Delta Confidential

Visions on

Power Electronic

and Electrical

Drive Systems

Dr.-Ing. Peter Wallmeier

30.01.2020

Delta Confidential

Contents

• Introduction

• PEDS today and future

• Requirements to PEDS

• Related research areas

• Datacenter Power Technology

today / tomorrow and resulting research topics

• EV on-board power system technology

today / tomorrow and resulting research topics

• Research topics to be considered in addition

2

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3

Delta Group Overview

Founded in 1971

World’s Leader in Switching Power Supplies and DC

Brushless Fans

Dedicated to providing:

Telecom / Datacenter Power Systems

Industrial Automation

Passive and Magnetic Components

Networking Products

Visual Displays

Renewable Energy and Energy

Storage

EV Charging Infrastructure

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4

Delta Global Operations

~450 Eng.

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DES - Global Operations

Bucharest,

Romania

East Kilbride, UK

Soest, GermanyTeningen, Germany

Hangzhou,

China

Bangkok, ThailandDubnica, Slovakia

Fremont, USA

Raleigh, USA

Production

Sales

R&D

Adv.R&D

150 300

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DES - Delta Energy Systems History

Quandt

Group

Locations

History

Founded 1906

Key Business

Stations

Since 2003

Delta Energy Systems (Germany) GmbH

1930

Soest Teningen

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Business Categories

7

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Power Solutions - Target Applications

8

Electicial Vehicle

On Board

Charger

DCDC 48V DCDC

Bi-Directional

OBCMEVCC

DCGM

Traction Inverter Traction Motor

4 in 1

CCU / Combo

Auxiliary Inverter

BJB

Power Tool

Medical

Industrial

Mat. Handling

Vehicles

Note Book

Game

Console

Set Top Box

Server

Networking

Desktop

LED

Display

High Voltage &

Precision

AppliancesDisplay

Water

Treatment

Wind Generator

EV/HEV Charging

Power Gen. & Mining

Solar Energy

Telecom

BTS/CO

Data Center

Energy

Solutions

MCI Power

Backup

Power Systems Infrastructure

Communication & Telecom

Infrastructure

Energy & Industrial

Basestation

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Efficiency of electrical energy production

100 %

Source IEA

63 %

100 %96%

91%100 %

~ 30 %

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G~

Large power plant

G~

Back-to-back

grid coupling

HVDC

Off-shore wind

H2

~

~G~

~A

G~

Hydro

Railway intertie

~M

110 kV

220 / 380 kV

10-30 kV

400 V

G~ ~

~

Residential power generation

Regional power generation

Bulk power generation and storage

15 kV

110 kV

50 Hz 16.6 Hz

Data centers,

routers

Grid

Grid~

~ ~MG

~

~MG

~

~ ~M100-500 kV 0.1-3 GW

1 GW

5 MW

1 GW

PV

Fuel cell

AutomationConveyanceLightingConsumer Electronics

Railway systems

Transportation

PV

Wind

Combined heat and power

Pumped storage

~

0,5-2 MWHome appliances

~ 100 kW

~ 100 kW

~ 10 kW

200 - 500 W

30 - 200 W

~ 1 W

10 W

1 - 2 kW

10 kW

1 kW

~ 100 kW1 - 50 kW

50-1000kW

20-100 MVA

20 MW

5 MW

4-10 MW

10-30 kW

~

50-600 MW

~

~

~

~\

~

~

~

~

~

~

~

~

~~

~~

~

~

~

~~

~~

~~

~~

~~

~~

~~

~~

High voltage

Medium voltage

Low voltage

~

STATCOM

~~ ~

M

1-100 MW

MV drive

~

STATCOM

Extra high voltage

DC Power transmission

Industry

10 W

~

~~

~

AC EV-Charging

< 22 kW

< 50 - 350 kW

DC EV-Charging

~0.2 - 10 kW

~

Mobile Network

10

PEDS todayPower Electronic Systems

in

• generation,

• distribution,

• utilization

of electrical energy with:

- Low renewable content

- High carbon footprint

- Limited functionality

- Not sustainable

- Uni-directional

- Low efficient

- Low intelligence

- No or low load source

coordination

- Oversized and space

consuming

- Non-resilient

modified from LEA skript, Prof. Böcker, UPB

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Today / Future

• Fossil, high GHG emissions

• Petroleum fueled cars

• unsustainability energy infrastructure

• Low efficiency

• Uni-directional

• Low intelligence

• Now or low load source

coordination

• Oversized and space consuming

• Non-resilient

• Limited functionality

• Non harmonized policies

11

• Renewable energy

• Electric vehicles

• Electrified economy

• High Efficiency

• Bi-directional, grid integration,

• smart power delivery

• load-source coordination

• energy storage

• High density

• Resilient Microgrids

• Systems function perspective

• Harmonized WW policies

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Requirements to PEDSQuality

Reliability

Mission profile

Maintenance

Service

Repair and installation

Requirements to Functional safety (ISO26262)

Regulations

Safety relevant requirements / goals

Requirements on production, service and

operation

System software integration

Protection of infrastructure

Safe states

Diagnosis

Fire Protection

Contact Protection

Electrical Safety Creepage and Clearance

Operational and environmental

Mechanical interface

Thermal operation / storage

Cooling fluid chemistry / flow rate

Temperature / Pressure /

Chemical boundary

Mission profile Load currents / Load voltage

Environmental compatibility / Dangerous substancesRequirement on functionality

DC/DC Converter

Charger

eDrive

Pedal

SW-Architecture

Testing and validation

Functional tests

Quality and reliability tests

Legal requirements

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Power Characteristics

Output voltage range and adjustment precision

Rated power and conversion function

Power Factor

Mechanical Characteristics

Size / weight

Marking

Installation space / clearance / mounting

Endurance strength (Vibration)

Working load from special events (crash)

Handling

Software Design

Electronic Design

Isolation resistance

Electrical I/O (Power / current / voltage / frequency )

Ripple generation and susceptibility

Line / load regulation / Dynamic load / Efficiency

Surge load and power derating (V,C,T)

Operation states, limited operation, wake up

EMC (Simulation, test plan)

Wake up and sleep, quiecent current

Inrush current

Acoustic

Technical cleaness

Corrosion

Material Selection

Thermal integrity of operation

Crash Requirement

4. Requirement on integration

Interface description:

mechanical, electrical,

communication

Electronic Design contd.

Electrical diagnostics

Energy consumption of board grid

Max. differential mode and

common mode capacitance

Jump start / Power down

Cable dimensioning

Requirements to PEDS

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PEDS disciplines research areasComponents and packaging:

Power semiconductors

Power integrated circuits (PIC), Hybrids, Modules

Passive components

Magnetics (SST, FACTS)

Packaging technologies (Thick-Film, Integration)

Wide bandgap semiconductor technologies (GaN,SiC)

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System-Technologies:

Applications of power electronics in power systems

Traction & automotive systems

Datacenter and Cloud computing power systems

Home appliances, industry & aerospace

Robotics systems and application

Renewable energy technologies

Distributed generation & smart-grid

Intelligent electronic systems

Mobile Networks power systems

Thermal management

EMI

Methods

Analysis & design of electrical machines

Modelling & simulation in power electronics

Power electronics related education

/professional development

Reliability analysis

Circuits:

Bi-directional

MHz conversion circuit technology

Hard-switching & soft-switching

Single stage power conversion

Multilevel

Controls:

High speed digital ctrl for MHz conversion

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Datacenter energy consumption

15https://www.researchgate.net/figure/Global-electricity-demand-of-data-centers-2010-2030_fig2_275653947

~ 2% in 2017

to ~ 12 % 2030

of WW energy

demand

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Datacenter efficiency

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5V

(TTL)

12V

(CMOS)

48V

History of uP board input voltages

60V

HSV

SELV

80 90 00 10 3020

V

t

uP-Voltages

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Motherboard power architecture

Memory

…12 V

CPU ==

MEM ==

MEM ==

MEM ==

CPU ==

CPU ==

…

…

…

…

…

Other

CPU

Rails

==

MEM ==

MEM ==

MEM ==

Other

System

Rails

==

Stb.

CPU =

=…

…

…

…

Memory

…

48 V

CPU ==

MEM MEM MEM

CPU CPU

…

…

…

…

…

Other

CPU

Rails

MEM MEM MEM ==

Other

System

Rails

Stb.

CPU =

=…

…

…

…

• CPU & MEM: PoL VR (Multiphase Buck)

• Other & MEM: PoL VR (Multiphase Buck)

• Max. Current is limited ~ 30A (DOSA)

• Efficiency ~ 93 % @ 1.5 V

• Low cost power conversion

• CPU & MEM: D2D new design 48 V -> PoL

• Low Power Other & MEM: PoL VR (Multiphase Buck)

• Max. current ~130 A

• Efficiency ~ 97 % @ 1.5V

• Higher cost power conversion

==

==

==

==

==

==

==

==

==

==

==

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Components and packaging

Today(48 V):

• PCB main component carrier

• Discrete THT and SMT

• Wound magnetics

• Si only

Power density: 50 W/in3 (3 kW/l)

Efficiency:

93,2% @ 10 % Load

97,8% @ 50 % Load

96,5% @100 % Load

FAN cooled

Future:

Power density: 170 W/in3 (10 kW/l)

Efficiency: >99 % pk@50 % Load

No FAN

?Source: Infineon

Single Phase AC->12V,48,400VDC

PCB embedded modules

Ceramic Module

GaN / SiC / WBG

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Efficiency counts

20

@ 25 °C, Uo_n

„Almost“ 98 %

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Circuits

Today: Future:

?

Single Phase AC-> 12V, 48V, 400V DC

• Two or multistage stage

(PFC, DC/DC, Decoupling)

• Uni-directional

• 2 or 3 level

• Up to 200kHz

• Single Stage

Combine all stages

• Bi-directional

• Multilevel

• MHz

~

=

~~~~~~

~

=

=

~ =~~~~

~~~

Server PSUEMI PFC Bulk Inv Rec EMI

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Data Center Power System TechnologyToday: Future:Datacenter MV AC-> uC

• DC-Distribution

• Bi-directional

• High efficient

• Small

• Renewables

• Fuelcell

MV

=

~

=

=

800 V

1 %

48 V

=

=

=

=

BID

FC

=

=

PV

=

~

WP

2 %

=

=2 %

uC

< 1V

MV

2 %400 VAC

=~

2 %

uC

3 %

2 %

2 %

230/

400 VAC

~=

=~

== 3 %

GS

48 VDC

MV

230

/400 VAC

uC

3 %

2 %

=~

== 3 %

GS

48 VDC

8 %14 %

• AC Distribution

• Unidirectional

• Low efficient

• Large

• No Renewables

• Diesel Genset

5 %< 1V< 1V

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Research directions:

• < 5% loss, Datacenter efficiency and carbon footprint optimization

• < 2 % loss MV->DC solid state transformer technology

• < 2% loss POL converter optimization

• Increase of Board supply voltage

• System reliability analysis and optimization

• DC-Distribution Electrical Safety analysis and optimization

• 800 V -> 12V/48V conversion technology

• Renewable integration optimization and power flow

• Total cost of ownership analysis and optimization

• Availability and on-time optimization

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Data Center Power System Technology

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Wireless Charging

OBCM DCDC

EVCC

BJB

Bi-dir. OBCM

Auxiliary Inverter

On Board Generator(OBG)

Traction Inverter

Traction Motor

Inverter+OBCM+DCDC+EVCC

48V DCDC

CCU / ComboOBC+DCDC

DCGM

EV Power System Technology

Delta custom made products: No System, components

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OB EV Power System Technology

~

=

=

~ =~~~~

~~~

OBC

NV-Grid400 V

WB

==

~= EM

12 V

==

12 V

System

48 V

System=

=

48 V

Do we need all these elements ?

What can be integrated ?

System optimization ?

Are there more cost efficient solutions ?

EMI PFC Bulk Inv Rec EMI

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Components and packaging

Today:

• PCB main component carrier

• Discrete THT and SMT

• Wound magnetics

Power density: 33W/in3 (2 kW/l)

Efficiency:

85% @ 10 % Load

95,5% @ 50 % Load

95,% @100 % Load

Liquid cooled

Future:

Power density: 100 W/in3 (6 kW/l)

Efficiency: >97 % pk@50 % Load

?

1/3 Phase AC -> HVDC

PCB embedded modules

Cermic Module Source: VisIC

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Needs to be considered in PEDS research in add.

• Reliability / Maintenance

• Endurance / strength

• Electrical diagnostics

• State of health monitoring (New)

• Safety relevant requirements / goals

• Electrical and Functional Safety

• System reliability

• Physics of fail

• System integration

• Environmental compatibility

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G~

Large power plant

G~

Back-to-back

grid coupling

HVDC

Off-shore wind

H2

~

~G~

~A

G~

Hydro

Railway intertie

~M

110 kV

220 / 380 kV

10-30 kV

400 V

G~ ~

~

Residential power generation

Regional power generation

Bulk power generation and storage

15 kV

110 kV

50 Hz 16.6 Hz

Data centers,

routers

Grid

Grid~

~ ~MG

~

~MG

~

~ ~M100-500 kV 0.1-3 GW

1 GW

5 MW

1 GW

PV

Fuel cell

AutomationConveyanceLightingConsumer Electronics

Railway systems

Transportation

PV

Wind

Combined heat and power

Pumped storage

~

0,5-2 MWHome appliances

~ 100 kW

~ 100 kW

~ 10 kW

200 - 500 W

30 - 200 W

~ 1 W

10 W

1 - 2 kW

10 kW

1 kW

~ 100 kW1 - 50 kW

50-1000kW

20-100 MVA

20 MW

5 MW

4-10 MW

10-30 kW

~

50-600 MW

~

~

~

~\

~

~

~

~

~

~

~

~

~~

~~

~

~

~

~~

~~

~~

~~

~~

~~

~~

~~

High voltage

Medium voltage

Low voltage

~

STATCOM

~~ ~

M

1-100 MW

MV drive

~

STATCOM

Extra high voltage

DC Power transmission

Industry

10 W

~

~~

~

AC EV-Charging

< 22 kW

< 50 - 350 kW

DC EV-Charging

~0.2 - 10 kW

~

Mobile Network

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What is PEDS futurePower Electronic

Systems

in

• generation,

• distribution,

• utilization

of electrical energy with:

- Renewable

- 0 carbon footprint

- High functionality

- Sustainable

- Bi-directional

- Efficient

- Intelligent

- load source

coordination

- Small

- Resilient

How to change in detail ?

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Backup

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Key Note from Divan 2009The fossil fuel based energy economy that brought us so far is heading for a transformation. Higher oil

prices, increasing GHG emissions, and accelerating climate change point to the unsustainability of

the present course, and point towards developing an energy infrastructure that is sustainable.

Possible major technology shifts are imminent, including a shift to an electrified economy, with electric

vehicles displacing petroleum fueled cars, and with increased emphasis on renewable energy and

increased efficiency. Power electronics will play a critical role in this transformation – ranging from

sustainable energy sources, grid integration, smart power delivery, load-source coordination,

energy storage, microgrids, and increased efficiency of energy use.

However, the solutions have to be examined from a systems perspective, looking at a complete

resource and emissions picture, and at sustainability of the solutions on a global basis.

Further, the economics of the solution, not only at the final point, but along the path, have to be addressed

for success to be achieved. Finally, it is important to understand the impact of current policies on

technology solutions, and possible changes in policy that can be driven by new technology developments.

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Lorenz 2009Abstract: The demands on future electric drives will include a significant need for

dynamic efficiency control, while not compromising dynamic performance.

Machine drives that allow continuous dynamic manipulation of losses have the potential to become

dominant candidates, especially in the rapidly evolving EV and HEV applications and more

electric aerospace applications. For such applications, dynamically variable loading with high

peak-to-average torque and speed requirements are typical.

Flux intensifying- and flux weakening-interior permanent magnet (FIIPM & FW-IPM) machines and

induction machines (IM) are most compatible with these applications since they intrinsically enable

manipulation of flux linkage to dynamically trade off copper, iron, and inverter losses.

Drive controls need to take advantage of this opportunity. Of the candidate technologies,

fixed switching frequency, deadbeat-direct torque and flux control (DBDTFC) is most directly compatible.

DB-DTFC uses one control law to handle the full operating space, including voltage limits, allowing simple

and robust implementation. The fixed switching frequency also enables the use of zero speed self-sensing

methods and dynamic loss minimizing control. This technology appears to have the potential to become

the dominant control methodology for future motor drives.

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Smarter. Greener. Together.

To learn more about Delta, please visit

www.deltaenergysystems.com.