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Transcript of Extreme Power Density Converters - Fundamental … Power Density Converters - Fundamental Techniques...
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Extreme Power Density Converters -Fundamental Techniques and Selected
Applications
Robert Pilawa-Podgurski
University of Illinois Urbana-Champaign
PELS Bay Area Chapter Seminar
July 13th, 2017
1
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Acknowledgment
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The Goals of Power Electronics
3Credit: Tesla Motors
Credit: SamsungCredit: EWEA Credit: Google
Credit: CAT
Credit: NASA/MIT/Aurora Flight Sciences
Credit: ABB
Credit: AES
Credit: Tesla
High Power Density High Efficiency
High Reliability Low Cost
High EfficiencyHigh Power Density
High Performance Power Converters
Integration of power electronics in systems for
overall performance improvements
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The Tools of Power Electronics
4
Active devices Passive devicesCircuit topologies
Integration/Packaging
Control
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Conventional Path to High Power Density
5
Switching frequency
Size
Switching frequency
Pow
er L
oss
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Component Choices
6
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Hybrid Switched-Capacitor Converters
R.C.N. Pilawa-Podgurski, D.J. Perreault, “Merged Two-Stage Power Converter with Soft Charging Switched-Capacitor Stage in 180 nm CMOS,” IEEE Journal of Solid-State Circuits, Vol. 47, No 7, pp. 1557-1567, 2012
Y. Lei, R.C.N. Pilawa-Podgurski “A General Method for Analyzing Resonant and Soft-charging Operation of Switched-Capacitor Converters,” IEEE Transactions on Power Electronics, Vol. 30, No. 10, pp. 5650-5664, October 2015
Y. Lei, R. May, R.C.N. Pilawa-Podgurski, “Split-Phase Control: Achieving Complete Soft-Charging Operation of a Dickson Switched-Capacitor Converter,” IEEE Transactions on Power Electronics, Vol. 31, No. 1, pp. 770-782, January 2016 7
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Hybrid Switched-Capacitor Converters
8Active devices Passive devices
Circuit topologies
Integration/Packaging
Control
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9
DC-AC and AC-DC Power Conversion
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The Importance of DC/AC and AC/DC
10
Power Electronics:DC/AC & AC/DC
Power Electronics:DC/AC & AC/DC
Grid Integration of Renewables and Storage Electric Transportation
Credit: CAT Credit: GM Credit: NASA
Credit: Nissan
Credit: Nissan
Credit: Tesla
Credit: iStockphoto
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Google/IEEE $1M Little Box Challenge
2 kW, single-phase 240 V, 60 Hz AC
Example usage: solar inverter, electric car charger, grid storage integration
Current state-of-the-art: 95% efficiency, 400 in3.
Target goal: >95% efficiency, 10x smaller (40 in3)
$1M prize to winning entry
11Prior (lack of!) experience
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Our Goal
12
Develop a radically different solution – make significant
research contribution to the field of power electronics. May not win competition, but will have
long-term impact
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Original Team
13
Chris Barth Integration Mechanical Thermal Capacitor
evaluation
Yutian Lei Inverter
design Inverter
control
Shibin Qin Twice-line-
frequency buffering
System control
$30k funding through Google Academic Grant
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Key Technical Challenges
14𝐸𝑠𝑡𝑜𝑟𝑒 =
𝑃𝑑𝑐2𝜋𝑓𝑙𝑖𝑛𝑒
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Buffer Solutions
15
Twice-line frequency power decoupling solutions
Passive buffering Large volume = poor system power density Poor lifetime
Active buffering Low efficiency Increased system complexity Higher cost
Passive: dc-link capacitor bank
Active: full-ripple port
Passive: series resonant LC
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Passive Series Resonant LC Buffer
At resonant frequency:
16
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Passive Series Resonant LC Buffer
17
Express the 2ωL voltage and current components in phasor representation:
purely reactive power
Example: If C = 100 uF then L = 18mH for resonance at 120 Hz
Can we implement the resonant buffer without such a large physical inductor?
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Passive Component Density
18
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Active Series Resonant LC Buffer
19
Use a dc-ac converter with capacitive load to emulate an active inductor Vastly improve power density of passive resonant solution Implement resonant impedance behavior with proper control Series-stacked buffer (SSB) architecture
Active inductor at 2ωL
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Buffer Solutions – Series-Stacked Buffer
20
Benefits:
High efficiency Partial power processing
High power density
[1] S. Qin. TPEL, 2017.[2] Y. Lei. APEC, 2016.
2 kW SSB, Google Little Box[1],[2]
Shortcomings:
Complex non-intuitive control
Current sensing and control Not a two-terminal device
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Active Series Resonant LC Buffer
21
Dc-ac buffer converter: full-bridge buck
Practical buffer converter is lossy VC2 will gradually decay
additional real power term
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Passive Series Resonant LC Buffer with Loss
22
Incorporate practical buffer converter loss with a series resistance, Rab, in the equivalent impedance model
real power = power loss
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Control Architecture with Loss
23
Characteristic equations:
Powerphasor portrait:
Control architecture:
Voltage/currentphasor portrait:
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Experimental Results
24N. Brooks, S. Qin, R.C.N. Pilawa-Podurski “Design of an Active Power Pulsation Buffer Using an Equivalent Series-Resonant Impedance Model”, COMPEL 2017 [Best Paper Award]
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Hardware Prototype – Energy Density
25
Way of measurement
Volume Power density
Rectangularbox
4.88 inch^3 410 W/inch^3
passive component
2.01 inch^3 995 W/inch^3
Design requirement:- 2 kVA (PF = 0.7~1)- 400 V ~ 450V bus voltage, - 10 A peak to peak current
The highest prior active filtering power density reported was 79.4W/inch^3 by component volume, by Chen et al, TPELS 2013 (120 W, metal film capacitors)
GaN full bridge
auxiliary
supply
sensing
circuitry
microcontroller𝐶1
58.3mm
𝐶2
98.0mm
inductor
auxiliary
supply
𝐶1𝐶3
𝐶𝑏𝑢𝑠
14.0mm
> 99% efficiency across load range
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Overall Size Reduction
26
7-10x size reduction
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Key Technical Challenges
27𝐸𝑠𝑡𝑜𝑟𝑒 =
𝑃𝑑𝑐2𝜋𝑓𝑙𝑖𝑛𝑒
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Inverter – Today’s Practice
28
High switch voltage stress
High power loss at high frequencies
Large inductor
Wide band-gap semiconductors alone will not address these challenges. We need to consider new inverter architectures.
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Multi-Level Flying-Capacitor Converter
29
Reduced switch voltage stress [VDC/6] Can utilize fast, low-voltage transistors
Inductor ripple frequency [Fsw*6]
Reduced ripple magnitude [VDC/6]
Much smaller inductor!
T. Meynard and H. Foch, “Multi-level conversion: high voltage choppers and voltage-source inverters,” PESC ’92
7-Level Convert
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7-level Flying Capacitor Converter
30
Challenges
Capacitor voltage balancing
Gate driving complexity
Parasitic inductance (especially with GaN devices)
No demonstrated examples of > 4 level flying capacitor multi-level inverter using GaNtransistors, and none switching in the 100’s of kHz at kW levels.
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Key Challenge: Parasitic Loop Inductance
100% OvershootRg= 5 Ohm
31
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Modular Switching Cell
32
20% OvershootRg = 15 Ohm
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Digital Control
Control objective: Generate correct amplitude Switch only minimum inductance loops Maintain capacitor voltage balance
33
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Prototype #1
34
80 W/in3, 98% efficient
500 total entries July 23, 2015, 120 submitted final report 18 finalists selected to October 21 NREL testing
Credit: ETH/Fraunhofer
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Growing the Team
35
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Shrinking the Hardware
36
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2 kW Hardware Prototype
37
Y. Lei, C. Barth, S. Qin, W.-C. Liu, I. Moon, A. Stillwell, D. Chou, T. Foulkes, Z. Ye, Z. Liao and R.C.N. Pilawa-Podgurski “A 2 kW, Single-Phase, 7-Level, GaN Inverter with an Active Energy Buffer Achieving 216 W/in^3 Power Density and 97.6% Peak Efficiency”, IEEE Applied Power Electronics Conference, Long Beach, CA, 2016
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Experimental Results
38
0.3% THD
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Little Box Finalists’ Symposium
39
Venderbosch
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After NREL Testing
40
Venderbosch
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NREL Testing Details
41
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Research Impact
Demonstrated the feasibility of multi-level flying capacitor power converters at kW-scale
Achieved significant performance improvements compared to state-of-the-art Integration Digital control Device utilization
GaN transistors Multi-layer ceramic capacitors
42
Laid the foundation for several promising future research areas
Active devices Passive devicesCircuit topologies
Integration/Packaging
Control
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New Applications
Electric vehicles Bidirectional chargers (6.6 kW) On-board dc-dc (50 kW) Superchargers (150 kW)
Consumer electronics Ultra high efficiency power supplies
for datacenters LED lighting Chargers
Renewable integration Grid-scale storage
43
Credit: Ford
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Specific Example: AC-DC PFC
Power factor correction (PFC) front-end Datacenter applications (server) EV charging Any high power, single-phase grid
connected device
44
Liu et al., Design of GaN-based mhz totem-pole PFC rectifier, JESTPE 2016Raggl et al., Comprehensive design and optimization of a high-power-density single-phase boost pfc," TIE 2009.Biela et al., Optimal design of a 5kw/dm3 98.3% rectifier," ECCE ASIA 2010 Lange et al., Three-level single-phase bridgeless pfc rectifiers," TPELS 2015
240 Vac to 400 Vdc, 1.5 kW prototype
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45
DC-AC Power Conversion for Electric Transportation
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Aviation is the Last Horizon of Hybridization
Obstacles for Electrifying Aircraft
• Electric and turbo-electric aircraft propulsion
requires both very high efficiency and low
weight
[1] NASA press release “NASA Electric Research Plane Gets X Number, New Name” (June, 17 2016)
[2] N. Madavan et al., “A NASA Perspective on Electric propulsion technologies for commercial aviation” April 2016
[3] Jansen, Ralph H., et al. "Turboelectric Aircraft Drive Key Performance Parameters and Functional Requirements." (2015).
NASA Roadmap for MEA for 2025 [2]:
• Reduce landing/takeoff NOx emissions by 80%
• Reduce cruise NOx emissions by 80%
• Reduce fuel consumption by 60%
• Develop X-Plane concept aircraft
[3]
[1]
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High Specific Power, Low Inductance Motor
University of Illinois at Urbana-Champaign
1MW Outer-Rotor PMSM Architecture
• Maintain high efficiency & specific power for high fundamental frequency (3 kHz)
• Provide sinusoidal voltage with low distortion since machine is ultra-low
inductance (minimal iron)
Inverter Requirements:
[1] Zhang et al., “High-specific-power electric machines for electrified transportation - technology options,” IEEE ECCE 2016
[1]
3
• Rated Power = 1 MW
• Rotational Speed = 14,000 RPM
• Pole Count = 20
• Electrical Frequency = 3 kHz
• Specific Power 15 kW/kg
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Aircraft Power Density/Efficiency Challenges
48
HiQ Solar, NREL Best Venture Award 2014
Wolfspeed/U. Ark/Toyota, R&D100 2014
NASA minimum goal
NASA target
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Conventional Solution
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Achieving extreme power density through removal of all iron -> very low inductance machine
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Our approach, 9-level FCML converter
Each module contains two interleaved inverters.
50Inverter commutation loop
Large commutation inductance will lead to voltage overshoot and ringing
Double-sided integrated switching cell
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Modular FCML-based Inverter
51Double Interleaved Module 200kW inverter
9-24X
Modular Inverter Configuration
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Experimental Results, 9-level Interleaved FCML
In: 1000V dcOut: 345Vrms, 1.2kW, 750 Hz98.5% at 120kHz switching frequency
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output voltagesfiltered output voltageoutput current
Inverter leg A Inverter leg B
DC in
AC out
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Efficiency – Single FCML Leg
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Peak efficiency at 98.5% and 3kW
Close to Rev. 0thermal limit.
Target: efficiency ≥99.0% at 4.2kW (12 modules @16.7kW)or at 5.6kW (9 modules @22.2kW)
[1] T. Modeer, C. Barth, N. Pallo, W.H. Chung, T. Foulkes, and R. Pilawa-Podgurski, Design of a GaN-based, 9-level Flying Capacitor Multilevel Inverter with Low Inductance Layout, in Applied Power Electronics Conference and Exposition (APEC), 2017.
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Performance Evaluation
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HiQ Solar, NREL Best Venture Award 2014
Wolfspeed/U. Ark/Toyota, R&D100 2014
NASA minimum goal
NASA target
UIUC 2017
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Heatsink Optimization
Work in collaboration with Ken Goodson at Stanford 55
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Interdisciplinary Research Challenges
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5-year, $4M/year NSF-funded Engineering Research Center, with Illinois, University of Arkansas, Stanford, and Howard
University
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Interdisciplinary Research Examples
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Conclusions
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Active devices Passive devicesCircuit topologies
Integration/Packaging
Control
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Acknowledgments
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