2012 Advisory Panel

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Nov 24, 2013 (3 years and 8 months ago)

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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


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
-
DC

Converter

Algal Cell Lyser

Pressure Tolerant Subsea Inverter

Sampling of Recent Power
Electronics Projects

ARCP Soft
-
Switching Converter

Bidirectional, Solid State Marx
Generator

DC Inline Fault Generator

5.6 kV, 3
-
Level Inverter

Sampling of Recent Power
Electronics Projects

Silicon Carbide Switch
Development

Motor Controllers

SiC SGTO Switch Development
and Failure Investigation

11

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 converter

with 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)
Current (A)
Max and Min Inductor Current vs. Inductance
V
Hi
= 750 V, f
s
= 3 kHz, P
batt
= -40 kW
220
220
220
410
410
410
220
220
220
410
410
410
Imax
Imin
V
IN

220


410 V

V
OUT

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

Reputation

Presentation

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