Additively Manufactured Photovoltaic Inverter (AMPVI)
Successful integration of hundreds of gigawatts of solar photovoltaics (PV) into the electric power system requires transformative power conversion system design that optimizes various trade-offs among conflicting objectives, such as performance, reliability, functionality, and cost. To address this need, National Renewable Energy Laboratory, Oak Ridge National Laboratory, and Purdue University teamed up to develop a unique PV inverter design. The Additively Manufactured Photovoltaic Inverter (AMPVI) combines newer wide bandgap high-voltage silicon carbide (SiC) semiconductor devices with revolutionary concepts such as additive manufacturing and multi-objective magnetic design optimization. The AMPVI will not only provide superior technical capabilities in terms of energy conversion but also mitigate market barriers for SiC-based PV inverters. The benefits for this design will include better utilization of PV power due to higher DC voltage, lower operations and maintenance costs, better system efficiency, longer system lifetime, and advanced grid support functionalities for easier grid integration. All these advantages will lead to a significant reduction of the levelized cost of energy for PV systems. Activities in Budget Period 1 (BP1) of this 3-year integrated project were focused on development and component-level validation of the foundational building blocks needed for the AMPVI. Multiple interrelated tasks were completed in parallel during work towards the initial development of the high-voltage SiC-based power block, gate driver, controller board, and control algorithms. Initial development of magnetic design tools and initial inverter thermal and mechanical design was also completed in this period. All these activities ensured that the initial prototype (called “alpha-prototype”) power block and controller would be ready after BP1 for integration into the first inverter prototype (i.e., the alpha-prototype inverter) in BP2.