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

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At least 145 records · Page 8

Bonded Interfaces for High-Temperature Power Electronics

Wide-bandgap devices have pushed the operational limit of semiconductor devices in automotive power electronics packages to higher temperatures (>200 degrees C). While a higher efficiency can be achieved through the use of wide-bandgap devices, the entire package must be re-designed with components that can withstand the higher temperature limits. Sintered silver and transient liquid phase bonds are potential candidates as bonded materials for use in higher temperatures however, the underlying mechanics of deformation under thermal loads and the resulting failure mechanisms in these materials are not well understood. Furthermore, thermomechanical modeling plays a key role in understanding the degradation behavior of bonded interface materials and for design optimization of power electronics packages.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗

Onset of chaos in a single-phase power electronic inverter

Supported by experiments on a power electronic DC/AC converter, this paper considers an unusual transition from the domain of stable periodic dynamics (corresponding to the desired mode of operation) to chaotic dynamics. The behavior of the converter is studied by means of a 1D stroboscopic map derived from a non-autonomous ordinary differential equation with discontinuous right-hand side. By construction, this stroboscopic map has a high number of border points. It is shown that the onset of chaos occurs stepwise, via irregular cascades of different border collisions, some of which lead to bifurcations while others do not.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Modeling and Simulation of Power-Electronic Inverters in Analog Electronic Circuit Simulators

This paper demonstrates how equivalent-circuit representations of grid-following power-electronic inverters can be realized within a SPICE-based development environment using common circuit components and VerilogA code. This facilitates computationally lean simulations of inverter networks leveraging the strengths of SPICE in large-scale simulations. We validate the approach with time-domain simulations for a modified version of the IEEE standard 118-bus system modeled in Virtuoso (a SPICE-based solver). Simulation results are compared-focusing on accuracy and computation speed-with results from a commonly used power-electronics simulation package. We note a significant decrease in simulation time with comparable signal resolution when simulating the network in SPICE.

Billmeyer, Ryan↗

Power Electronics Thermal Management R&D: Annual Report

The objective for this project is to develop thermal management strategies to enable efficient and high-temperature wide-bandgap (WBG)-based power electronic systems (e.g., emerging inverter and DC-DC converter). Device- and system-level thermal analyses are conducted to determine the thermal limitations of current automotive power modules under elevated device temperature conditions. Additionally, novel cooling concepts and material selection will be evaluated to enable high-temperature silicon and WBG devices in power electronics components. WBG devices (silicon carbide [SiC], gallium nitride [GaN]) promise to increase efficiency, but will be driven as hard as possible. This creates challenges for thermal management and reliability.

30 DIRECT ENERGY CONVERSION↗

Power Electronics Thermal Management Research: Annual Progress Report

The objective for this project is to develop thermal management strategies to enable efficient and high-temperature wide-bandgap (WBG)-based power electronic systems (e.g., emerging inverter and DC-DC converter). Reliable WBG devices are capable of operating at elevated temperatures (≥ 175 °Celsius). However, packaging WBG devices within an automotive inverter and operating them at higher junction temperatures will expose other system components (e.g., capacitors and electrical boards) to temperatures that may exceed their safe operating limits. This creates challenges for thermal management and reliability. In this project, system-level thermal analyses are conducted to determine the effect of elevated device temperatures on inverter components. Thermal modeling work is then conducted to evaluate various thermal management strategies that will enable the use of highly efficient WBG devices with automotive power electronic systems.

30 DIRECT ENERGY CONVERSION↗

Directly Fused Porphyrin‐Tetracyanopentacenequinone Conjugates: Role of the Cross‐Conjugated, Powerful Electron Acceptor in Promoting Highly Efficient Charge Separation

Tetracyanopentacenequinone, a powerful electron acceptor, is fused directly to the porphyrin π-system to create a new class of donor-acceptor conjugates. Owing to the direct fusion and electron-deficient property of tetracyanopentacenequinone, strong intramolecular charge transfer both in the ground and excited states was witnessed. As a control, porphyrin fused with pentacenequinone was also investigated. Upon complete spectral and electrochemical characterization, the excited state properties were initially probed by time-dependent DFT studies, and the occurrence of electron transfer from different excited states was established. Free-energy calculations revealed higher exothermic electron transfer (>600 mV) than the control pentacenequinone-porphyrin systems. Pump-probe studies covering broad spatial and temporal regions revealed efficient excited state charge separation. This was unlike the control pentacenequinone-porphyrin system, where slow charge separation was witnessed only in the case of the zinc derivatives but not the free-base ones, followed by the populating of the triplet excited state. The lifetimes of the charge-separated states ranged between 30–500 ps depending on the solvent and metal ion in the porphyrin cavity. Nanosecond transient absorption studies established the charge recombination path to populate the triplet state of porphyrin or directly to the ground state as a function of solvent polarity and the nature of the conjugate. Furthermore, the significance of cross-conjugated tetracyanopentacenequinone fused directly to the porphyrin π system in promoting highly exothermic and efficient charge separation, irrespective of its cross conjugation, is borne out from this study.

Cross conjugation↗

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

The emergence of wide-bandgap (WBG) devices in power electronics packages has brought significant attention to the reliability and thermal performance of the bonded interfaces. These interfaces, such as die-attach and substrate-attach, need to withstand the severe stress induced on them by the high-temperature (> 200°C) operation of the WBG devices. Sintered silver and transient liquid phase alloys are key bonded interfaces that can enable the high-temperature operation of WBG devices, however it is essential to evaluate their reliability and study the possible failure mechanisms before they can be used in power electronics packages. Sintered silver is already being adopted in commercial packages as a die-attach, but large-area substrate-attach offers additional reliability challenges. In this project, we investigate the reliability of these interface materials under accelerated thermal cycling and correlate these results with finite element simulations to develop lifetime prediction models. The failure mechanisms of these bonded interfaces are also studied.

47 OTHER INSTRUMENTATION↗

Power Electronics Materials and Bonded Interfaces - Reliability and LIfetime

The emergence of wide-bandgap (WBG) devices in power electronics packages has brought significant attention to the reliability and thermal performance of the bonded interfaces. These interfaces, such as die-attach and substrate-attach, need to withstand the severe stress induced on them by the high-temperature (> 200 degrees C) operation of the WBG devices. Sintered silver and transient liquid phase alloys are key bonded interfaces that can enable the high-temperature operation of WBG devices, however it is essential to evaluate their reliability and study the possible failure mechanisms before they can be used in power electronics packages. Sintered silver is already being adopted in commercial packages as a die-attach, but large-area substrate-attach offers additional reliability challenges. In this project, we investigate the reliability of these interface materials under accelerated thermal cycling and correlate these results with finite element simulations to develop lifetime prediction models. The failure mechanisms of these bonded interfaces are also studied.

33 ADVANCED PROPULSION SYSTEMS↗

Online Dynamic Cyber-Attack Diagnosis in Power Electronics Systems Based on Few-Shot Learning

With increasing exposure to software-based sensing and control, power electronics systems are facing higher risks of cyber-physical attacks. To ensure system stability and minimize potential economic losses, it is critical to monitor the operating states and detect those attacks at the early stage. However, anomaly detection and diagnosis of attacks are still challenging, especially when labeled anomaly data is difficult or even infeasible to obtain. To overcome this problem, we propose a Few-Shot Learning (FSL) based approach for cyber-attack diagnosis leveraging the waveform data. To the best of our knowledge, this work is the first attempt at leveraging FSL for cyber-attack diagnosis in power electronics systems. Extensive experimental results demonstrate that our proposed approach can achieve comparable diagnosis accuracy with the state-of-the-art data-driven methods using less than 0.04% of the training samples.

Li, Qi↗

FY2014 Oak Ridge National Laboratory Annual Progress Report for the Power Electronics and Electric Motors Program

The US Department of Energy (DOE) announced in May 2011 a new cooperative research effort comprising DOE, the US Council for Automotive Research (composed of automakers Ford Motor Company, General Motors Company, and Chrysler Group), Tesla Motors, and representatives of the electric utility and petroleum industries. Known as U.S. DRIVE (Driving Research and Innovation for Vehicle efficiency and Energy sustainability), it represents DOE’s commitment to developing public–private partnerships to fund high-risk–high-reward research into advanced automotive technologies. The new partnership replaces and builds upon the partnership known as FreedomCAR (derived from “Freedom” and “Cooperative Automotive Research”) that ran from 2002 through 2010 and the Partnership for a New Generation of Vehicles initiative that ran from 1993 through 2001. Oak Ridge National Laboratory’s (ORNL’s) Advanced Power Electronics and Electric Motors (APEEM) subprogram within the DOE Vehicle Technologies Office (VTO) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE), electric motor, and traction drive system (TDS) technologies that will leapfrog current on-the-road technologies, leading to lower cost and better efficiency in transforming battery energy to useful work. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow’s automobiles will function as a unified system to improve fuel efficiency through research in more efficient TDSs.

33 ADVANCED PROPULSION SYSTEMS↗

Dielectrics for Power Electronics Applications

This presentation discusses the role of dielectric materials in power electronic packages. Two dielectric technologies - a dielectric material film-based substrate for insulation and a dielectric coolant - are discussed. The thermal performance benefits of dielectric film-based substrate in comparison with traditional direct-bond-copper substrates are studied through finite element analysis. Also, a novel cooling concept based on dielectric liquids that can contact electrically active surfaces are presented.

30 DIRECT ENERGY CONVERSION↗

Evaluation of high temperature dielectric films for high voltage power electronic applications

Three high temperature films, polyimide, Teflon perfluoroalkoxy and poly-P-xylene, were evaluated for possible use in high voltage power electronic applications, such as in high energy density capacitors, cables and microelectronic circuits. The dielectric properties, including permittivity and dielectric loss, were obtained in the frequency range of 50 Hz to 100 kHz at temperatures up to 200 C. The dielectric strengths at 60 Hz were determined as a function of temperature to 250 C. Confocal laser microscopy was performed to diagnose for voids and microimperfections within the film structure. The results obtained indicate that all films evaluated are capable of maintaining their high voltage properties, with minimal degradation, at temperatures up to 200 C. However, above 200 C, they lose some of their electrical properties. These films may therefore become viable candidates for high voltage power electronic applications at high temperatures.

Suthar, J. L.↗

Multilayered Film Capacitors for Advanced Power Electronics and Electric Motors for Electric Traction Drives

Biaxially oriented polypropylene (BOPP) film capacitors are the most suitable technology for high voltage, high temperature, and high ripple current power electronic systems in high performance electric vehicles (EVs). These capacitors, however, occupy 1/4th to 1/3rd of the power electronic unit and have a 50% voltage derating above 85 °C due to their drastically deteriorated breakdown strength and lifetime at high temperature. Development of a new dielectric material system for capacitors to increase temperature use and reduce size is critical in many EV related applications. Multilayer dielectric film developed by PolymerPlus and team has demonstrated improved dielectric constant and breakdown strength as compared to BOPP films. In this program, several film formulations were developed and investigated for dielectric performance and further down-selected for production scale up. Because this technology uses commercial polymers, fabrication of film rolls to demonstrate scalability for initial capacitor fabrication trials was successfully achieved. The film production feasibility, metallization and capacitor prototype fabrication was successfully demonstrated in Year 1 of the program. In Year 2 of the program, film production scale-up leading to significantly large film quantities for metallization and capacitor fabrication led to 600 µF size capacitors. Capacitor characterization was also completed during this year.

25 ENERGY STORAGE↗

Real-time Simulation Model of a Vanadium Redox Flow Battery Energy Storage System with Power Electronics Integration

This paper presents a real-time (RT) model of a 20 kW multi-stack vanadium redox flow battery (VRFB) system including power electronics converters in a single real-time framework. Implemented on a Typhoon HIL 604 device, this model is designed to simulate the operation of the flow battery with system-level controls. To provide a realistic overview of a VRFB system, the model incorporates a closed-loop control system for managing the speeds of two centrifugal pumps and an electro-thermal model of the battery stacks, enabling realtime temperature estimation. Furthermore, a two-stage power electronics topology and associated control solution are presented, operating with distinct strategies for interfacing the battery model with the main grid and a local load. Results from simulations demonstrate that the VRFB model is well suited for RT environment, and system can manage power during both charging and discharging cycles, while a SCADA monitor is used to display critical variables for safe, efficient, and reliable operation of the VRFB systems.

Rezende Da Costa Reis Kimpara, Renata [ORNL] (ORCI↗

Multikilowatt power electronics development for spacecraft

Attention is given to several multikilowatt power electronic components developed by TRW for the Space Station Power Management and Distribution test bed at NASA Lewis Research Center. These components include a 12.5-kW DC-DC converter, a 6.25-kW battery charge/discharge regulator, an 82-channel sequential shunt unit, a 10-A remote power controllers, and three different types of 1-kW load converters. TRW is also monitoring the development of 120-V fuses for space applications. The authors discuss these developments and provide steady-state and dynamic performance parameters.

Decker, D. K.↗

Power electronics for a 1-kilowatt arcjet thruster

After more than two decades, new space mission requirements have revived interest in arcjet systems. The preliminary development and demonstration of new, high efficiency, power electronic concepts for start up and steady state control of dc arcjets is reported. The design comprises a pulse width modulated power converter which is closed loop configured to give fast current control. An inductor, in series with the arcjet, serves the dual role of providing instantaneous current control, as well as a high voltage arc ignition pulse. Benchmark efficiency, transient response, regulation, and ripple data are presented. Tests with arcjets demonstrate that the power electronics breadboard can start thrusters consistently with no apparent damage and transfer reliably to the nondestructive high voltage arc mode in less than a second.

Gruber, R. P.↗

Cooling Strategies for an Electric Motor with Additively Manufactured Hollow Conductors and Distributed Power Electronics Integrated with Heat Pipes

This paper discusses design tradeoffs and thermal modeling explored in cooling strategies for an aircraft propulsion electric motor with additively manufactured coils and distributed power electronics integrated with heat pipes. Design tradeoffs include heat pipe Qmax performance related to inclination, condenser configuration, coolant type, coolant flow path complexity, and ease of access to modular power electronics. Three cooling strategies were selected and realized into CAD models. These models were further evaluated using 3D thermal FEA and optimization tools to explore cooling geometry details that include fin thickness, spacing and count with the objective to minimize fin mass under a set of constraints. Lastly, motorette test data is presented comparing air versus liquid cooling of heat pipes.

additive manufacturing↗