Environmentally Neutral Automated Building Electric Energy ... · ―renewable energy resources...
Transcript of Environmentally Neutral Automated Building Electric Energy ... · ―renewable energy resources...
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Environmentally Neutral Automated Building Electric Energy (ENABLE) Platform
TRAC Program ReviewUS Department of Energy, Office of Electricity
Presented at Oak Ridge National LaboratoryOak Ridge, TN
August 13, 2019
Burak Ozpineci, Group Leader
ORNL
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Project Overview
• Project summary▪ Develop a 5 kW higher performance SPIN (ENABLE) Power Module
taking advantage of wide bandgap (WBG) 3-Dimensional (3D) printed version of an AC to DC and dual active bridge DC-DC converter circuit.
• Total value of award (federal + cost share)▪ $1,250K
• Period of performance▪ 3/1/2017 to 4/30/2019
• Project lead and partners▪ Oak Ridge National Laboratory (Lead)▪ Flex Power Control
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Context concerning the problem being addressed
• Need for “building to grid” power conversion systems continues to grow for ― renewable energy resources― energy storage systems― wired and wireless charging― variable speed appliances
• Any energy load or resource needs its own power conversion system― redundancy, increased costs― complex coordination and communication― reduced energy conversion efficiency
• Significant challenges exist in firmware update
Making establishing a practical and efficient energy management system for building power demand and generation difficult
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State of the art approaches for addressing the problem
• Separate power conversion systems:
– PV to Grid/Home
– Home Battery to Grid/Home
– Grid to EV Charging
– Various appliances
• No way for centralized/coordinated control for all systems
• Lack of flexibility / smarts
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• Centralized hardware/software hub that powers and controls loads and sources through a single connection to the utility grid– Easier utility and consumer interaction with
the energy resources and loads. – No need for a grid interface inverters for each
energy source or load. – “plug and play” addition of new renewables,
passive and active loads, and their power conversion modules.
• “Smart phone” like system for Connected and Autonomous Buildings
• Can be scaled up for other grid applications
Uniqueness of the proposed solution
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• One dynamic box to correct, control, secure,
predict, and transact
• Automates rate arbitrage based on real time
demand, forecasts, customer preferences, and
grid constraints
• Charging control signals support DER
management speed, accuracy, and scale
• Real Time power correction supports grid
stability
• PEV Smart Charging balances intermittent
solar
The Smart Power Integrated Node (SPIN) – Flex Power Control
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Power module - (ORNL)– High density and high efficiency bidirectional isolated AC-DC converter using WBG devices and
3D printing technologies
– High speed low level control functions
System controller (Flex Power Control)– Dictate operation modes
– System control and grid interactive functions
Data acquisition (Flex Power Control)– Tests and real-time data collection
– Performance evaluation
ENABLE TCF System Architecture
Data Acquisition System Controller
Power Module embedded with low-level control
functions
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SPIN Enables Grid Functionality
Significance of the results, if successful
What
• Digital Control
Where
• At the edge of the grid where needed
• Any building location
When
• 24 hours, 365 days a year
How
• Closing the control loop at the edge of the grid
• Integration of non centralized resources
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SPIN Enables Features
Significance of the results, if successful
What
• Reduction in energy cost
• Stand Alone Power
• Hi Power DC Vehicle Charging
Where
• Any building location
When
• 24 hours, 365 days a year
How
• SPIN’s integration of discrete elements
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Three elements of cost benefit▪ Life Cycle Cost
▪ Power electronics life increase 2X from current solar inverter technology
▪ Single box
▪ Simplified installation
▪ Increased functionality
▪ Operating Cost▪ Lower energy cost through control of power
flows (when, where, and how)
▪ Ancillary Grid Services▪ Allow for quick response power regulation
control
▪ Aggregation of power
Significance of the results, if successful
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Specific research questions being addressed
• How do 3D printed heat sinks perform compared to traditional heat exchangers?
• How does the WBG-based power module for SPIN/ENABLE perform against a Si version?
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Technical explanation of the proposed approach
• Design, build and test a 5 kW power converter prototype using WBG devices, film capacitors, and 3D printed heat exchangers
― Design the 5kW grid-connected ENABLE hardware platform with a source and a load module
― Analyze and simulate the designed hardware system for component sizing and control development
― Build the WBG-based 3D printed ENABLE hardware system― Evaluate the system
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Power Converter Architecture
• AC input▪ 240Vrms/25Arms▪ 120Vrms/25Arm
• DC Output▪ 5kW (at 240Vac input, 250Vdc – 450Vdc output)▪ 200Vdc – 450Vdc
• WBG devices• Air-cooled
▪ Commercial and 3D printed heat sinks
L1
120V/240V60Hz
L2
N
G
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Overview of Control System
• CPU system clock: 200 MHz• PWM clock: 100 MHz
TMS320F28377D
S12
S11
S14
S13
S8
S7
S10
S9
S2
S1
S4
S3
S6
S5
L1
L2
N
Lf
Cf
Vdcs
Vdcp
vL1N
vL2N
iLf1 iLf2
GS1 – GS6 GS7 – GS10 GS11 – GS14vL1N, vL2N iLf1, iLf2 VdcsVdcp
ADCA ADCB ADCC ADCD
CANACANB
CAN Bus
PWM7,8,9 PWM1,2 PWM3,4
CMPSS CMPSSECAP1
CPU2 CPU1PLLIPC
Test and Control GUI
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• Ducted Cooling 1 Heat Sink per Phase• Extremely low profile• 2 Fans (increased reliability)• Minimal dead space (also usable)• Duct design ensures equal flow across heat sinks• Duct outlet has asymmetrical orientation
18.94
11.37
4.17
System Assembly using COTS Heat Sinks
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3D-Printed Heat Sink - Genetic Algorithm Implementation
Initialization
Evaluation Selection
Mating pool Crossover/Mutation
Recombination
Machine learning based Automatic Co-simulation
Iterating Loop
General concept of Genetic Algorithm
“Survival of the fittest”
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• Optimization target: Junction temperature & Height
3D-Printed Heat Sink - Genetic Algorithm Based Optimization
Hexagon
Fins
Optimization parameters:
Baseplate thickness
Layer of hexagons
# of hexagons per layer
Thickness of hexagon boundary
Secondary baseplate thickness
# of fins
Thickness of fins (Distributed)
Distribution of fins
Overall height
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3D-Printed Heat Sink - Summary
• Applying GA based optimization on single unit reduced
▪ height by 38%
▪ maximum device junction temperature by more than
20%.
• Further improvement possible with
• larger optimization iterations
• more design features
• higher design freedoms to fully utilized the benefits
of 3D printing
Height comparison between Aavid HS (Red) and GA HS (Blue)
Temperature comparison between
Aavid HS(Right) and GA HS(Left)
MOSFET
MOSFET
Diode
Diode
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• Completed designs for a 5kW WBG-based ENABLE hardware system
– Ver. 1 designed for operating at a fixed dc output voltage (400V)
– Ver. 2 designed for operating at over a wide output dc voltage range (200V-450V)
Hardware Design Summary
Ver. 2 Ver. 1 Note
SiC MOSFET Rohm SCT3022ALGC1114
Rohm SCT3022ALGC1114
Replaced Cree/WolfspeedC2M0025120D
SiC diode Microsemi APT30SCD120B14
Microsemi APT30SCD120B14
DC Cap EPCOS B32778J5367K000 6x360=2160μF
EPCOS B32778J4487K000*4x480=1920μF
*not in stock
Inductor Coilcraft SER2918H2 (10μH each)
Wurth 744355803302 (3.3μH each)
Transformer Custom made (4:3) Custom made (1:1)
Output Cap EPCOS B32778J5367K0001
EPCOS B32778J4487K000*2
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Hardware Assembly
System using COTS heat sinks
COTS heat sinks
System using 3D-printed heat sinks
Power Board
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AC to DC conversion
Test Results
AC-DC conversion efficiency vs. output power
Peak efficiency: 93.0%DAB voltages
DAB currents
Source voltage
Source current
Output current
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DC to AC conversion
Test Results
DC-AC conversion efficiency vs. output power
Peak efficiency: 94.4%DAB voltages
DAB currents
Output voltage
Output currentSource current
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Project schedule, deliverables, and current status
• $1250K spent
Date Milestones and Deliverables Status
Jun 2017 Complete circuit analysis to size components and to develop a control strategy
Complete
Sep 2017 Complete circuit simulation to verify the analysis results, generate efficiency data for various operating and power flow conditions, and to validate the controls
Complete
Dec 2017 Complete design for WBG-based 5kW ENABLE hardware system
Complete
Sep 2018 Complete the build of the hardware Complete
Apr 2019 Complete test and evaluation of the hardware system Complete
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Anticipated challenges and risk mitigation strategies
• Project complete
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Next steps
• Project is complete• For commercialization, the power module needs to be extensively
evaluated for each mode described earlier.
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Broader Impact
• A manuscript will be prepared for publishing the results of the project.• More discussions will be held with Flex Power Control for
commercialization of this technology.
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Contact Information
Burak Ozpineci, Ph. D.
PI
Power Electronics and Electric Machinery Group
Oak Ridge National Laboratory
Knoxville, TN 37932 USA
Email: [email protected]
Gui-Jia Su, Ph. D.
Technical Lead
Power Electronics and Electric Machinery Group
Oak Ridge National Laboratory
Knoxville, TN 37932 USA
Email: [email protected]
Robert (Bob) Dawsey
Commercialization Partner
Flex Power Control
Torrance, CA 90503
Email: [email protected]