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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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All sources NASA NTRS DOE OSTI

DOE OSTI2019

Levelized-Cost-of-Electricity-Driven Design Optimization for Medium-Voltage Transformerless Photovoltaic Converters

Design approaches for power electronics are typically focused on efficiency and power density; however, these strategies do not guarantee cost optimality in any well-defined sense. To overcome this shortcoming, we propose a design framework that yields circuit parameters that minimize the levelized cost of electricity (LCOE) of a generation system. LCOE serves as a meaningful metric since it captures total lifetime costs - including hardware, balance of system, and maintenance costs - and includes the impacts of power conversion efficiency and revenue from harvested energy. To obtain a tractable design problem, we formulate an approximate LCOE improvement model that quantifies the changes in LCOE resulting from a candidate converter design. We apply this framework to a multilevel cascaded topology for low-voltage dc to medium-voltage ac conversion without line-frequency transformers. An example 200 kW commercial-scale system is studied and the solution yields a design with 15 cascaded stages, 98.01% efficiency, and an LCOE reduction of 2.0%.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2018

Numerical Stiffness based Simulation of Mixed Transmission Systems

Inclusion of power electronics allows increased controllability and stability in power systems. The simulation of such systems on a large-scale is challenging due to the presence of a large number of switches and nonlinear devices. This paper presents an advanced simulation algorithm to solve the aforementioned problem. The algorithm considers separation of differential algebraic equations (DAEs) on the basis of numerical stiffness and applies hybrid discretization algorithms to simulate the DAEs. The DAEs, in this paper, represent the nonlinear nonautonomous switched system dynamics of power systems. Stability analysis is performed on a general class of nonlinear nonautonomous switched systems to show the constraints under which the proposed algorithm is stable. To show the validity of the proposed algorithm, two case studies are considered: single high-voltage direct current (HVdc) substation based on the modular multilevel converter (MMC); and an example three-terminal MMC-HVdc system. Furthermore, relaxation techniques are introduced to create a stable interface for the separated DAEs. The developed algorithms are also validated with PSCAD/EMTDC-detailed reference models.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Medium- and Heavy-Duty Vehicle Electrification: An Assessment of Technology and Knowledge Gaps

The objective of this assessment was to leverage current medium- and heavy-duty vehicle (MHDV) data and information to evaluate the state of commercial vehicle electrification technologies, including the following: 1. Assessment and inventory of current MHDV electrification architectures; 2. Identification and assessment of MHDV component technologies; 3. Assessment of potential performance and cost drivers; and, 4. Identification of R&D gaps where appropriate R&D and technology would accelerate commercial vehicle electrification. These gaps include shortfalls in technology, gaps in data, and inadequate knowledge and understanding. To inform this study, the National Renewable Energy Laboratory–Oak Ridge National Laboratory team examined the open literature; conducted workshops; assessed and analyzed data on more than 175 electrified MHDVs, including vehicle and powertrain specifications; and conducted one-on-one meetings with industry representatives. This systems-level information was concatenated and parsed with respect to key characteristics such as battery energy, power, and range compared across vehicle classes. Operational data of many conventional vehicles were also examined to help determine the requirements on electrified vehicle attributes such as range. Previous studies on the total cost of ownership of electrified MHDVs were reviewed to determine where improvements in technologies (efficiency, cost, maintenance) were needed to accelerate adoption. The team also assessed the state of the art in electric drivetrains for component specifications and challenges for the commercial vehicle sector, including electric machines, power electronics, and off-board high-power charging systems (extreme fast charging and beyond). The goal of this analysis was to identify the barriers to widespread adoption of commercial vehicle electrification technologies and prioritize the research and development gaps that need to be overcome to accelerate significant market penetration of these technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2018

Nonpolar vertical GaN-on-GaN p–n diodes grown on free-standing $(10\bar{1}0)$ m -plane GaN substrates

We report nonpolar vertical GaN-on-GaN p–n diodes grown on m-plane free-standing substrates. Cathodoluminescence measurements showed that the nonpolar p-GaN had a high quality with very few deep-level states. The device exhibited good rectifying behaviors with a turn-on voltage of 4.0 V, on-resistance of 2.3 mΩ∙cm 2 , and high on/off ratio of 10 10 . The reverse current leakage was described by a trap-assisted space-charge- limited current conduction mechanism. The critical electrical field was calculated to be 2.0 MV/cm without field plates or edge termination. Finally, these results pave the way for development of novel nonpolar power electronics and polarization-engineering-related advanced power devices.

36 MATERIALS SCIENCE↗

NASA NTRS1991

Description of the PMAD DC test bed architecture and integration sequence

NASA-Lewis is responsible for the development, fabrication, and assembly of the electric power system (EPS) for the Space Station Freedom (SSF). The SSF power system is radically different from previous spacecraft power systems in both the size and complexity of the system. Unlike past spacecraft power system the SSF EPS will grow and be maintained on orbit and must be flexible to meet changing user power needs. The SSF power system is also unique in comparison with terrestrial power systems because it is dominated by power electronic converters which regulate and control the power. Although spacecraft historically have used power converters for regulation they typically involved only a single series regulating element. The SSF EPS involves multiple regulating elements, two or more in series, prior to the load. These unique system features required the construction of a testbed which would allow the development of spacecraft power system technology. A description is provided of the Power Management and Distribution (PMAD) DC Testbed which was assembled to support the design and early evaluation of the SSF EPS. A description of the integration process used in the assembly sequence is also given along with a description of the support facility.

Beach, R. F.↗

NASA NTRS1991

Description of the PMAD DC test bed architecture and integration sequence

NASA-LEWIS is responsible for the development, fabrication, and assembly of the electric power system (EPS) for the Space Station Freedom (SSF). The SSF power system is radically different from previous spacecraft power systems in both the size and complexity of the system. Unlike past spacecraft power systems, the SSF EPS will grow and be maintained on orbit and must be flexible to meet challenging user power needs. The SSF power system is also unique in comparison with terrestrial power systems because it is dominated by power electronic converters which regulate and control the power. A description is provided of the Power Management and Distribution DC Testbed which was assembled to support the design and early evaluation of the SSF EPS. A description of the integration process used in the assembly sequence is also given along with a description of the support facility.

Beach, R. F.↗

NASA NTRS2014

Controllable Multi-Functional Heat Exchanger for Space Applications

Team Spacering will design SpaceRing, a cooling and waste heat recycling system that addresses NASA’s interest for a cooling and power-generating unit in its prototype deep space habitat[1]. The merits of this system are as follows: - Controllable cooling is critical in maintaining a habitable environment and in the functionality of life support systems, powering electronics and other devices in a spacecraft. - Power is expensive to produce in a space environment. Converting wasted thermal energy into electricity will save energy and money for the space station. Space habitation is a highly complex endeavor. Consequently, the SpaceRing must adhere to additional constraints, which include: - Lack of natural fluid or gas convection due to micro-gravity environment - Limited range for heat source and cold sink temperature - Subject to high fluctuations of incoming thermal energy - Minimal weight due to the high cost of transporting items into space After consulting with NASA and experts in thermal studies, several design objectives were identified and are listed below in order of importance: - High cooling capacity - Reliable safety control and alert system - Maximization of energy generation from wasted heat - Optimization of cooling capability and power generation - Long operational life and minimization of maintenance In space, conventional cooling systems utilize passive heat pipe systems for small-scale heat rejection and pumped pipes with heat exchangers for large-scale heat rejection. Thermal power generation in space is mainly achieved by using thermoelectric material that produces electric energy from temperature differentials. We propose a design that combines cooling and thermoelectric power generation. Using a hot pipe connected to a heat source, a cold pipe connected to a radiator, a heat exchanger in contact with both pipes, and a pump in each pipe to move the fluid, we make an active cooling system. The thermoelectric material is inserted in the heat exchanger between the hot and cold pipes to extract energy from the maximum temperature difference coming from the two pipes. It also provides controllable cooling capacity through the use of the thermoelectric material as cooling modules. We have tested our system under target heat source and sink conditions and measured the temperatures and flow rates. Our preliminary results are promising, demonstrating the output of 25 Watts of power on average. We are in the process of running control tests to compare the heat transfer performance without the thermoelectric generators, which is vital in determining whether or not the generators introduce an unacceptable amount of thermal resistance. While some control tests have been run already, the results have been noisy. We have modified our testing environment and data acquisition methods to allow for simple comparison between the control test results and thermoelectric performance results. Lastly, we have modified the heat exchanger design slightly to include acrylic baffles. This will allow the heat to flow through the heat exchanger more efficiently. We have presented our preliminary results to NASA and will deliver the final product by the end of May 2014.

Lee Xiong↗

DOE OSTI2019

Levelized-Cost-of-Electricity-Driven Design Optimization for Medium-Voltage Transformerless Photovoltaic Converters: Preprint

Design approaches for power electronics are typically focused on efficiency and power density; however, these strategies do not guarantee cost optimality in any well-defined sense. To overcome this shortcoming, we propose a design framework that yields circuit parameters that minimize the levelized cost of electricity (LCOE) of a generation system. LCOE serves as a meaningful metric since it captures total lifetime costs -- including hardware, balance of system, and maintenance costs\textemdash and includes the impacts of power conversion efficiency and revenue from harvested energy. To obtain a tractable design problem, we formulate an approximate LCOE improvement model that quantifies the changes in LCOE resulting from a candidate converter design. We apply this framework to a multilevel cascaded topology for low-voltage dc to medium-voltage ac conversion without line-frequency transformers. An example 200-kW commercial-scale system is studied and the solution yields a design with 15 cascaded stages, 98.89% efficiency, and an LCOE reduction of 3.6%.

14 SOLAR ENERGY↗

DOE OSTI2020

Holistic Thermal Management

This presentation, part of the 2019 Applied Power Electronics Conference (APEC), discusses holistic thermal management.

28 EE - Advanced Manufacturing Office (EE-5A)↗

DOE OSTI2026

Thermal Management Solution for an Integrated Outer-Rotor Motor Drive: Opportunities and Challenges

This work highlights an integrated thermal management solution for the outer-rotor motor (ORM) drive. The integrated ORM drive utilizes water-ethylene glycol coolant for power electronics and stator cooling. Air cooling is used for rotor laminations, magnets and outer-rotor structures, and the rotor shaft. To fully understand the performance of the integrated ORM drive and thermal management coupling effects, a full drive conjugate heat transfer model has been developed to investigate coupled cooling performance of various components of the ORM drive. Various motor rotational speeds, power output scenarios, and cooling options for the integrated ORM drive have been investigated. The model estimates the operating window for the ORM drive while keeping component operating temperatures below prescribed limits. The model also highlights the importance of windage losses at higher rotational speeds for this ORM design, which involves higher rotor surface area per unit width of the rotor. Different designs are also investigated, particularly focusing on rotor cooling with air either naturally induced by rotor spin or forced airflow with the help of a blower, to circumvent challenges imposed by higher windage losses. The work highlights motor rotational speed limitations and the need for potential liquid cooling options for desired rotor performance at higher rotational speeds. Liquid cooling for the rotor may even become more critical for nonuniform rotor-stator gaps, leading to even higher and uneven windage losses across the full circumference of the motor, consequentially, more heating for the rotor.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Wind Systems Integration Workshop

The U.S. Department of Energy’s Wind Energy Technologies Office (WETO) Wind Systems Integration Workshop was held to facilitate an exchange of information and to solicit feedback to inform WETO’s near- to mid-term research priorities and to accelerate near-term, rapid deployment and integration of wind technologies at both the transmission and distribution levels. Workshop participants identified key research challenges and opportunities for grid services, power electronics, modeling and decision-support tools, transmission and distribution system coordination, and applying energy equity principles to wind grid integration research.

17 WIND ENERGY↗

DOE OSTI2023

Ampaire ARPA-e Electric Flight Testbed

A hybrid-electric aircraft flying testbed was developed in this program with the intent to serve as a dedicated, enduring testbed to test and evaluate ARPA-e CIRCUITS Program and other electrified aviation technologies in relevant flight environments. This testbed enabled rapid development cycles of novel and innovative technologies in the electrified aviation space, maturing them from a research lab environment to flying in an aircraft. By providing research groups with the means to test their transformative technologies in a real-world, aircraft environment, the path to validating the safety and reliability of their technologies for future commercial opportunities was greatly accelerated. Three core technologies were integrated and tested: an inverter/motor drive built by the University of Arkansas, a solid-state circuit breaker (iBreaker) built by the Illinois Institute of Technology, and a Flying Capacitor Multi-level (FCML) DC/DC converter built by the University of California, Berkeley. In each of these cases, the requirements established for safety of flight resulted in a holistic approach to the designs, evoking a deeper understanding of the potential failure modes and mitigations necessary to build a robust and flightworthy system. Further, the integration into a hybrid-electric aircraft de-risked the potential electrical and mechanical issues that cannot easily be experienced or replicated in a lab environment. The experiments were also required to undergo representative temperature, shock, and vibration testing as the FAA prescribes for this category of aircraft, facilitating familiarity with the relevant design and test guidelines necessary to commercialize the technologies. This testbed unlocks the massive potential of core power electronics technologies necessary for a safe, robust, and efficient electric aviation future. With quick iterative design, test, and flight cycles, these core technologies are on a quicker path to technology readiness level maturity and commercialization, enabling a more sustainable future for the aviation industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2014

Thermal Performance Benchmarking (Presentation)

This project will benchmark the thermal characteristics of automotive power electronics and electric motor thermal management systems. Recent vehicle systems will be benchmarked to establish baseline metrics, evaluate advantages and disadvantages of different thermal management systems, and identify areas of improvement to advance the state-of-the-art.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2016

FY2015 Electric Drive Technologies Annual Progress Report

The Electric Drive Technologies research and development (R&D) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies under development. Research is focused on developing power electronics (PE), electric motor, and traction drive system (TDS) technologies that will reduce system cost and improve their efficiency in transforming battery energy to useful work. The R&D is also aimed at better understanding and improving how various components of tomorrow’s automobiles will function as a unified system to improve fuel efficiency.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

FY2016 Electric Drive Technologies Annual Progress Report

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

An overview of the operation architectures and energy management system for multiple microgrid clusters

The emerging novel energy infrastructures, such as energy communities, smart building-based microgrids, electric vehicles enabled mobile energy storage units raise the requirements for a more interconnective and interoperable energy system. It leads to a transition from simple and isolated microgrids to relatively large-scale and complex interconnected microgrid systems named multi-microgrid clusters. In order to efficiently, optimally, and flexibly control multi-microgrid clusters, cross-disciplinary technologies such as power electronics, control theory, optimization algorithms, information and communication technologies, cyber-physical, and big-data analysis are needed. This paper introduces an overview of the relevant aspects for multi-microgrids, including the outstanding features, architectures, typical applications, existing control mechanisms, as well as the challenges.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Modular Wide-bandgap String Inverters for Low-cost Medium-voltage Transformerless PV Systems

The proposed technology combines advances in wide-bandgap power electronics with breakthroughs in distributed and decentralized control to produce ultra-low-cost medium-voltage transformerless PV inverters that are composed of stackable lightweight blocks. Taken together, the proposed circuit designs and accompanying control strategies will yield integrated control+circuit (C2) blocks, each comprising a converter and local controller, that can be assembled in a modular fashion to obtain distributed conversion interfaces for next-generation commercial and utility-scale PV systems. We will utilize SiC devices to obtain C2 blocks that can individually operate at a voltage and power in excess of 1 kV and 100 kW, respectively, such that ensembles of series-connected blocks perform direct dc to three-phase ac conversion at medium voltages (e.g., 12 kV–35 kV) and at multi-MW power levels.

42 ENGINEERING↗

DOE OSTI2014

Microstructure and Sn crystal orientation evolution in Sn-3.5Ag lead-free solders in high temperature packaging applications

Understanding the reliability of eutectic Sn-3.5Ag lead-free solders in high temperature packaging applications is of significant interest in power electronics for the next generation electric grid. Large area (2.5mm 2.5mm) Sn-3.5Ag solder joints between silicon dies and direct bonded copper substrates were thermally cycled between 5 C and 200 C. Sn crystal orientation and microstructure evolution during thermal cycling were characterized by electron backscatter diffraction (EBSD) in scanning electron microscope (SEM). Comparisons are made between observed initial texture and microstructure and its evolution during thermal cycling. Gradual lattice rotation and grain boundary misorientation evolution suggested the continuous recrystallization mechanism. Recrystallization behavior was correlated with dislocation slip activities.

high temperature packaging↗