2012 advisory panel power electronics mark flynn center for electromechanics the university of texas...
TRANSCRIPT
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2012 Advisory PanelPower Electronics
Mark FlynnCenter for Electromechanics
The University of Texas at Austin12/4/2012
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Outline
• Introduction• Recent/current work• Capabilities• Vision for future• Summary
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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
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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
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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
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Outline
• Introduction• Recent/current work• Capabilities• Vision for future• Summary
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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
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Sampling of Recent Power Electronics Projects
Multiphase, Bidirectional DC-DCConverter
Algal Cell Lyser
Pressure Tolerant Subsea Inverter
60 kW
1500 kW, pk
30 kW
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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
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5.6 kV, 3-Level Inverter
Sampling of Recent Power Electronics Projects
Silicon Carbide Switch Development
Motor Controllers
2000 kW
1000’skW
200+ kW
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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
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2MW “ARCP” converter(Auxiliary Resonant Commutated Pole)
10 kW tabletop test-bed converterwith advanced ARCP topology
2 MW ARCP Soft-Switching Converter
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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
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60 kW 3-Phase Bidirectional DC-DC Converter
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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
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Outline
• Introduction• Recent/current work• Capabilities• Vision for future• Summary
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Define the CEM Niche
• Analysis and Design: Electrical, Thermal, Magnetic, Structural
• Solid modeling• Controllers• Fabrication
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Detailed Electrical Simulations
IGBT Model
Diode Model
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Thermal Analysis of Complete Systems
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Magnetic Analysis
Compute stray inductances
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Stress Analysis of Bus Bar
Stress concentrations result in 26 ksi VM stress Deflection due to load
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Solid Modeling Capabilities
• Optimize electrical performance• Optimize thermal management• Optimize ergonomics
Solid Model Assembly Real World Hardware
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Embedded Controllers
Controller
• Customized to demand• Circuit design, capture• PCB layout, assembly• SMT, TH soldering• Software, controls• Numerous licenses to
partners
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Verified Pressure Tolerant Controller
• Monitors 2 IGBT junction temperatures in real-time
• Tested to 4200 psi hydrostatic pressure
• 16-bit processor
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Outline
• Introduction• Recent/current work• Capabilities• Vision for future• Summary
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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
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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
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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.
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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.
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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
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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
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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
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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
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Key Challenges – Attracting and Maintaining Sponsors
Expertise
ReputationPresentation Client Entry
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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
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Outline
• Introduction• Recent/current work• Capabilities• Vision for future• Summary
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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