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DOE OSTI2021

Design and Optimization of a 200-kW Medium-Frequency Transformer for Medium-Voltage SiC PV Inverters

This paper presents a design and optimization methodology for a 200-kW medium-frequency transformer (MFT) based on low-loss magnetic core (FINEMET FT-3TL). The proposed optimal design methodology consists of predesign, preliminary design, and optimal design. In the preliminary design, the parallel-concentric winding structure is selected to increase the current carrying capability and reduce the leakage inductance. Based on the parallel-concentric winding concept, a novel cooing and insulation structure with 3-D printed bobbins are proposed. The optimal designed MFT prototype achieves a power density higher than 19.23 kW/L. The electrical insulation system is tested at 12 kV ac peak voltage. In addition, the partial discharge (PD) test is conducted at 7.5 kV ac peak voltage to ensure the PD-free design. The high-frequency bipolar pulsewidth modulation voltage insulation (PD) test is the first time applied in MFT design and test process. Finally, the transformer is applied in a dual-active-bridge (DAB) converter with 200 kW rated power. The peak efficiency of the DAB converter is 99.53%, and the efficiency at 200 kW is 98.85%. The peak efficiency of MFT is 99.844%, and the efficiency at 200 kW is 99.842%.

42 ENGINEERING↗

DOE OSTI2021

Advances in Processing, Manufacturing, and Applications of Magnetic Materials

Magnetic materials are increasingly important for many green energy technologies. Probably, the best known of these are permanent magnets. They are used to supply a magnetic field and are widely used in actuators, motors, generators, data storage, and sensors. These are “hard magnets,” meaning that they retain a large permanent magnetization (difficult to be demagnetized), which is what makes them so useful in motors where an opposing magnetic field can be used to push against them. A coercivity (resistance to demagnetization) of ~400 Oe (32,000 A/m) or more is typically the threshold value for a hard magnet and is typical of isotropic sintered ferrite (SrFe 12 O 19 ) such as found in many “refrigerator magnets.” Comparably important soft magnets are useful for directing magnetic fields and can be very easily (de)magnetized. As such, they typically have a coercivity < 12.5 Oe (1000 A/m), and specialized very soft magnets can have coercivities < 0.00125 Oe (1 A/m). Some common applications include coil cores, transformer cores, and magnetic shielding. Additionally, they are important for many AC electrical applications such as inductors, filters, and resonators, particularly at high frequencies up to and including microwaves.

36 MATERIALS SCIENCE↗

NASA NTRS1998

Radio-Frequency Illuminated Superconductive Disks: Reverse Josephson Effects and Implications for Precise Measuring of Proposed Gravity Effects

We have previously reported results using a high precision gravimeter to probe local gravity changes in the neighborhood of large bulk-processed high-temperature superconductors. It have been indicated three essential components to achieve anomalous gravity effects, namely large, two-layer high-temperature YBCO superconductors, magnetic levitation and AC input in the form of radio-frequency (RF) electromagnetic fields. We report experiments on RF-illuminated (1-15 MHz) superconducting disks with corresponding gravity readings indicating an apparent increase in observed gravity of approximately 3-5 x l0(exp -5)cm/sq s, above and to the side of the superconductor. In this preliminary study, RF- illumination is achieved using a series of large radius (15 cm) spiral antenna with RF power inputs equal to or greater than 90 W. The observed gravitational modification range is significantly lower than the 2.1% gravity modification. The error analyses of thermal and electromagnetic interference in a magnetically shielded gravimeter with vacuum enclosures, Faraday cages and shielded instrument leads, are outlined both experimentally and theoretically. The nearly exact correspondence between the peak gravity effects reported and the well-known peak in AC resistance in superconductors (2-7 MHz, owing to reverse Josephson quantum effects) suggests that electrical resistance will arise in this frequency range and subsequently any trapped magnetic fields in the superconductor may disperse partially into the measuring instrument's local environment. Implications for propulsion initiatives and RF-heating in superconductors will be discussed.

Noever, David A.↗

DOE OSTI2023

A Smart Silicon Carbide Power Module With Pulse Width Modulation Over Wi-Fi and Wireless Power Transfer-Enabled Gate Driver, Featuring Onboard State of Health Estimator and High-Voltage Scaling Capabilities

A wide range of utility applications require controllable switches with features such as high-voltage blocking and high-current carrying capacity, especially at high pulse width modulation (PWM) frequency. Low- and medium-voltage utility applications such as motor drives and flexible AC transmission systems as well as solid state transformers could also benefit from a low-cost high-voltage switching module. Wide-bandgap semiconductors such as silicon carbide (SiC) and gallium nitride (GaN) metal oxide semiconductor field effect transistors (MOSFETs) are considered to be the present and next-generation device choices, although they have limitations. For relatively high-voltage applications with demanding thermal management, SiC is still the only choice, and GaN dominates the low-voltage regime. This manuscript proposes a new half-bridge power MOSFET module that is suitable for conventional H-bridge of multilevel configurations used in high-voltage applications. Constructed from bare SiC dies, this half-bridge module takes advantage of (1) optimized MOSFET placement inside the module, (2) customized heat exchanger, manifold, and cooling, (3) integrated gate driver module with pulse width modulation (PWM) over wi-fi to eliminate the need for low-voltage signals, (4) wireless power transfer (WPT)-enabled gate driver and other ancillary circuits, (5) and the option to incorporate an onboard state-of-health (SOH) estimator module. The entire architecture has been designed and built at the National Renewable Energy Laboratory (NREL) in Golden, CO.

Ga2O3 devices↗

DOE OSTI2020

A Novel AC to AC Wireless Power Transfer System for EV Charging Applications

In this paper, a novel ac to ac wireless power transfer (WPT) system is introduced for electric vehicle (EV) charging applications to reduce cost and design complexity. The presented wireless power transfer concept achieves unity power factor (UPF) on the grid-side by using a hybrid frequency ac / ac converter without an additional converter stage and closed loop control compared to the conventional systems. Due to inherent merit of the proposed ac / ac converter, ac input with 60 Hz grid frequency can be directly transferred to the load by superimposing with high frequency switching signal through the wireless coils. To validate the theoretical analysis of the proposed WPT system, the experimental results of the proposed converter are provided for 650 W output power by using 6 inches air gap between the couplers with the input of 110 VRMS ac source. The system overall efficiency is measured 89 % achieving 0.99 power factor (PF) and 1.5 % current total harmonic distortion (THD).

Asa, Erdem↗

DOE OSTI2021

Hybrid Data-Driven Based HVdc Ancillary Control for Multiple Frequency Data Attacks

The high voltage direct current (HVdc) intertie has been applied to provide ancillary-services for ac grids, utilizing the real-time feedback from phasor measurement units (PMUs). However, PMU data communication is vulnerable to false data injection attacks (FDIA) due to protocol defects, thus the HVdc ancillary control and system stability will be threatened. To address this issue, this article proposes a novel HVdc control strategy based on a hybrid data-driven (HDD) methodology. In this work, the HDD methodology is first proposed to detect the types and duration time of multiple frequency attacks. Specifically, the Hilbert Huang transform (HHT) is used to decompose the frequency data, using variational mode decomposition instead of the traditional empirical mode decomposition, to extract data features. Second, a multikernel support vector machine is proposed to classify the attacked data based on the designed distinctive features from HHT. Meanwhile, the attacking duration time is decided using an unsupervised technique. Third, an HDD-based HVdc ancillary control strategy is established to eliminate the effect of FDIAs on the HVdc frequency response. Comprehensive experiments of HDD-based HVdc ancillary controls under different FDIAs suggest that the proposed HDD could fast and accurately classify the FDIAs, and the HDD-based HVdc ancillary control strategy could significantly suppress the impact of the FDIAs.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

A Single-Stage Multilevel AC-DC Bidirectional Converter With Natural Grid Harmonic Elimination

Generally, AC-DC converters have an AC-DC stage followed by a DC-DC stage. In these two stage approaches, the AC-DC stage is hard-switched, whereas the DC-DC stage is soft-switched. Therefore, the devices in the AC-DC stage can be switched only at tens of kHz to avoid excessive switching losses, thus limiting the bandwidth of the current control loop. Hence, the control of these converters with distorted grid voltages requires multiple harmonic compensation loops or other complex control algorithms in order for the grid currents to comply with IEEE standards. By integrating both the stages, the devices in the AC-DC stage can also be soft-switched, thus facilitating higher switching frequency, and thereby higher current control bandwidth. This paper proposes an integrated multilevel bidirectional AC-DC converter with improved control bandwidth and disturbance rejection. It is shown experimentally that the high bandwidth current control loop of the converter can reject grid harmonic current disturbances, without the need for any compensation loops or complex control techniques, and comply with IEEE standards.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1994

Evaluation of a Multi-kw, High Frequency Transformer for Space Applications

Various NASA studies have shown that high power (multi-kW and higher) electrical systems for various aerospace applications favor high frequency distribution systems, due to the improved safety and weight factors associated with those systems. Other favorable characteristics include low EMI, minimal wiring and ease of system parameter sensing and control of a single phase system. In aerospace power systems, as in terrestrial AC distribution systems, transformers are needed to provide voltage changes, isolation and the resetting of ground. Under NASA contract NAS3-21948 a multi-kW high frequency transformer was designed, fabricated and tested by Thermal Technology Lab, Inc. of Buffalo, New York. 'The goals of this program included the determination of the relationships between transformer weight, efficiency and operating frequency; low internal temperatures and reduced specific weight; and the validation of these new design concepts through experimentation and the fabrication and testing of transformers and their insulation systems.' The transformer was delivered to NASA-Lewis, where an evaluation program was conducted in Lewis' High Power High Frequency Component Test Facility. The transformer was tested in both atmosphere and under vacuum conditions. This paper will discuss the design of the transformer, the evaluation program and test results, the failures experienced and conclusions.

Roth, Mary Ellen↗

DOE OSTI2024

Controlled skyrmion ratchet in linear protrusion defects

Using atomistic simulations, we investigate the dynamical behavior of a single skyrmion interacting with an asymmetric linear protrusion array under external ac driving. The linear protrusion array is placed in the xy plane and is composed of magnetic walls near the edge of the nanotrack that have angled linear protrusions into the nanotrack. The structure forms a hard axis for –x direction motion and an easy axis for +x direction motion. When the ac drive is applied along the x direction, the skyrmion moves along the hard direction of the substrate asymmetry in three phases: a pinned phase with localized skyrmion orbits, a constant velocity phase where the orbits become delocalized, and a reentrant pinned phase with larger localized orbits. We measure the dependence of the skyrmion velocity on the frequency and amplitude of the ac drive. All three phases appear for all frequency values simulated here, and in the constant velocity phase the skyrmion velocity depends only on the frequency and not on the amplitude of the ac drive. When ac driving is applied in the y direction, the skyrmion moves along the easy direction of the substrate asymmetry and exhibits the same three phases as for x-direction driving along with a fourth phase which, at high driving frequencies, consists of a series of constant velocity phases, each with different average skyrmion velocities. For low frequencies, the constant velocity phase is lost and the skyrmion speed increases linearly with increasing ac drive amplitude due to a Magnus boost effect. Finally, our findings suggest new ways to create reliable data transport for spintronic devices using skyrmions as information carriers, where the skyrmion direction and speed can be controlled by varying only the ac drive amplitude and frequency.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1987

Radiation from large space structures in low earth orbit with induced ac currents

Large conducting space structures in low earth orbit will have a nonnegligible motionally induced potential across their structures. The induced current flow through the body and the ionosphere causes the radiation of Alfven and lower hybrid waves. This current flow is taken to be ac and the radiated power is studied as a function of the ac frequency. The current may be ac due either to inductive coupling from the power system on the structure or by active modulation. A Space Station-like structure and tether are studied. For the Space Station structure the radiation impedance is particularly high for frequencies in the tens of kilohertz range which suggests that the Space Station may be efficient source of lower hybrid waves. The tether is also shown to be a generator of VLF waves up to source ac frequencies in the megahertz range. The implications for these two structures are discussed.

Hastings, D. E.↗

DOE OSTI2020

Design Optimization for Weighted Conduction Loss Minimization in a Dual-Active-Bridge-Based PV Microinverter

This manuscript presents a harmonic-superposition based frequency-domain approach for analysis and optimal design of a single-stage DAB-based DC-AC converter used in low-voltage DC to high voltage AC applications, such as PV microinverter. Specifically, two topological variations and correspondingly different modulation strategies involving up to four control variables (three phase shifts and switching frequency) are analyzed. Optimal trajectories of control variables are determined that result in minimized transformer RMS current at a given average power, while enforcing near-uniform ZVS. To make the design process holistic, an outer optimization loop is used to determine optimal values for the power transfer inductance (integrated as the transformer’s leakage inductance) and turns ratio, which minimize the weighted-average conduction loss contribution to the microinverter’s CEC efficiency. Based on the optimization analyses, a 400 W microinverter prototype is built and experimental results at one operating point are presented, achieving a measured efficiency of 92.8%.

14 SOLAR ENERGY↗

NASA NTRS1987

The ac power system testbed

The object of this program was to design, build, test, and deliver a high frequency (20 kHz) Power System Testbed which would electrically approximate a single, separable power channel of an IOC Space Station. That program is described, including the technical background, and the results are discussed showing that the major assumptions about the characteristics of this class of hardware (size, mass, efficiency, control, etc.) were substantially correct. This testbed equipment was completed and delivered and is being operated as part of the Space Station Power System Test Facility.

Mildice, J.↗

DOE OSTI2021

Modeling and Measuring the Stress Distribution in Soft Magnetic Cores due to Epoxy Impregnation and Curing

Understanding the effects of viscoelastic relaxation of stresses is critical in electric motor and inductor applications, where the magnetic material is fully or partially comprised of an amorphous phase and impregnated in an epoxy. Magnetic Amorphous Nanocomposites (MANCs) are a class of recently developed high-frequency magnetic materials that exhibit low magnetic hysteresis, high saturation flux density and very low AC magnetic losses. MANCs are formed as long, thin ribbons, a shape factor that minimizes eddy current-induced self-heating. This feature, in addition to their 1 GPa strength, and makes them attractive candidates for high-speed, high-power density, electric motors. MANCs are used in the form of tape-wound cores (TWCs). During the manufacturing process, the cores are impregnated with liquid epoxy between each layer of ribbon. Validated knowledge of the stresses imposed by the manufacturing process and during operation is necessary to understand motor performance limitations with respect to strength. Magnetostriction, the strain imposed by reversal of the magnetic field, also affects performance. When the epoxy cures, it contracts volumetrically by 8%, imposing radial and circumferential stresses that vary along the radial direction. To date, these stresses have received little attention in the literature. Here, we model the stress distribution throughout a TWC due to epoxy curing. Strain gauge measurements reported here indicate substantially lower tangential strain than model values, which is beneficial and which we attribute to viscoelastic relaxation of the epoxy layers. We will incorporate a constitutive model of this viscoelastic relaxation, and conduct more detailed strain measurements to understand how this takes

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1995

Power control electronics for cryogenic instrumentation

In order to achieve a high-efficiency high-density cryogenic instrumentation system, the power processing electronics should be placed in the cold environment along with the sensors and signal-processing electronics. The typical instrumentation system requires low voltage dc usually obtained from processing line frequency ac power. Switch-mode power conversion topologies such as forward, flyback, push-pull, and half-bridge are used for high-efficiency power processing using pulse-width modulation (PWM) or resonant control. This paper presents several PWM and multiresonant power control circuits, implemented using commercially available CMOS and BiCMOS integrated circuits, and their performance at liquid-nitrogen temperature (77 K) as compared to their room temperature (300 K) performance. The operation of integrated circuits at cryogenic temperatures results in an improved performance in terms of increased speed, reduced latch-up susceptibility, reduced leakage current, and reduced thermal noise. However, the switching noise increased at 77 K compared to 300 K. The power control circuits tested in the laboratory did successfully restart at 77 K.

Ray, Biswajit↗

DOE OSTI2021

High-Fidelity Models and Fast EMT Simulation Algorithms for Isolated Multi-port Autonomous Reconfigurable Solar power plant (MARS)

The integration of hybrid photovoltaic (PV) and energy storage system (ESS) based plants has become a promising way of solving the intermittency of PV plants and providing frequency support to the power grid. The multi-port autonomous reconfigurable solar power plant (MARS) can integrate the PV systems and ESSs to an ac grid and dc lines. The proposed isolated MARS incorporates an isolated converter that connects to the PV arrays and is based on the dual active bridge (DAB) converter. The high frequency switching in the DAB and the means to control the DAB converter using delays between switching signals lead to the need for a small timestep in simulations. Moreover, several hundreds of modules that include a DAB converter are present in the MARS. The small timestep and the presence of several hundreds of modules lead to a significant rise in the overall simulation time. To address this issue, simulation algorithms like numerical stiffness-based hybrid discretization and the hysteresis relaxation technique are applied to the switched system model of isolated MARS. Additionally, an event-driven interpolating method is introduced to help increase the minimum timestep to simulate the conventional DAB converter model while maintaining high accuracy in the simulation results. The developed model is validated by comparison with its reference model built in the PSCAD/EMTDC and MATLAB software environments using library components.

Xia, Qian↗

NASA NTRS1987

AC power system breadboard

The object of this program was to design, build, test, and deliver a high-frequency (20-kHz) Power System Breadboard which would electrically approximate a pair of dual redundant power channels of an IOC Space Station. This report describes that program, including the technical background, and discusses the results, showing that the major assumptions about the characteristics of this class of hardware (size, mass, efficiency, control, etc.) were substantially correct. This testbed equipment has been completed and delivered to LeRC, where it is operating as a part of the Space Station Power System Test Facility.

Wappes, Loran J.↗

NASA NTRS2021

Effect of High Temperature Storage on AC Characteristics of Polymer Tantalum Capacitors

Replacement of MnO2 with conductive polymers as cathode materials in chip tantalum capacitors allows for a substantial reduction of the equivalent series resistance (ESR), improvement of frequency characteristics, and elimination of the possibility of ignition during failures. One of the drawbacks of chip polymer tantalum capacitors (CPTCs) is a relatively poor long-term stability at high temperatures. In this work, variations of capacitance, dissipation factor, and ESR in different types of capacitors including automotive grade parts from three manufacturers have been monitored during storage at temperatures from 100 ºC to 175 ºC for up to 18,000 hours. Results show that ESR is the most and capacitance the least sensitive to degradation parameter. Times to parametric failures have been simulated using a Weibull-Arrhenius model that allowed for assessments of activation energies of the degradation and prediction of times to failure at the use temperature. Degradation of CPTCs was explained by thermo-oxidative processes in conductive polymers that result in exponential increasing of the resistivity with time of ageing. This process starts after a certain incubation period that depends on packaging materials and design and corresponds to the time that is necessary to form delamination between the encapsulating molding compound and lead frame. The effectiveness of the existing qualification procedures to assure stable operation of CPTCs is discussed.

Alexander A Teverovsky↗

NASA NTRSDate not supplied

Effect of High Temperature Storage on AC Characteristics of Polymer Tantalum Capacitors

Aging↗