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This presentation provides a state of the art of electric-drive vehicle power electronics, and covers the APEEM Group research in thermomechanical and reliability aspects of advanced power electronics packaging. Some future directions are identified.
There are many applications of precise time and time interval (frequency) in operating modern electric power systems. Many generators and customer loads are operated in parallel. The reliable transfer of electrical power to the consumer partly depends on measuring power system frequency consistently in many locations. The internal oscillators in the widely dispersed frequency measuring units must be syntonized. Elaborate protection and control systems guard the high voltage equipment from short and open circuits. For the highest reliability of electric service, engineers need to study all control system operations. Precise timekeeping networks aid in the analysis of power system operations by synchronizing the clocks on recording instruments. Utility engineers want to reproduce events that caused loss of service to customers. Precise timekeeping networks can synchronize protective relay test-sets. For dependable electrical service, all generators and large motors must remain close to speed synchronism. The stable response of a power system to perturbations is critical to continuity of electrical service. Research shows that measurement of the power system state vector can aid in the monitoring and control of system stability. If power system operators know that a lightning storm is approaching a critical transmission line or transformer, they can modify operating strategies. Knowledge of the location of a short circuit fault can speed the re-energizing of a transmission line. One fault location technique requires clocks synchronized to one microsecond. Current research seeks to find out if one microsecond timekeeping can aid and improve power system control and operation.
Silicon cell Photovoltaic (PV) power modules are key components of the Space Station Electrical Power System (EPS) scheduled to begin deployment in 1994. Four PV power modules, providing 75 KWe of user ac power, form the cornerstone of the EPS; which is comprised of Photovoltaic (PV) power modules, Solar Dynamic (SD) power modules, and the Power Management and Distribution (PMAD) system. The PV modules are located on rotating outboard sections of the Space Station (SS) structure and each module incorporates its own nickel-hydrogen energy storage batteries, its own thermal control system, and some autonomous control features. The PV modules are a cost-effective and technologically mature approach for providing reliable SS electrical power and are a solid base for EPS growth, which is expected to reach 300 KWe by the end of the Space Station's 30-year design lifetime.
Although there are increasing numbers of distributed energy resources (DERs) and microgrids being deployed, current IEEE and utility standards generally strictly limit their interconnection inside secondary networks. Secondary networks are low-voltage meshed (non-radial) distribution systems that create redundancy in the path from the main grid source to each load. This redundancy provides a high level of immunity to disruptions in the distribution system, and thus extremely high reliability of electric power service. There are two main types of secondary networks, called grid and spot secondary networks, both of which are used worldwide. In the future, primary networks in distribution systems that might include looped or meshed distribution systems at the primary-voltage (mediumvoltage) level may also become common as a means for improving distribution reliability and resilience. The objective of this multiyear project is to increase the adoption of microgrids in secondary networks and meshed distribution systems by developing novel protection schemes that allow for safe reliable operation of DERs in secondary networks. We will address these challenges by working with the appropriate stakeholders of secondary network operators, protection vendors, and standards committee. The outcomes of this project include: a) development and/or demonstration of candidate methods for enabling protection of secondary networks containing high levels of DER; b) development of modeling and testing tools for protection systems designed for use with secondary networks including DERs; and c) development of new industrial partnerships to facilitate widespread results dissemination and eventual commercialization of results as appropriate.
Although there are increasing numbers of distributed energy resources (DERs) and microgrids being deployed, current IEEE and utility standards generally strictly limit their interconnection inside secondary networks. Secondary networks are low-voltage meshed (non-radial) distribution systems that create redundancy in the path from the main grid source to each load. This redundancy provides a high level of immunity to disruptions in the distribution system, and thus extremely high reliability of electric power service. There are two main types of secondary networks, called grid and spot secondary networks, both of which are used worldwide. In the future, primary networks in distribution systems that might include looped or meshed distribution systems at the primary-voltage (medium-voltage) level may also become common as a means for improving distribution reliability and resilience.
Managing heat in electrical conductors is a major challenge to meet the demands for sustainable energy use and electrical reliability, most notably power electronics and energy-critical electrical machines. Achieving such disparate functionalities, such as high temperature thermal and electrical reliability, require rational design and manufacturing of thermal conductor material and its hierarchical structures. Here we present hierarchical thermal-conductive nanocomposites, consisting of nanostructured ceramic conformal coating and aligned ultrahigh molecular weight polyethylene fiber, to tailor heat dissipation in electric conductors. The hybrid aligned thermal interface exhibits a highly desirable temperature dependent anisotropic high thermal conductivity with 0.98W m –1 K –1 and dielectric strength with 3.4. In addition, electrically insulating thermal interfaces demonstrate high-performing and reliable electrical systems under the dynamic load conditions. The surface temperature of heterogeneous ceramic-polymer encapsulated conductor is 17.8 °C lower than that of polymer-encapsulated conductor at the same electrical load. Consequently, the findings shown here hold great promises for directing heat extraction in electrical machine systems, advancing thermal management for emerging electronic applications.
The National Aeronautics and Space Administration is developing battery and fuel cell technology to meet the expected energy storage needs of human exploration systems. Improving battery performance and safety for human missions enhances a number of exploration systems, including un-tethered extravehicular activity suits and transportation systems including landers and rovers. Similarly, improved fuel cell and electrolyzer systems can reduce mass and increase the reliability of electrical power, oxygen, and water generation for crewed vehicles, depots and outposts. To achieve this, NASA is developing non-flow-through proton-exchange-membrane fuel cell stacks, and electrolyzers coupled with low permeability membranes for high pressure operation. The primary advantage of this technology set is the reduction of ancillary parts in the balance-of-plant fewer pumps, separators and related components should result in fewer failure modes and hence a higher probability of achieving very reliable operation, and reduced parasitic power losses enable smaller reactant tanks and therefore systems with lower mass and volume. Key accomplishments over the past year include the fabrication and testing of several robust, small-scale non-flow-through fuel cell stacks that have demonstrated proof-of-concept. NASA is also developing advanced lithium-ion battery cells, targeting cell-level safety and very high specific energy and energy density. Key accomplishments include the development of silicon composite anodes, lithiatedmixed- metal-oxide cathodes, low-flammability electrolytes, and cell-incorporated safety devices that promise to substantially improve battery performance while providing a high level of safety.
As the grid evolves, the communications architecture will need to evolve with it. That architecture affords a structured means by which the evolving complexities of the modern electric grid can be managed. This document provides best practices that can be implemented in the grid of today and evolve towards the grid and grid architecture of the future. The evolving grid and its control communications increasingly rely on commercial communications providers and a variety of technologies, from wireless (e.g., 5G, microwave, Wi-Fi) to wireline (fiber, copper) to radio communications (P25, other repeater-based systems), and all these communications systems rely on electric power. A reliable and resilient grid must account for this complex set of interdependencies in its planning activities, especially those involving restoration and recovery. The participation of all relevant parties in both planning and exercising of plans can prevent unexpected conditions that impede the reliable operation and recovery of the grid. Best practices for grid communications include using a Network Management System to document the operational state, define and monitor baselines, detect changes, and accelerate response to abnormalities. If transitioning from SONET to IP/packet-based systems, translating grid requirements into communications requirements for latency, bandwidth and throughput, IP packet delay variation, packet loss, and availability should inform and drive technology planning and selection as well as that communication system’s Quality of Service (QoS) policies and Service Level Agreements (SLAs). Secure and reliable timing is another key component of a reliable and resilient grid that can operate through adverse events. A trusted internal NTP configuration, an integrated and diverse timing delivery system, optimizing the timing architecture based on the transport technologies of the communications system, and using established standards can deliver the level of timing accuracy required by a range of time-sensitive power system applications.
Development of failure sensing switching circuitry for electrical power system reliability during extended space missions
Reliability of electrical power subsystem designed for manned spacecraft
A large number of planetary missions under consideration for the next two decades will be using radioisotope thermoelectric generators to provide the necessary spacecraft electrical power. Performance, reliability, lifetime and cost of these RTGs are expected to be more demanding and will require the development of advanced thermoelectric materials. An advanced thermoelectric materials development program is being conducted by JPL and is the subject of this paper. Under this program, alloys of rare earth chalcogenides have been synthesized and their thermoelectric properties evaluated. The selection of specific compounds on which the program is currently concentrating is influenced by criteria such as low thermal conductivity, reasonably high operating temperatures (not less than 1000 C) and stability of the compounds. The paper discusses the rationale, approach and current status of the program. In addition, the thermoelectric and thermophysical property measurement used to evaluate the materials are described. The preliminary results and analysis of these experimental data are also given.
The National Aeronautics and Space Administration (NASA) is working towards developing and demonstrating new technologies, capabilities, and business approaches that are needed for future human deep space exploration missions. This includes collaborating with commercial and international partners to establish the first long-term presence on the Moon under the Artemis mission. Artemis lunar surface operations begin with robotically exploring the lunar south polar region for locations suitable for harvesting lunar surface resources. Over time, activities will expand beyond robotic operations, increasing the need for highly reliable and available electrical power. Beyond Artemis, there are interests in full commercial lunar surface activities. A lunar microgrid is being proposed to deliver highly reliable and available electrical power on the lunar surface and meet the power needs. Microgrids are of interest in terrestrial applications due to their ability to integrate a variety of renewable power sources. A similar approach can be taken for the lunar surface. A lunar microgrid would offer the ability to integrate various power sources to maximize power availability, including nuclear, solar arrays, batteries, and regenerative fuel cells. Microgrids are flexible and can be designed to allow for islanded operation, where power is utilized near the loads to minimize power distribution losses, or in a power sharing mode where power is transmitted longer distances. This capability is crucial during failures where overall power availability is reduced. Microgrids will also allow for the power system to grow and evolve over time, meeting the need to expand beyond initial lunar surface activities.
NLR's advanced power electronics and electric machines (APEEM) research group develops world-class experimental and modeling capabilities to design and evaluate efficient and reliable power electronics and electric machines, as well as innovative thermal management systems to maximize their performance. They also design, fabricate, and characterize advanced power electronics packaging and are developing state-of-health monitoring techniques.
Hydrogen fuel cell powered vehicles for heavy duty trucks is a potential path for reducing heavy duty vehicle emissions in the future. The air handling system delivers the proper amount of air (oxygen) to react with fuel (hydrogen) in the fuel cell to produce power. Air delivery requires significant power and is the largest parasitic loss for a 300 kW fuel cell. Today’s systems use an electric motor to power an air compressor that supplies oxygen to the fuel cell stack. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications. The air handling is provided by a twin vortices series (TVS) compressor in addition to adding a TVS expander to recover waste heat energy back into the compressor. The final configuration includes a 600 V, 39 kW motor connected with a single shaft to the compressor and expander. This configuration reduced the total electrical power consumption from 48.6 kW to 37 kW at full load, 27 kW to 9 kW at half load and 0.44 kW to 0.22 kW at idle. The response time requirement was to be less than 2 seconds while the final demonstration yielded 0.62 sec. The study includes additional technologies including water dosing into the compressor, a recuperator and elimination of the intercooler.
Sensing and measurement systems are quintessential to the safe and reliable operation of electric power grids. Their strategic placement is of ultimate importance because it is not economically viable to install measurement systems on every node and branch of a power grid, though they need to be monitored. An overwhelming number of strategies have been developed to meet oftentimes multiple conflicting objectives. The prime challenge in formulating the problem lies in developing a heuristic or an optimisation model that, though mathematically tractable and constrained in cost, leads to trustworthy technical solutions. Further, large-scale, long-term deployments pose additional challenges because the boundary conditions change as technologies evolve. For instance, the advent of new technologies in sensing and measurement, as well as in communications and networking, might impact the cost and performance of available solutions and shift initially set conditions. Also, the placement strategies developed for transmission grids might not be suitable for distribution grids, and vice versa, because of unique characteristics; therefore, the strategies need to be flexible, to a certain extent, because no two power grids are alike. Despite the extensive literature on the present topic, the focus of published works tends to be on a specific subject, such as the optimal placement of measurements to ensure observability in transmission grids. There is a dearth of work providing a comprehensive picture for developing optimal placement strategies. Because of the ongoing efforts on the modernisation of electric power grids, there is a need to consolidate the status quo while exposing its limitations to inform policymakers, industry stakeholders, and researchers on the research-and-development needs to push the boundaries for innovation. Accordingly, this paper first reviews the state-of-the-art considering both transmission and distribution grids. Then, it consolidates the key factors to be considered in the problem formulation. Finally, it provides a set of perspectives on the measurement placement problem, and it concludes with future research directions.
Deep space missions have a strong need for compact, high power density, reliable and long life electrical power generation and storage under extreme temperature conditions. Conventional power generating devices become inefficient at very low temperatures (temperatures lower than 200 K encountered during Mars missions for example) and rechargeable energy storage devices cannot be operated thereby limiting mission duration. At elevated temperatures (for example for planned solar probe or Venus lander missions), thin film interdiffusion destroys electronic devices used for generating and storing power. Solar power generation strongly depends upon the light intensity, which falls rapidly in deep interplanetary missions (beyond 5 AU), and in planetary missions in the sun shadow or in dusty environments (Mars, for example). Radioisotope thermoelectric generators (RTGs) have been successfully used for a number of deep space missions RTGs. However, their energy conversion efficiency and specific power characteristics are quite low, and this technology has been limited to relatively large systems (more than 100 W). The National Aeronautics and Space Administration (NASA) and the Jet Propulsion Laboratory (JPL) have been planning the use of much smaller spacecrafts that will incorporate a variety of microdevices and miniature vehicles such as microdetectors, microsensors, and microrovers. Except for electrochemical batteries and solar cells, there are currently no available miniaturized power sources. Novel technologies that will function reliably over a long duration mission (ten years and over), in harsh environments (temperature, pressure, and atmosphere) must be developed to enable the success of future space missions. It is also expected that such micropower sources could have a wide range of terrestrial applications, in particular when the limited lifetime and environmental limitations of batteries are key factors. Additional information is contained in the original extended abstract.
Hydrogen fuel cell powered vehicles are one of the potential paths to reducing vehicle emissions. An important subsystem of the hydrogen fuel cell system is an air handling system that provides the needed oxygen (in air) to react with hydrogen in the fuel cell stack for electric power generation. Today’s systems use an electric motor to power an air compressor that supplies oxygen to the fuel cell stack. This process requires significant electrical power and is the largest parasitic power loss in hydrogen fuel cell vehicles. In addition to parasitic power loss, hydrogen fuel cell systems often have reliability issues associated with the air handling system. Reliability is of significant concern for heavy duty applications (especially long-haul applications). This project aims to improve both the electrical power consumption and reliability of hydrogen fuel cell air handling systems to meet the needs of heavy duty on-highway vehicle applications.
The formulation of a philosophy for devising a reliable, efficient, lightweight, and cost effective electrical power system for advanced, large transport aircraft in the 1980 to 1985 time period is discussed. The determination and recommendation for improvements in subsystems and components are also considered. All aspects of the aircraft electrical power system including generation, conversion, distribution, and utilization equipment were considered. Significant research and technology problem areas associated with the development of future power systems are identified. The design categories involved are: (1) safety-reliability, (2) power type, voltage, frequency, quality, and efficiency, (3) power control, and (4) selection of utilization equipment.