Inc.

• SPCO

C onsu ltan t: D ave B land ing(B oe ing)

(B N A )

C onsu ltan ts :D enn is B raun,B ruce Be iho ff,

P erry D e lVecch io(R ockw e ll Au tom ation)

D r. H seuh-R ong C hang,D r. C .L . C hen

(R S C )

C onsu ltan ts :D r. Je ff G o lden,

Jerry F rank, R obert M organ(B erke ley R esearch

A ssoc ia tes)

D r. Jon C lare ,D r. P a t W hee ler,

D r. M . S um ner, P ost D oc (T BN )(N ottingham U nv ie rs ity )

S ubcon trac to rs :John D risco ll (PT S C o .),

D r. B ill N unna lly (U n iv . M issouri-C o lum b ia),D ick B oothe (V A Pow er T ech. S ystem s)

C onsu ltan t:D r. F ang Peng

(O ak R idge N a tiona lLabora tiry , D O E )

D an M itche ll(C A C D ),

D r. J ian S un(R ockw e ll)

S teve C h iu ,C harles N eft,R ichard Tan,

C . W in te rha lte r(R S C )

D r. E d S canne l(A R L)

D r. S u jee t C hand(R S C )

A lex S tew artA R L Team Leade r

D r. J ie C hangR S C Team Leader &P rinc ipa l Investiga to r

D r. T om Pod lesakP rinc ipa l Investiga to r

(sys tem )

D r. R .A . K ehs,K laus K erris ,

E ric T u ttle(A R L)

AC-AC Power Converter Design

Snubber

a

b

c

M

On-board VVVFpower

generatione

a

eb

ec

G

High

speed

engine

4-quadrant high

performancepropulsion drive

Modular

integrated phasebank circuit

Modular high power AC-AC converter (100Hp) and 400Hz electric drive system

New Electric Drive System

125 mm Involute Data10 milliohm PFN (21mF) into 1.45 milliohm load

Rep Rate Data

Charging Voltage

500 V/division

Charge Current

100 A/division

20 second/division