Flynn-Power Electronics - The University of Texas at Austin

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Transcript Flynn-Power Electronics - The University of Texas at Austin

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

Sampling of Recent Power Electronics Projects 5.6 kV, 3-Level Inverter Silicon Carbide Switch Development Motor Controllers

SiC SGTO Switch Development and Failure Investigation

ARL SGTO Pulse Test Results Polyimide Damage ANSYS Conduction Current Coupled Simulations Thermal Imaging Experiments EMAP3D Semiconductor Physics Simulations SiC Device Design Improvements 11

2 MW ARCP Soft-Switching Converter

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

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

Max and Min Inductor Current vs. Inductance V Hi = 750 V, f s = 3 kHz, P batt = -40 kW -50 -100 -150 150 100 41 0 50 0 22 0 41 0 220 Imax Imin 410 220 410 220 410 220 -200 200 400 600 800 1000 1200 Inductance (  H) 1400 1600 1800 2000 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

• • • • • •

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

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 Presentation Reputation 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