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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Modular Coaxial Power Converter for High-Density Integration into Medium-Voltage Cables

This work proposes to combine the functionality benefits of power electronics with the power density benefits of medium-voltage cables to create a streamlined, high-density power electronics solution that seamlessly integrates with medium-voltage cables. Located at the ends of a medium- or high-voltage line, the proposed converter uses a cascade of coaxial power conversion cells to gradually step down the voltage, and excels in high step-down applications. By mimicking the coaxial geometry of medium-voltage cables, the converter preserves the axisymmetric electric field of the cable which, when combined with a solid insulating dielectric, provides a voltage scaling advantage over conventional planar and PCB-based converter solutions. Similar to medium voltage cables, the converter is fully passively cooled. A passive cooling strategy allows for combined installation with existing medium voltage cable systems without the added cost, maintenance needs, infrastructure, and reliability concerns associated with active cooling systems. The scalability of the modular structure in combination with the integration benefits provide a flexible power electronics system that can adapt to the evolving demands of the grid.

coaxial power conversion cells↗
DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Guest Editorial: Special Issue on InterPACK 2019 - Part 1

This is a collection of papers drawn from the 2019 ASME InterPACK Conference. The content spans the areas of heterogeneous integration, servers, flexible and wearable electronics, photonics, power electronics, energy storage, and autonomous and electric vehicles.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Calculating electronic stopping power in materials from first principles

From the early models of electronic stopping power to the current first principles simulations, the techniques evolved to increase the range of validity and to reduce empiricism. Thanks to a combination of theoretical advances provided by Time Dependent Density Functional Theory and the development of numerical codes, it is currently possible to predict electronic stopping power for realistic materials by performing direct simulations of the electron excitation processes beyond linear response, and including electronic band structure effects. Electronic stopping power is an important quantity used to predict and understand the effects of particle radiation in matter. First principles calculations of electronic stopping power can be applied to any atomistic system, solids, liquids and alloys. This review aims here to help graduate level students and researchers immerse themselves into state-of-the-art techniques to computationally model and calculate electronic stopping power.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Comparison of Thermal Management Approaches for Integrated Traction Drives in Electric Vehicles

The continuous push to increase power densities of electric vehicle (EV) traction drive systems necessitates combining electric motor and power electronics into one unit. A single, compact traction drive unit with fewer interconnecting components also facilitates fast, automated assembly of electric vehicles, driving production costs down and enabling wider adoption of EVs. There are a number of challenges associated with the integration of power electronics with the electric machine, including thermal management of the combined traction drive system. However, one important benefit of integration from the thermal management system perspective is the potential for using a single fluid loop instead of two separate cooling systems for the electric machine and the power electronics/inverter. This paper reviews several integration approaches and, employing finite element analysis (FEA), compares thermal management solutions for the combined electric machine and power electronics systems. Namely, three different scenarios are modeled: (1) independent component (motor and power electronics) cooling, which is compared to the combined cooling system approach for (2) radially and (3) axially integrated power electronics modules into the motor enclosure. Temperature distributions for selected thermal loads and thermal resistances from the key heat-generating components to the cooling fluid are compared for each scenario.

47 OTHER INSTRUMENTATION↗
DOE OSTI2018

Electronic stopping power of protons and alpha particles in nickel

The electronic stopping power of nickel for protons and alpha particles at velocities below and around the Fermi velocity has been obtained to high accuracy using time-dependent density functional theory. For the wide range of projectile velocities considered, we observed di erent regimes of electronic stopping due to the alternative participation of s- and d-band electrons. Despite the sharp discontinuity in the electronic density of states near the Fermi energy characteristic of the nickel band structure, we do not nd an anomalous non-linear electronic stopping power limit as a function of velocity. However, we nd a crossover region above v = 0:15 a:u: both for protons and alpha particles, related to the increase in participating host electrons and, in the case of alpha particles, to an increase of the charge state. We compare our calculated results with widely available experimental data and analyze the low velocity limits in the context of Lindhard's linear response theory and previous non-linear density functional calculations. The comparison shows good accord with the lowest velocity experiments available. This may indicate that the adiabatic local density approximation is already a good theory to calculate electronic stopping power in materials at low velocity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Semiconductor: Supply Chain Deep Dive Assessment

In February 2021, President Biden signed Executive Order (EO) 14017, “America’s Supply Chains,” directing seven executive agencies to evaluate the resilience and security of the nation’s critical supply chains and to craft strategies for six industrial bases that underpin America’s economic and national security. See Sec. 3(b) of E.O. 14017. As part of the one-year response to EO 14017, the U.S. Department of Energy (DOE), through the national laboratories, conducted evaluations of the supply chains that encompass the Energy Sector Industrial Base, with a particular focus on technologies required to decarbonize the U.S. by 2050. This report focuses on one of these technologies, semiconductors, both conventional and wide bandgap (WBG) power electronics (PE). As noted in the 100-Day report, conventional semiconductors are a keystone technology that are essential for the operation of nearly every electronic device, including those that are critical to decarbonization, such as electric vehicles (EVs), industrial and building applications, and electricity generation and end use. In addition, power electronics have been applied to industrial equipment to improve energy efficiency and enhance controllability. Power electronics have also been used to improve the reliability of data centers and critical infrastructure, including the stabilization of the electric grid while subjected to disturbances. Increasingly, power electronics are being used to integrate renewable energy and battery storage systems, enabling new grid services and the development of microgrids. It is estimated that 30% of the electricity used in the U.S. passes through power electronic devices, and studies suggest that this number could reach 80% as power electronics are deployed in more markets. Nearly all forms of electrified transportation will depend on power electronics. Power electronic systems utilize high-capacity semiconductor devices at their core. The continued growth in power electronics depends on sustained innovation in the semiconductor industry.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2019

Photovoltaic Inverter Reliability Assessment

As the price of PV modules drops, the price of power electronics become more important. Power electronics now constitute 8%-12% of the total lifetime PV cost. As of 2010, the inverter and associated power conditioning components accounted for $\$0.25$/W, well above the DOE benchmark of $\$0.12$/W by 2020. As efforts to reduce PV module costs yield diminishing returns, the importance of understanding and reducing inverter costs becomes an increasingly critical and cost-effective investment toward achieving the DOE SunShot goals. With this in view, this report showcases and describes an approach to help assess and predict the reliability of photovoltaic (PV) inverters. To predict the reliability, thermal cycling is considered as a prominent stressor in the inverter system. To evaluate the impacts of thermal cycling, a detailed linearized model of the PV inverter is developed along with controllers. This research also develops models and methods to compute the losses of the power electronics switches and other components in a PV inverter. The losses are then used to estimate the junction and heat sink temperature. The model is verified by developing an in-house inverter. Additionally, to assess the scalability of the research, the hardware inverter is placed inside a thermal chamber to verify the losses for different ambient temperatures. After the verification of the model, a reduced-order model of the inverter is implemented to translate the profile of ambient temperature and solar irradiance into the profile of junction temperatures of the switches. The estimated junction temperature data are used to identify inverter reliability indices and predict the useful lifetime of the inverter system. After developing the models to predict the useful lifetime of the system, the impact of reactive power on the overall reliability of the system will be studied. The first chapter involves the motivation behind the research on assessing the reliability of PV inverters. The inverter power stage and controller design of the power converter used in this research is also explained in detail in this chapter. The second chapter presents the various losses of the power converter system and the translation of power loss into temperature increase with thermal modeling. The results of the loss modeling and the thermal modeling are also explained in detail in this chapter. The third chapter involves implementing the reduced-order model to translate the mission profile of ambient temperature and solar irradiance into profile of the junction temperatures of the switches. The final chapter involves identifying reliability indices, which are of interest for this system to predict the remaining useful life of the system, and concludes with the impact of reactive power on the overall reliability of the inverter system.

14 SOLAR ENERGY↗
NASA NTRS2019

Low Power Microrobotics Utilizing Biologically Inspired Energy Generation

The Low Power Microrobotics (LPM) project is a NASA NIAC-funded multi-disciplinary research effort involving the research and advancement of low power electronics, low power mobility and their integration with state of the art microbial fuel cell for power generation. The goal of this project was to advance the capabilities of each of these systems with a 10-year future target of a near one kilogram space exploration vehicle that contains each of these systems. In order to accomplish this task, each system was investigated independently in order to establish the power requirements/limitations while considering how each system affects the other systems. This was performed through numerous trade studies and experimental work, primarily focused around the power capacity of the microbial fuel cell base-lined for this project and how its strengths and limitations affected the design of the remaining onboard systems. Finally an end-to-end system test utilized a microbial fuel cell to charge a super capacitor through an energy harvesting circuit, which was discharged to activate a robotic locomotion system.

Microrobotics↗
DOE OSTI2022

Making Wireless Power Matter (CRADA Final Report)

The Resonant Link project team investigated the integration of their novel, self-resonant magnetic structure for electromagnetic coils into inductive wireless power transfer systems. Relative to conventional wireless power coils, their multi-layer self-resonant structure (the “MSRS”) reduces losses by up to 6x and lowers to BOM cost by up to 10x. These power-dense, cost-effective coils are a promising path towards the first value-add wireless power systems in a variety of applications, from phones to medical devices to kitchen appliances to mobile robots to electric vehicles. The researchers explored development of the power electronics for wireless power transfer systems using the multi-layer self-resonant structure (MSRS) concept that efficiently transmits power over air gaps for in-home applications, including through-wall power transfer, appliances built around the Ki and Qi standards, and other potential use cases This project specifically focused on the power electronics design, development, and testing for these applications. Resonant Link’s proprietary wireless power technology holds the promise of matching the performance of wired chargers in size and efficiency, especially when operated from a DC distribution grid.

42 ENGINEERING↗
NASA NTRS1993

Power Switching Device

The MOS-Controlled Thyristor is a new type of power switching device for faster and more efficient control and management of power electronics. It enables power electronic switching at frequencies of 50 to 100 thousand times a second with much lower power losses than other semiconductor devices. Advantages include electric power savings and smaller space. The device is used in motor and power controllers, AC & DC motor drives and induction heating. Early development was supported by Lewis Research Center (LEW) and other agencies. General Electric''s power semiconductor operation, the initial NASA contractor, was later purchased by Harris Semiconductor.

Source record↗
DOE OSTI2021

High Power Superconducting Electron Linear Accelerators For Industrial Application

Fermilab is executing a technology development program to develop a compact yet powerful electron accelerator. We are leveraging R&D breakthroughs in SRF cavities, cost-effective radio-frequency sources, modern cryo-coolers, and high average current electron guns. We show that a single accelerator module can deliver average beam power as high as 1 MW through detailed thermal, RF, and particle simulations.

Thangaraj, Jayakar Tobin↗
DOE OSTI2019

Part 1: Detailed Electromagnetic Design of an Integrated and Compact 1.3 GHZ Superconducting Radio Frequency (SRF) Electron

There exists a need for compact, reliable, high-power electron sources for applications including those in water treatment, basic science, defense, and security. There also exists a need for compact electron-beam based light and power sources of various power levels and at different frequencies (mm-wave to gamma rays) for applications also in the fields of basic science, industry, and defense and security. Today’s examples of high-average-power electron sources are neither very compact nor highly efficient. The same may be said for many of the electron-beam based light sources operated worldwide for myriad of applications. Recent breakthroughs in superconducting (SC) materials technology, radio-frequency (RF) power systems, specialized cathodes, and RF cavity designs offer ways to overcome the above-mentioned shortcomings. In this report, all these new features are integrated in a comprehensive design into one promising concept for a compact superconducting RF (SRF) high-average power electron linear accelerator. This design is capable of 5-50 kW average electron beam power and continuous wave operation with the corresponding electron beam energy up to 10 MeV.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Wide-Bandgap Semiconductor Amplifiers for Fusion Plasma Heating and Control

This paper discusses power electronics developed under the ARPA-E GAMOW program to support nuclear fusion power production. The goal of this project was to develop and assess the potential for wide-bandgap (WBG) semiconductor devices in power electronics to enable high-efficiency and high-voltage solid-state systems for fusion plasma generation, heating, and control. The power electronics use an architecture in which multiple high-power boards can be combined to produce megawatt-level power, where using multiple boards provides high reliability. Two main areas of power electronics boards are developed in this project for fusion plasma heating and control applications: (1) pulse generation and control and (2) radiofrequency generation. The first area is for boards capable of driving high-voltage millisecond pulses at high duty cycles. The envisioned application of these pulses is in plasma control of magnetohydrodynamic instabilities, plasma position, and edge-localized modes. Pulse-width modulation allows for the implementation of a wide variety of linear and nonlinear control systems. The boards developed for this project could actuate control coils based on digital input signals and can be parallelized to provide megawatts of output power. The design of the pulse generator is a low-side load switch. A load switch was designed and constructed that utilized 2-kV-rated field-effect transistor (FET)-based cascodes developed by Qorvo under this project to perform initial testing of these cascodes. The second area is being implemented using class E amplifiers with WBG devices and a reactance steering network to handle inductive or capacitive plasma loads. Applications include ion cyclotron resonance heating (ICRH) and high-harmonic fast-wave (HHFW) heating. A class E reactance steering network is demonstrated in modeling and experiment with a resistive-inductive load that models an inductively-coupled plasma. Power combining of boards with class E reactance steering networks is also simulated and demonstrated experimentally, to enable scaling up to high power. Modeling of high-power-density cooling and remaining useful life is conducted to enable reliable, effectively cooled high-power electronics for fusion applications.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Integration Methods for High-Density Integrated Electric Drives (Final Technical Report)

The project goal was to research, design and fabricate high-power-density, high-performance SiC power electronic modules for motor drive inverters in electric vehicles (EVs) to enable the subsequent motor drive to achieve a power density of 100 kW/l. EVs use electric motors instead of internal combustion engines as the prime mover, and their core components are semiconductor-based power electronic modules. Efficient power electronic modules play a vital role in power conversion systems. The performance of power modules directly affects the energy efficiency and overall performance of electric vehicles. Therefore, it is particularly important to develop power modules with high power density and high electrical performance that will perform reliably under EV environmental conditions. To achieve these goals, advanced electronic packaging technologies are required. This report describes a 5-year effort to integrate key aspects surrounding the basic power devices into the module itself to increase power density. These include sensing and sensing readout circuits, gate driver circuits, and two-sided cooling solutions.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2012

Robust, Rework-able Thermal Electronic Packaging: Applications in High Power TR Modules for Space

The higher output power densities required of modern radar architectures, such as the proposed DESDynI [Deformation, Ecosystem Structure, and Dynamics of Ice] SAR [Synthetic Aperture Radar] Instrument (or DSI) require increasingly dense high power electronics. To enable these higher power densities, while maintaining or even improving hardware reliability, requires improvements in integrating advanced thermal packaging technologies into radar transmit/receive (TR) modules. New materials and techniques have been studied and are now being implemented side-by-side with more standard technology typically used in flight hardware.

Hoffman, James Patrick↗
NASA NTRS2009

A High Power Density Power System Electronics for NASA's Lunar Reconnaissance Orbiter

A high power density, modular and state-of-the-art Power System Electronics (PSE) has been developed for the Lunar Reconnaissance Orbiter (LRO) mission. This paper addresses the hardware architecture and performance, the power handling capabilities, and the fabrication technology. The PSE was developed by NASA s Goddard Space Flight Center (GSFC) and is the central location for power handling and distribution of the LRO spacecraft. The PSE packaging design manages and distributes 2200W of solar array input power in a volume less than a cubic foot. The PSE architecture incorporates reliable standard internal and external communication buses, solid state circuit breakers and LiIon battery charge management. Although a single string design, the PSE achieves high reliability by elegantly implementing functional redundancy and internal fault detection and correction. The PSE has been environmentally tested and delivered to the LRO spacecraft for the flight Integration and Test. This modular design is scheduled to flight in early 2009 on board the LRO and Lunar Crater Observation and Sensing Satellite (LCROSS) spacecrafts and is the baseline architecture for future NASA missions such as Global Precipitation Measurement (GPM) and Magnetospheric MultiScale (MMS).

Hernandez-Pellerano, A.↗