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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Early Oscillation Detection Technique for Hybrid DC/DC Converters

Oscillation or instability is a situation that must be avoided for reliable hybrid DC/DC converters. A real-time electronics measurement technique was developed to detect catastrophic oscillations at early stages for hybrid DC/DC converters. It is capable of identifying low-level oscillation and determining the degree of the oscillation at a unique frequency for every individual model of the converters without disturbing their normal operations. This technique is specially developed for space-used hybrid DC/DC converters, but it is also suitable for most of commercial and military switching-mode power supplies. This is a weak-electronic-signal detection technique to detect hybrid DC/DC converter oscillation presented as a specific noise signal at power input pins. It is based on principles of feedback control loop oscillation and RF signal modulations, and is realized by using signal power spectral analysis. On the power spectrum, a channel power amplitude at characteristic frequency (CPcf) and a channel power amplitude at switching frequency (CPsw) are chosen as oscillation level indicators. If the converter is stable, the CPcf is a very small pulse and the CPsw is a larger, clear, single pulse. At early stage of oscillation, the CPcf increases to a certain level and the CPsw shows a small pair of sideband pulses around it. If the converter oscillates, the CPcf reaches to a higher level and the CPsw shows more high-level sideband pulses. A comprehensive stability index (CSI) is adopted as a quantitative measure to accurately assign a degree of stability to a specific DC/DC converter. The CSI is a ratio of normal and abnormal power spectral density, and can be calculated using specified and measured CPcf and CPsw data. The novel and unique feature of this technique is the use of power channel amplitudes at characteristic frequency and switching frequency to evaluate stability and identify oscillations at an early stage without interfering with a DC/DC converter s normal operation. This technique eliminates the probing problem of a gain/phase margin method by connecting the power input to a spectral analyzer. Therefore, it is able to evaluate stability for all kinds of hybrid DC/DC converters with or without remote sense pins, and is suitable for real-time and in-circuit testing. This frequency-domain technique is more sensitive to detect oscillation at early stage than the time-domain method using an oscilloscope.

Wang, Bright L.↗
NASA NTRS2011

Early Oscillation Detection for DC/DC Converter Fault Diagnosis

The electrical power system of a spacecraft plays a very critical role for space mission success. Such a modern power system may contain numerous hybrid DC/DC converters both inside the power system electronics (PSE) units and onboard most of the flight electronics modules. One of the faulty conditions for DC/DC converter that poses serious threats to mission safety is the random occurrence of oscillation related to inherent instability characteristics of the DC/DC converters and design deficiency of the power systems. To ensure the highest reliability of the power system, oscillations in any form shall be promptly detected during part level testing, system integration tests, flight health monitoring, and on-board fault diagnosis. The popular gain/phase margin analysis method is capable of predicting stability levels of DC/DC converters, but it is limited only to verification of designs and to part-level testing on some of the models. This method has to inject noise signals into the control loop circuitry as required, thus, interrupts the DC/DC converter's normal operation and increases risks of degrading and damaging the flight unit. A novel technique to detect oscillations at early stage for flight hybrid DC/DC converters was developed.

Wang, Bright L.↗
NASA NTRS1990

High power density dc/dc converter: Selection of converter topology

The work involved in the identification and selection of a suitable converter topology is described. Three new dc/dc converter topologies are proposed: Phase-Shifted Single Active Bridge DC/DC Converter; Single Phase Dual Active Bridges DC/DC Converter; and Three Phase Dual Active Bridges DC/DC Converter (Topology C). The salient features of these topologies are: (1) All are minimal in structure, i.e., each consists of an input and output bridge, input and output filter and a transformer, all components essential for a high power dc/dc conversion process; (2) All devices of both the bridges can operate under near zero-voltage conditions, making possible a reduction of device switching losses and hence, an increase in switching frequency; (3) All circuits operate at a constant frequency, thus simplifying the task of the magnetic and filter elements; (4) Since, the leakage inductance of the transformer is used as the main current transfer element, problems associated with the diode reverse recovery are eliminated. Also, this mode of operation allows easy paralleling of multiple modules for extending the power capacity of the system; (5) All circuits are least sensitive to parasitic impedances, infact the parasitics are efficently utilized; and (6) The soft switching transitions, result in low electromagnetic interference. A detailed analysis of each topology was carried out. Based on the analysis, the various device and component ratings for each topology operating at an optimum point, and under the given specifications, are tabulated and discussed.

Divan, Deepakraj M.↗
DOE OSTI2026

System-Level Efficiency Study of Modular DC/DC and Fuel Cell Stack Series–Parallel Configurations

This paper presents a system-level efficiency study of modular DC/DC converter and fuel cell stack configurations under series, parallel, and series–parallel connections. The investigation considers selected DC/DC converter topologies, including isolated and non-isolated architectures, boost, non-inverting buck-boost, and resonant converters, integrated with commercially available fuel cell stacks, including the Accelera FCE150, Ballard FCgen-HPS, and Toyota TFCM2. DC/DC converter modules are evaluated in modular configurations rated at 60 kW and 90 kW and two distinct output voltage ranges, specifically 580–730V and 780–930V, examining how different interconnection schemes impact overall system efficiency. The converters are evaluated under full load (100%), partial load (66%), and light load (33%) conditions, providing a comprehensive assessment of efficiency and operational characteristics across varying power demands. Approximately two-thousand efficiency data points are obtained from laboratory prototype–level component measurements and validated design evaluations across multiple converter topologies, modular configurations, voltage ranges, and load conditions, providing a robust dataset for comparative system-level efficiency analysis. The results highlight the effects of modularity and topology selection on system-level efficiency, offering a “playbook” framework for designers to select appropriate DC/DC converter arrangements and fuel cell stack connections for series, parallel, or hybrid configurations based on efficiency considerations.

DC/DC↗
NASA NTRS2009

Failure modes and low temperature performance of DC/DC converters

Several standard tests to evaluate key (direct current) DC/DC converter parameters were performed on different models of hybrid radiation-hard DC/DC converters. These tests were done to assess both performance and reliability during space applications that operate the converters at temperatures below the lower military range of -5°C. One of the converters failed near -110°C, but another DC/DC converter model started normally at temperatures as low as 140°C. The latter showed acceptable performance during turn-on, load transient, and synchronization tests even though some minor anomalies were observed. These results show good promise for its use in applications where the DC/DC converters will be operated at lower temperatures. An application circuit was also built and preliminary tests were performed on a commercial (low drop out) LDO type of DC to DC converter with adjustable output voltage. These can be used in point of load (POL) applications. This latter device functioned properly on the few tests that were performed; however, more testing is needed to identify potential issues with space use of this and similar devices.

Leon, Rosa↗
DOE OSTI2024

Data-Driven Digital Twin for Reliability Assessment of DC/DC Buck Converter

In commercial applications, the operation of DC/DC converters significantly impacts overall system performance and long-term reliability. This study introduces a data-driven digital twin (DT) approach for estimating critical degradation parameters of DC/DC BUCK converter under steady-state condition. Initially, a circuit-level MATLAB/Simulink digital model (DM C ) is refined against a hardware prototype’s switching model dataset using offline particle swarm optimization. The optimized digital model’s steady-state response is then verified with its average model response while varying the duty and load. Subsequently, degradation profiles are imposed on the inductor, capacitor, MOSFET in the DMC. A large dataset is generated from this model, allowing training, validation, and testing of machine learning (ML) models for component health regression tasks. The proposed method employs random forest ML models, achieving impressive regression results with a squared R value as high as 0.99978 and a root mean square error of 4.2× 10 –6 . The method is further validated on a medium power level DC/DC BUCK prototype with varying load conditions, and includes the analysis of MOSFET’s on-resistance under degradation conditions. This data-driven DT method shows promise for identifying parasitic degradation and ohmic loss parameters, enhancing converter reliability assessments in a non-invasive, generalized, and computationally efficient manner.

14 SOLAR ENERGY↗
NASA NTRS2005

Advanced DC/DC Converters Towards Higher Volumetric Efficiencies For Space Applications

A new emphasis on planetary exploration by NASA drives the need for small, high power DC/DC converters which are functionally modular. NASA GSFC and other government space organizations are supporting technology development in the DC/DC converter area to both meet new needs and to promote more sources of supply. New technologies which enable miniaturization such as embedded passive technologies and thermal management using high thermal conductivity materials are features of the new designs. Construction of some simple DC/DC converter core circuits using embedded components was found to be successful for increasing volumetric efficiency to 37 W/inch. The embedded passives were also able to perform satisfactorily in this application in cryogenic temperatures.

Shaw, Harry↗
NASA NTRS2010

Test Results of Selected Commercial DC/DC Converters under Cryogenic Temperatures - A Digest

DC/DC converters are widely used in space power systems in the areas of power management and distribution, signal conditioning, and motor control. Design of DC/DC converters to survive cryogenic temperatures will improve the power system performance, simplify design, and reduce development and launch costs. In this work, the performance of nine COTS modular, low-tomedium power DC/DC converters was investigated under cryogenic temperatures. The converters were evaluated in terms of their output regulation, efficiency, and input and output currents. At a given temperature, these properties were obtained at various input voltages and at different load levels. A summary on the performance of the tested converters was given. More comprehensive testing and in-depth analysis of performance under long-term exposure to extreme temperatures are deemed necessary to establish the suitability of these and other devices for use in the harsh environment of space exploration missions.

Patterson, Richard↗
NASA NTRS2011

Early Oscillation Detection for Hybrid DC/DC Converter Fault Diagnosis

This paper describes a novel fault detection technique for hybrid DC/DC converter oscillation diagnosis. The technique is based on principles of feedback control loop oscillation and RF signal modulations, and Is realized by using signal spectral analysis. Real-circuit simulation and analytical study reveal critical factors of the oscillation and indicate significant correlations between the spectral analysis method and the gain/phase margin method. A stability diagnosis index (SDI) is developed as a quantitative measure to accurately assign a degree of stability to the DC/DC converter. This technique Is capable of detecting oscillation at an early stage without interfering with DC/DC converter's normal operation and without limitations of probing to the converter.

Wang, Bright L.↗
NASA NTRS1989

High power density dc/dc converter: Component selection and design

Further work pertaining to design considerations for the new high power, high frequency dc/dc converters is discussed. The goal of the project is the development of high power, high power density dc/dc converters at power levels in the multi-kilowatt to megawatt range for aerospace applications. The prototype converter is rated for 50 kW at a switching frequency of 50 kHz, with an input voltage of 200 Vdc and an output of 2000 Vdc. The overall power density must be in the vicinity of 0.2 to 0.3 kg/kW.

Divan, Deepakraj M.↗
NASA NTRS1990

Light weight, high power, high voltage dc/dc converter technologies

Power-conditioning weight reductions by orders of magnitude will be required to enable the megawatt-power-level space systems envisioned by the Strategic Defense Initiative, the Air Force, and NASA. An interagency program has been initiated to develop an 0.1-kg/kW dc/dc converter technology base for these future space applications. Three contractors are in the first phase of a competitive program to develop a megawatt dc/dc converter. Researchers at NASA Lewis Research Center are investigating innovative converter topology control. Three different converter subsystems based on square wave, resonant, and super-resonant topologies are being designed. The components required for the converter designs cover a wide array of technologies. Two different switches, one semiconductor and the other gas, are under development. Issues related to thermal management and material reliability for inductors, transformers, and capacitors are being investigated in order to maximize power density. A brief description of each of the concepts proposed to meet the goals of this program is presented.

Kraus, Robert↗
NASA NTRS2000

Efficiency and Regulation of Commercial Low Power DC/DC Converter Modules at Low Temperatures

DC/DC converters that are capable of operating at cryogenic temperatures are anticipated to play an important role in the power systems of future NASA deep space missions. Design of these converters to survive cryogenic temperatures will improve the power system performance, and reduce development and launch costs. At the NASA Glenn Research Center Low Temperature Electronics Laboratory, several commercial off-the-shelf dc/dc converter modules were evaluated for their low temperature performance. Various parameters were investigated as a function of temperature, in the range of 20 C to -190 C. Data pertaining to the efficiency and voltage regulation of the tested converters is presented and discussed.

Elbuluk, Malik E.↗
NASA NTRS2003

Cryogenic Evaluation of an Advanced DC/DC Converter Module for Deep Space Applications

DC/DC converters are widely used in power management, conditioning, and control of space power systems. Deep space applications require electronics that withstand cryogenic temperature and meet a stringent radiation tolerance. In this work, the performance of an advanced, radiation-hardened (rad-hard) commercial DC/DC converter module was investigated at cryogenic temperatures. The converter was investigated in terms of its steady state and dynamic operations. The output voltage regulation, efficiency, terminal current ripple characteristics, and output voltage response to load changes were determined in the temperature range of 20 to -140 C. These parameters were obtained at various load levels and at different input voltages. The experimental procedures along with the results obtained on the investigated converter are presented and discussed.

Elbuluk, Malik E.↗
NASA NTRS1998

High-Voltage 1-kW dc/dc Converter Developed for Low-Temperature Operation

Recently, Lewis developed and demonstrated a high-voltage, 1-kW dc/dc converter that operates from room temperature to -184 C. A power supply designed for use in a NASA ion beam propulsion system was utilized as a starting point for the design of a low- (wide-) temperature dc/dc converter. For safety, we decided to halve the output voltage and power level, so the converter was designed for an 80-Vdc input and a 550-Vdc output at 1 kW.

Patterson, Richard L.↗
NASA NTRS2008

DC/DC Converter Stability Testing Study

This report presents study results on hybrid DC/DC converter stability testing methods. An input impedance measurement method and a gain/phase margin measurement method were evaluated to be effective to determine front-end oscillation and feedback loop oscillation. In particular, certain channel power levels of converter input noises have been found to have high degree correlation with the gain/phase margins. It becomes a potential new method to evaluate stability levels of all type of DC/DC converters by utilizing the spectral analysis on converter input noises.

Wang, Bright L.↗
DOE OSTI2024

1 kV 150 A Bidirectional Isolated DC/DC Converter With Full Range ZVS For Charger Application

This paper focusses on the development of a bidirectional DC/DC converter based on dual active bridge (DAB) converter for 1 kV class fast charger applications. A novel modulation technique is proposed to achieve zero voltage switching across the entire operating range of a vehicle battery system. The topology includes a tap changer to support multiple class of vehicles. The full range ZVS operation will allow high efficiency operation even at light load, reduced dv/dt to improve transformer insulation lifetime and mitigate EMI impact. A 1 kV class, 150 A prototype was developed to validate the proposed concepts.

Kandula, Prasad↗
NASA NTRS1982

High-Efficiency dc/dc Converter

High-efficiency dc/dc converter has been developed that provides commonly used voltages of plus or minus 12 Volts from an unregulated dc source of from 14 to 40 Volts. Unique features of converter are its high efficiency at low power level and ability to provide output either larger or smaller than input voltage.

Sturman, J.↗