Climate specific thermomechanical fatigue of flat plate photovoltaic module solder joints
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Bosco, Nick↗
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Final Scientific/Technical Report. A closed path methane and water vapor gas analyzer
Robust, economical, low-power and reliable closed-path methane (CH 4 ), carbon dioxide (CO 2 ), and water vapor (H 2 O) analyzers suitable for long-term measurements are not readily available commercially. Such analyzers are essential for quantifying the amount of CH 4 and CO 2 released from various ecosystems (wetlands, rice paddies, forests, etc.) and other surface contexts (e.g. landfills, animal husbandry lots, etc.), and for understanding the dynamics of the atmospheric CH4 and CO 2 budget and their impact on climate change and global warming. The purpose of this project is to develop a closed-path methane, carbon dioxide gas and water vapor analyzer capable of long-term measurements in remote areas for global climate change and environmental research. The analyzer will be capable of being deployed over a wide range of ecosystems to understand methane and carbon dioxide exchange between the atmosphere and the surface. Measurements of methane and carbon dioxide exchange need to be made all year-round with limited maintenance requirements. During this Phase II effort, we successfully completed the design of the electronics, optical bench, trace gas detection method and mechanical infrastructure. We are using the technologies of two vertical cavity surface emitting lasers, a multiple-pass Herriott optical cell, wavelength modulation spectroscopy and direct absorption to measure methane, carbon dioxide, and water vapor. We also have designed the instrument application software, Field Programmable Gate Array (FPGA), along with partial completion of the embedded software. The optical bench has been tested in a lab setting with very good results. Major sources of optical noise have been identified and through design, the optical noise floor is approaching -60dB. Both laser modules can be temperature controlled to help maximize the stability of the analyzer. Additionally, a piezo electric transducer has been utilized to randomize the noise introduced from potential etalons. It is expected that all original specifications contained within the initial proposal will be met. We are currently in the beginning stages of assembling the first generation prototypes and finalizing the remaining design elements. The first prototypes will initially be tested in our environmental calibration chamber in which specific gas concentrations, temperature and humidity levels can be controlled. Once operation in this controlled setting is verified, the prototypes will be deployed at LI-COR's Experimental Research Station (LERS). Deployment at the LERS site will test the instrument's robustness in a real-world situation.
47 OTHER INSTRUMENTATION↗
Identifying Reverse-Bias Breakdown Sites in CuInxGa(1-x)Se2
CIGS mini-modules are stressed under reverse bias, resembling partial shading conditions, to predict and characterize where failure occurs. Partial shading can cause permanent damage in the form of 'wormlike' defects on thin-film modules due to thermal runaway. We use electroluminescence (EL) imaging and dark lock-in thermography (DLIT) to supplement current-voltage curves when reverse-bias breakdown occurs on various CIGS minimodules. For better understanding of how these defects originate and propagate, we have implemented a current-limited, reverse-bias stressing technique. This allowed for DLIT-based detection and detailed study of the region where breakdown initiates before thermal runaway leads to permanent damage. A correlation between suspected defect sites and actual breakdown has been determined using this method.
14 SOLAR ENERGY↗
Identification and Analysis of Partial Shading Breakdown Sites in CuIn x Ga (1-x) Se 2 Modules
In this paper, CuIn x Ga (1-x) (CIGS) mini-modules are stressed under reverse bias, resembling partial shading conditions, to predict and characterize where failures occur. Partial shading can cause permanent damage in the form of 'wormlike' defects on thin-film modules due to thermal runaway. This results in module-scale power losses. We have used dark lock-in thermography (DLIT) to spatially observe localized heating when reverse-bias breakdown occurs on various CIGS mini-modules. For better understanding of how and where these defects originated and propagated, we have developed techniques where the current is limited during reverse-bias stressing. This allows for DLIT-based detection and detailed studying of the region where breakdown is initiated before thermal runaway leads to permanent damage. Statistics of breakdown sites using current-limited conditions has allowed for reasonable identification of the as-grown defects where permanent breakdown will likely originate. Scanning electron microscope results and wormlike defect analysis show that breakdown originates in defects such as small pits, craters, or cracks in the CIGS layer, and the wormlike defects propagate near the top CIGS interface.
14 SOLAR ENERGY↗
Future Synchrotron Light Sources Based on Ultimate Storage Rings
The main purpose of this talk is to describe how far one might push the state of the art in storage ring design. The talk will start with an overview of the latest developments and advances in the design of synchrotron light sources based on the concept of an 'ultimate' storage ring. The review will establish how bright a ring based light source might be, where the frontier of technological challenges are, and what the limits of accelerator physics are. Emphasis will be given to possible improvements in accelerator design and developments in technology toward the goal of achieving an ultimate storage ring. An ultimate storage ring (USR), defined as an electron ring-based light source having an emittance in both transverse planes at the diffraction limit for the range of X-ray wavelengths of interest for a scientific community, would provide very high brightness photons having high transverse coherence that would extend the capabilities of X-ray imaging and probe techniques beyond today's performance. It would be a cost-effective, high-coherence 4th generation light source, competitive with one based on energy recovery linac (ERL) technology, serving a large number of users studying material, chemical, and biological sciences. Furthermore, because of the experience accumulated over many decades of ring operation, it would have the great advantage of stability and reliability. In this paper we consider the design of an USR having 10-pm-rad emittance. It is a tremendous challenge to design a storage ring having such an extremely low emittance, a factor of 100 smaller than those in existing light sources, especially such that it has adequate dynamic aperture and beam lifetime. In many ultra-low emittance designs, the injection acceptances are not large enough for accumulation of the electron beam, necessitating on-axis injection where stored electron bunches are completely replaced with newly injected ones. Recently, starting with the MAX-IV 7-bend achromatic cell, we have made significant progress with the design of PEP-X, a USR that would inhabit the decommissioned PEP-II tunnel at SLAC. The enlargement of the dynamic aperture is largely a result of the cancellations of the 4th-order resonances in the 3rd-order achromats and the effective use of lattice optimization programs. In this paper, we will show those cancellations of the 4th-order resonances using an analytical approach based on the exponential Lie operators and the Poisson brackets. Wherever possible, our analytical results will be compared with their numerical counterparts. Using the derived formulae, we will construct 4th-order geometric achromats and use them as modules for the lattice of the PEP-X USR, noting that only geometric terms are canceled to the 4th order.
43 PARTICLE ACCELERATORS↗
Study on impact of Cr and Mo on diffusion of H in 2.25Cr1Mo steel using first-principle calculations
Chrome-molybdenum steel (2.25Cr1Mo steel) is one of the main materials of a steam generator (SG) in high-temperature reactor-pebblebed modules (HTR-PM). It is essential to analyze the source term of tritium in this material, because the behavior of tritium in a SG is important for performing source term analysis in normal and accident conditions. In this article, the diffusion behavior of H atom in 2.25Cr1Mo steel was calculated to estimate the diffusivity of tritium using first-principles density functional theory. To develop and simplify the model of hydrogen diffusion in 2.25Cr1Mo steel, the impact of Cr and Mo on the diffusion of hydrogen in bcc-Fe were first calculated, all the possible diffusion paths were considered, and the minimum energy path was obtained. The diffusion activation energy and pre-exponential factor of the diffusion coefficient were obtained from Vienna Ab initio Simulation Package combined with the climbing image-nudged elastic band method. Here the results indicate that the minimum energy path for the impurity H atom is from one tetrahedral interstitial site to an adjacent tetrahedral interstitial site. The function of the diffusion coefficient of H in 2.25Cr1Mo steel with temperature T can be expressed as D = 1.486 X 10 -7 x ($\frac{-16.350kJ/mol}{RT}$) (M2/s). The diffusion coefficient of our calculation and some of the previous experiments have an excellent quantitative agreement, which indicates the reliability of our crystalline model and the practicability of the present theoretical approach. More importantly, the computational results in this work can be treated as a good screening method to collect reasonable experimental data, which will provide a good reference for tritium source term evaluation in the SG of the HTR-PM.
36 MATERIALS SCIENCE↗
Rapid advances enabling high-performance inverted perovskite solar cells
Perovskite solar cells (PSCs) that have a positive–intrinsic–negative (p–i–n, or often referred to as inverted) structure are becoming increasingly attractive for commercialization owing to their rapid increase in power conversion efficiency, easily scalable fabrication, reliable operation and compatibility with various perovskite-based tandem device configurations. In this report we review key material and device considerations for making highly efficient and stable p–i–n PSCs. First, we summarize key advances in charge transport materials, which were critical to the rapid power conversion efficiency progress. Second, we discuss promising perovskite compositions and fabrication methods. We highlight various additive engineering approaches to improve the perovskite layer as well as interface engineering strategies that target either the buried or top perovskite surface layer. Third, we review progress in tandem devices, focusing on optimization of the interconnection layer. Next, we summarize the status and strategies for improving p–i–n PSC stability, especially considering the challenges of outdoor applications. We also provide prospects for future research directions and challenges.
14 SOLAR ENERGY↗
Strategy and gaps for modeling, simulation, and control of hybrid systems
The purpose of this report is to establish a strategy for modeling and simulation of candidate hybrid energy systems. Modeling and simulation is necessary to design, evaluate, and optimize the system technical and economic performance. Accordingly, this report first establishes the simulation requirements to analysis candidate hybrid systems. Simulation fidelity levels are established based on the temporal scale, real and synthetic data availability or needs, solution accuracy, and output parameters needed to evaluate case-specific figures of merit. Accordingly, the associated computational and co-simulation resources needed are established; including physical models when needed, code assembly and integrated solutions platforms, mathematical solvers, and data processing. This report first attempts to describe the figures of merit, systems requirements, and constraints that are necessary and sufficient to characterize the grid and hybrid systems behavior and market interactions. Loss of Load Probability (LOLP) and effective cost of Effective Cost of Energy (ECE), as opposed to the standard Levelized Cost of Electricty (LCOE), are introduced as technical and economical indices for integrated energy system evaluations. Financial assessment methods are subsequently introduced for evaluation of non-traditional, hybrid energy systems. Algorithms for coupled and iterative evaluation of the technical and economic performance are subsequently discussed. This report further defines modeling objectives, computational tools, solution approaches, and real-time data collection and processing (in some cases using real test units) that will be required to model, co-simulate, and optimize; (a) an energy system components (e.g., power generation unit, chemical process, electricity management unit), (b) system domains (e.g., thermal, electrical or chemical energy generation, conversion, and transport), and (c) systems control modules. Co-simulation of complex, tightly coupled, dynamic energy systems requires multiple simulation tools, potentially developed in several programming languages and resolved on separate time scales. Whereas further investigation and development of hybrid concepts will provide a more complete understanding of the joint computational and physical modeling needs, this report highlights areas in which co-simulation capabilities are warranted. The current development status, quality assurance, availability and maintainability of simulation tools that are currently available for hybrid systems modeling is presented. Existing gaps in the modeling and simulation toolsets and development needs are subsequently discussed. This effort will feed into a broader Roadmap activity for designing, developing, and demonstrating hybrid energy systems.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Crowder College MARET Center (Final Scientific Technical Report)
Following decades of success in solar energy projects, the Missouri Legislature designated Crowder College in 1992 as the State's renewable energy education center. The resulting Missouri Alternative and Renewable Energy Technology (MARET) Center is recognized internationally for its contributions to the energy field. The mission of the MARET Center is to expand renewable energy throughout the region with education, applied research, and economic development. Educational programs include certification and transfer degrees encompassing green construction, solar thermal energy, solar electricity, and wind. The MARET Center also assists in new product development and other business support services in renewable energy. The Missouri Alternative and Renewable Energy Technology (MARET) Center at Crowder College hopes to eventually develop a 27,500 ft 2 facility as a living laboratory to support solar and other renewable and sustainable energy development through professional degrees, new product development and commercialization, renewable energy business incubation, and consumer education. The primary objective of the current project was to complete Stage One of this building, with solar, wind, and geothermal technologies installed to power its 9,216 ft 2 office, classroom, and research spaces. This MARET Center includes a modular roof structure that permits both solar module mounting and daylighting, PV/thermal hybrid modules pioneered in Crowder Solar Decathlon homes, modular electrical management subsystems; and modular delivery systems for heating and cooling the structure. The MARET Facility will operate as a Net Positive energy building, consistently producing surplus energy for distributed generation on the utility grid. The modular design of the energy systems within the building is to serve as a scalable and repeatable model for a wide variety of building applications and climate zones. As a living laboratory of renewable energy, exploring and validating new applications of solar and other renewable technologies, the MARET Facility will house a wide variety of programs which will advance implementation of renewable energy throughout the region. These program goals include; Curriculum in renewable energy for pre-engineering transfer programs; Certification and degree programs for technical degrees for Energy Efficiency, Wind, Photovoltaic and Solar Thermal professionals; Short courses and workshops for building management and design professionals; Public education and demonstration projects in renewable energy through conferences and K-12 educational outreach; Technical degree offering in building construction incorporating “best practices” for energy efficiency and renewables; and Business incubators for new renewable energy businesses and new product development. The new MARET facility will support the mission of the US Department of Energy (DOE) Solar Program, “to improve America’s security, environmental quality, and economic prosperity through public-private partnerships that bring reliable and affordable solar energy technologies to the marketplace,” through a variety of educational and business assistance programs. Further, technical innovations planned for the MARET facility and its applied research activities will advance the Solar Program strategic goals to “reduce the cost of solar energy to the point it becomes competitive in relevant energy markets (e.g., buildings, power plants) and for solar technology to enable a sustainable solar industry.” Overarching Goals relative to program needs, future expansion, flexibility, quality of materials, and construction and operational costs:; Experimental: The structure and systems of the building operate as an educational resource. The systems are meant to be a source for data collection and study for building users and instructors; Educational: Part of the evolution of this building and its ongoing goals is to use the building as an educational tool, one where new ideas developed in the world and especially at Crowder can be tested further as part of MARET's curriculum; LEED Platinum: achieve highest level of LEED certification; Net Zero: The building will utilize existing wind and alternate energy sources on campus and add solar PVT panels and achieve as close as possible to a net zero energy usage; and Phase II: The phase II portion of this project will expand the Internet student area, additional classrooms, and labs, as well as an auditorium and exhibit area.
14 SOLAR ENERGY↗
Movement of Cracked Silicon Solar Cells During Module Temperature Changes
Cracks in crystalline silicon solar cells can lead to substantial power loss. While the cells' metal contacts can initially bridge these cracks and maintain electrical connections, the bridges are damaged by mechanical loads, including those due to temperature changes. We investigated the metallization bridges that form over cracks in encapsulated silicon solar cells. Microscopic characterization showed that the crack in the silicon can immediately propagate through the metal grid, but the grid can maintain electrical contact once the load is removed. We also quantified the movement of the cell fragments separated by a crack as a function of temperature. Cell fragments are free to move diagonally and to rotate, so the change in gap across the crack during a temperature change varies along the length of the crack. In one sample, we showed that a 10 degrees C temperature change, causing a 2 um increase in the separation of cell fragments, was sufficient to cause a reversible electrical disconnection of metallization bridging a crack.
14 SOLAR ENERGY↗
An efficient method to identify uncertainties of WRF-Solar variables in forecasting solar irradiance using a tangent linear sensitivity analysis
Uncertainty in predicting solar energy resources introduces major challenges in power system management and necessitates the development of reliable probabilistic solar forecasts. As the first part of the development of probabilistic forecasts based on the Weather Research and Forecasting model with solar extensions (WRF-Solar), this study presents a tangent linear approach to identify input variables responsible for the largest uncertainties in predicting surface solar irradiance and clouds. A tangent linear analysis is capable of efficiently investigating sensitivities of output variables with respect to various input variables of WRF-Solar because this approach avoids the computational burden of perturbing the initial conditions of individual input variables. We develop tangent linear models (TLMs) for six WRF-Solar physics packages that control the formation and dissipation of clouds and solar radiation, and we evaluate the validity of TLMs using a linearity test. The tangent linear sensitivity analysis is conducted under various scenarios based on satellite observations and model simulations to consider realistic input conditions. A simple method is used to quantify the impact of the uncertainty of input variables on the output variables from the TLMs. The results demonstrate that uncertainties in the output variables that are the focus of this study—including global horizontal irradiance, direct normal irradiance, cloud mixing ratio, cloud tendency, cloud fraction, and sensible and latent heat fluxes—are highly sensitive to uncertainties in 14 input variables. This study indicates that the tangent linear method can identify key variables of physics modules in WRF-Solar that can be stochastically perturbed to generate ensemble-based probabilistic forecasts.
14 SOLAR ENERGY↗
Stimulus-Responsive Modulation of Solvation Environments in Solid Catalysts
Liquid environments play a crucial role in the biological processes occurring in living organisms as well as in many human-made processes involving electrochemistry, photo-, and thermocatalysis. In the majority of these systems, aqueous phases are ubiquitous due to water’s natural abundance. Water molecules, however, can exert large changes in the chemical environment of catalytically active sites, altering the reaction rates, selectivity, and catalyst stability. These solvation effects induced by water molecules near catalytic sites can drastically change the energy landscape and unlock unique reaction pathways with far more favorable kinetics. In nature, living organisms couple these complex interactions with detection, communication, and actuation mechanisms to induce self-regulatory behavior, ensuring stability of the system and thus long-term durability. Extrapolating this behavior to heterogeneous catalysis is desirable because the resulting “smart materials” can potentially unlock new chemical conversion processes with higher atom efficiency, rates, and stability. The combination of polymer chemistry and heterogeneous catalysis has introduced versatile approaches for creating materials that can respond to cues in the reaction medium that alter the accessibility, intrinsic activity, and selectivity of the catalyst. To achieve this, one could combine stimulus-responsive polymers, which undergo a large volumetric phase transition in response to an external stimulus, with a solid catalyst. This chemo-mechanical response has been employed to create a variety of nanoreactor vessels with stimulus-responsive character that turn on- and off- depending on the reaction conditions. In this Account, we focus on the impact of these polymer coatings on the solvation environment around the active site and the implications of these effects on the reaction energy landscape, molecular arrangement of the solvent, electric fields at the catalyst–liquid interface, binding energy, and mobility of surface reaction intermediates. These seemingly subtle changes in solvent molecules induced by the presence of polymers can have a tremendous impact on the development of bioinspired heterogeneous catalysts, reliable chemical clocks, micro/nanoreactors, and robots. The large library of polymer chemistries offers a plethora of combinations of stimulus-responsive mechanisms (e.g., temperature, pH, light, magnetic field, solvent composition), providing the possibility of creating homeostatic catalysts à la carte.
catalysts↗
Allosteric prediction via convolutional neural networks and protein structural and dynamical features
Allostery is the phenomenon whereby a binding event or covalent modification at one site in a protein modulates function at a distal site, thus changing a protein’s functional state. As such, it is a ubiquitous aspect of protein functional regulation. Computationally predicting allosteric states is important as part of the broader challenge of functional annotation, but it also has practical implications for drug development, as targeting an allosteric site often affords greater specificity compared with targeting an orthosteric site. This study introduces a machine learning approach to predict the allosteric functional state using the small G-protein KRas as the model system, due to its implication in many types of cancer and being well studied as a result with many x-ray crystallographic structures of KRas available with different mutations and ligands bound. Using structural and dynamical features that can be cast as images, namely interatomic distances, contact maps, covariance, and mutual information, supervised learning was performed using convolutional neural networks. Two pretrained convolutional neural network architectures, GoogLeNet and ResNet18, were fine-tuned to classify KRas into active or inactive states based on these features. Across training regimes, atomic contact maps emerged as the most effective structural feature, whereas linearized mutual information outperformed covariance in capturing dynamical correlations relevant to allostery. Models achieved significant validation accuracy, with atomic contact maps yielding up to 90% accuracy. In conclusion, the findings suggest that integrating global structural rearrangements and correlated motion patterns with deep learning can reliably predict protein allosteric states, offering a promising framework for understanding allosteric regulation and developing targeted therapeutics.
Rajeshwar T., Rajitha [Oak Ridge National Laborato↗
Technology Solutions Case Study: Optimizing Hydronic System Performance in Residential Applications, Ithaca, New York
Condensing boiler technology has been around for many years and has proven to be a durable, reliable method of heating. Based on previous research efforts, however, it is apparent that these types of systems are not designed and installed to achieve maximum efficiency. For example, in order to protect their equipment in the field, manufacturers of low-mass condensing boilers typically recommend design strategies and components that ensure steady, high flow rates through the heat exchangers, such as primary-secondary piping, which ultimately result in decreased efficiency. There is also a significant lack of information for contractors on how to configure these systems to optimize overall efficiency. In response to these findings, researchers from Building America team Consortium for Advanced Residential Buildings worked with industry partners to develop hydronic system designs that would address these issues and result in higher overall system efficiencies and improved response times.
AFUE↗
Reliable SOFC Systems
The goal of this U.S. Department of Energy (DOE) sponsored project was to advance the reliability, robustness and endurance of low-cost SOFC technology suitable for ultimate deployment in ≥100 MWe Integrated Gasification Fuel Cell (IGFC) or Natural Gas Fuel Cell (NGFC) systems capable of ≥97% CO2 capture. The ultimate SOFC program goals are ≤ 0.2% per 1000 hours power degradation over a 5-plus year stack life, high-volume (≥ 250 MW/year) stack production cost of ≤$225/kWsystem net AC, and “power block” (exclusive of fuel supply, contaminant removal, and CO2 capture subsystems) capital cost of ≤ 900/kWsystem net AC (in year 2011). To progress towards the ultimate program goals, the specific objectives of this project were to achieve an SOFC stack power degradation rate of ≤1.5% per 1000 hours in a 100 kW (125 kW Peak) Modular Power Block (MPB) stand-alone power system under thermally self-sustained normal operating conditions and to verify the prospects for high volume SOFC stack production cost below the DOE target of ≤ 225/kW. This final technical report summarizes the progress made during the project period of 36 months. Significant progress was made in the areas of cell and stack technology development, Modular Power Block (MPB) development, sub-MW MPB system development, and MW-class SOFC System Development and Costing. The work focused on areas necessary for comprehensive development of an SOFC fuel cell system, including, active cell improvement, contaminant resistance, process engineering, and development of non-repeat module components. Additionally, several custom built balance-of-plant components were designed and fabricated to support the fuel cell system. SOFC cell and stack development focused on improving cell performance and durability. Enhancements were achieved in areas of electrode stability and impurity tolerance. Additionally, several quality control techniques and tools were developed to ensure predictable and repeatable fabrication of SOFC stacks. Module development continued previous development efforts to achieve footprint reduction and higher efficiency by incorporating balance-of-plant functional equipment into the fuel cell containment module. Several improvements were made to prior design. Control and instrumentation hardware was integrated within the module for serviceability and size reduction. The design efforts culminated in a complete SOFC power plant system. The designed plant was constructed and tested at FCE. Stack and system costs were updated, reflecting advances made in this program.
20 FOSSIL-FUELED POWER PLANTS↗
Durability Research Is Pivotal for Perovskite Photovoltaics
Metal halide perovskite solar cells have shown promising power conversion efficiencies, but commercialization requires that decent durability is also demonstrated. Under normal operation, solar cells are subject to a complex combination of stressors, such as visible light, ultraviolet light, heat, humidity, mechanical stress and electric potential, which complicates the understanding of failure mechanisms. Existing stress tests do not act as a time machine. In new materials systems such as perovskite photovoltaics, the tests have no known relationship to field service. In this Perspective we recommend following a durability learning cycle that interleaves photovoltaic module engineering with field testing; accelerated testing; and preconditioning and performance engineering. We advocate for field testing to demonstrate real-world performance and identify field-relevant failure modes, and urge the community to develop accelerated and qualification tests that account for device metastability, variations in material composition and different/various processing methods. In conclusion, these practices are more difficult, but more important, than the simple pursuit of higher initial efficiencies.
14 SOLAR ENERGY↗
Progress and Strategies for Testing of Materials for Solar Panels
Accelerated testing is key to confident launch of a new product. However, for new products like solar panels, the best approach is not always clear. The challenge for materials manufacturers is that test times can be long. Also, small-coupon testing may not predict the behavior in the full-size module, but testing of the full-size module is too expensive. As a result, solar panel test standards like IEC 61215 are useful, but are not sufficient. Material manufacturers have needed to define their own test protocols. This presentation will review some historical data (e.g., data show that manufacturers are making great progress toward reducing encapsulant discoloration) and describe advances in material testing (for example, new techniques are being demonstrated on how to more quantitatively assess adhesion, detect tendency for delamination, and understand how encapsulant properties affect other properties like cracking of cells). The International PV Quality Assurance Task Force has been researching climate-specific weathering tests toward the goal of defining international standards that would simplify qualification and quality assurance testing for materials. The status of these tests and the strategies for how to organize these standards to best meet the needs of the industry will be discussed.
14 SOLAR ENERGY↗
A Disruptive Approach to Electric Vehicle Power Electronics Final Report
This project developed and demonstrated a new power electronics technology for electric vehicle drivetrains, that achieved significant improvements in power density and efficiency over standard drive cycles, relative to the commercial state of the art. In particular, the prototype measured loss and efficiency curves demonstrated a reduction in total loss over the US EPA US06 drive cycle by a factor of four. Similar reductions are observed for urban (UDDS) and highway (HWFET) drive cycles. Further, the project demonstrated a significant reduction in the total film capacitor requirements, by over an order of magnitude; this was achieved through fundamental improvements in converter circuit topologies. These nonincremental technology advances can lead to significant improvements in temperature rise, reliability, cost, and cooling system size and weight. These results were achieved through a new proposed composite converter architecture, and were demonstrated in a boost-type system similar to that employed by Toyota, Ford, and Honda. A 30 kW silicon prototype achieved a US06 average efficiency of 97.5%, which represents a reduction in average loss by a factor of approximately four relative to the 92.5% average efficiency of the commercial state of the art. A silicon carbide prototype achieved similar efficiency, while also achieving power densities of 23 kW/L (volumetric) and 20 kW/kg (gravimetric) in a boost dc-dc system including magnetics and film capacitors. This was achieved with a SiC switching frequency of 240 kHz, which allowed employment of planar magnetics. These power densities are roughly four times better than the commercial state of the art, and significantly exceed the DOE APEEM 2020 goals. In addition to the composite boost system, a SiC inverter was demonstrated at the 800 V 30 kW level. This inverter was demonstrated driving a permanent magnet machine over the US 06 drive cycle. The replacement of 1200 V Si IGBTs with 1200 V SiC MOSFETs led to improvement of CAFE average efficiency from 98.7% to 99.5%, which corresponds to a reduction of average loss by a factor of approximately two. The modular nature of the composite converter architecture opens the possibility of reuse of one or more converter modules during charging operations, providing a path for onboard charging capability at significant power levels while significantly reducing the volume and weight of the added charger module. This project demonstrated an integrated Level II charger whose add-on specific weight was approximately four times better than the DOE PHEV charger 2022 targets.
33 ADVANCED PROPULSION SYSTEMS↗