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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
DOE OSTI2020

Four-phase interleaved TCM DC-DC buck converter with matrix inductor in battery charging application

In this paper, a 1-kW DC-DC buck converter with a four-phase interleaved matrix inductor is proposed for battery charging applications. It is well-known that the DC bias on the inductor will cause high core loss as it changes the B–H characteristic. Typically, the transient conduction mode employed in high voltage applications for zero-voltageswitching of devices would cause higher inductor current ripple. The conventional approach to reduce the effect of DC bias and inductor current ripple is employing multi-phases. However, the cost and size of the converter will increase significantly. This paper proposes the matrix inductor which has a small volume and reduces the effect of the DC bias by flux sharing and flux cancellation at the same time, results in low inductor core loss. With the interleaved operations the output current ripple can be lower which is suitable for battery charging application. Besides, the comparison of the synchronous and interleaved operation is presented. A 1-kW prototype is built and the experimental results show that the peak efficiency is 99.1% and 99.2% for synchronous and interleaved control, respectively. Additionally, the output current ripple of the interleaved operation is reduced by 85% in comparison with the synchronous operation.

14 SOLAR ENERGY↗
DOE OSTI2021

Magnetic triggering — time-resolved characterisation of silicon strip modules in the presence of switching DC-DC converters

Modules for the ATLAS Inner Tracker (ITk) strip tracker include a DC-DC converter circuit glued directly to the silicon sensor which converts the 11 V supplied to the module to the 1.5 V required for the operation of the readout chips. The DC-DC converter unit, consisting of a copper solenoid and custom ASIC, is located directly above the silicon strip sensor and therefore needs to be shielded to protect the sensor from EMI noise created during the operation of the circuit. Despite dedicated shielding, consisting of an aluminium shield box with continuous solder seams encompassing the surface components and a copper layer in the PCB beneath it, module channels connected to sensor strips located beneath the converter circuit were found to show a noise increase. While the DC-DC converter unit causing the underlying EMI noise operates at a frequency of 2 MHz, module characterisation measurements for ITk strip tracker modules are typically performed asynchronously to the DC-DC switching and are therefore averaged over the full range of time bins with respect to the converter frequency. In order to investigate the time dependence of the noise injection relative to the DC-DC switching frequency, a dedicated setup to understand the time-resolved performance change in modules was developed. By using a magnetic field probe to measure the field leaking through the shield box and triggering on its rising edge, data taking could be synchronised with the DC-DC switching. This paper illustrates the concept and setup of such time-resolved performance measurements using magnetic triggering and presents results for the observed effects on signal and noise for ATLAS ITk strip modules from both laboratory and beam tests.

47 OTHER INSTRUMENTATION↗
DOE OSTI2023

Production and testing of the powerboard for ATLAS ITk Strip barrel modules

The upgrade of the ATLAS ITk strips detector for HL-LHC will employ a custom PCB (powerboard) for on-module DC-DC conversion, HV switching, and monitoring. Production of about 14100 of such PCBs with high reliability is a big challenge. In this paper we will present the production procedure and quality control (QC) testing system for the powerboards to be installed on ITk Strip barrel modules. During production, about 150 powerboards will be produced every week. Each powerboard will need to pass QC tests before they are assembled to module. The QC tests include thermal cycling between -35 °C and 40 °C, soak test (continuous running of DC-DC converter at high load at 20 °C), and basic functionality and characterization electrical tests of the low voltage (LV), high voltage (HV), and monitoring functions of the powerboard. A custom QC test system is described, which is based on a reusable PCB (active board) with all testing circuits, a one-time powerboard carrier card, and a Z-turn SoC board which hosts and runs the testing program. The production procedure and QC test system has been tested with 400 powerboards during pre-production, and the system has been proven ready for production with the desired testing program, speed, safety, and cost. Performance and typical failures of powerboards observed during the QC test of pre-production powerboards is also presented.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Duty-Cycle Predictive Control of Quasi-Z-Source Modular Cascaded Converter Based Photovoltaic Power System

A duty-cycle predictive control is proposed for dc grid integration of front-end isolated quasi-Z-source modular cascaded converter (qZS-MCC) photovoltaic (PV) power system. The post-stage qZS half-bridge dc-dc converter deals with PV maximum power point tracking, dc grid integration, and dc-link voltage balance; whereas, the front-end isolation converters operate at a constant duty cycle of 50%. Thus, it saves control hardware resources while overcoming challenges from PV-panel voltage variations and dc-bus voltage limit. The proposed control uses the derived circuit model to predict the global active-state duty cycle for grid-connected current control and predict the shoot-through duty cycles for dc-link voltage balance, achieving a fast and accurate tracking target. The proposed control method has advantages of: i) eliminating weighting factors that exist in conventional model predictive control (MPC), ii) no sophisticated loop parameters design that exists in proportional-integral (PI) control, iii) operating at constant switching frequency that is different from the conventional MPC with variable switching frequency. Simulation and experimental tests are carried out to verify the effectiveness of the proposed control method and compare with the PI-based control system.

42 ENGINEERING↗
DOE OSTI2020

Thermal Design Consideration of Medium Voltage High Frequency Transformers

This paper describes a thermal design using epoxy potting for high frequency transformer (HFT) for medium voltage high power electronic applications, namely emerging solid-state transformers. To address HFT’s thermal stress problem, thermal performance of the HFT with air and epoxy potting cooling method are both simulated by magnetothermal-fluid coupling method (MTFCM). The effectiveness of the simulation analysis is verified in a 100 kW DC-DC resonant converter. Influencing factors including distance between the high frequency transformer and the metal enclosure, epoxy thermal conductivity and heat sink placements are simulated and analyzed. Finally, an optimal cooling structure is proposed for future high power HFTs.

Wang, Haoming↗
DOE OSTI2020

Soft Switching Over the Entire Line Cycle for a Quadruple Active Bridge DCX in a DC to Three-Phase AC Module

This paper is focused on a transformer-isolated quadruple active bridge (QAB) dc-dc converter loaded by three full-bridge dc-ac inverters. The QAB functions as a "DC trans-former" (DCX) in the dc-to-three-phase ac module. The QAB outputs provide time-varying power at twice the line frequency, which presents challenges in maintaining zero voltage switching (ZVS) on the secondary sides during low-power portions of the line cycle. It is shown how ZVS can be achieved in a phase, even at zero-power transfer, using a relatively small circulating current provided by the magnetizing inductance of the high-frequency transformer. The approach is particularly effective in high-voltage applications using SiC MOSFETs, where reductions in switching loss outweigh additional conduction losses due to the circulating currents. A detailed analysis of ZVS switching waveforms at the zero power transfer is presented, including effects of nonlinear device capacitances. Analytical expressions are given for the optimal values of the magnetizing inductance and dead times of the QAB primary and secondary bridges. The approach is verified by experimental results on a 600 V, 4 kW prototype, demonstrating greater than 98.5% efficiency from 1 kW to 4 kW, with a peak efficiency of 99.0%. Compared to conventionally operated prototype, a 54% reduction in total loss is achieved at rated power.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2021

A Novel Decentralized PWM Interleaving Technique for Ripple Minimization in Series-Stacked DC-DC Converters

Cascaded dc-dc converters are commonly used in applications where distributed energy sources or loads are connected to elevated voltage levels for power transfer. In such systems, it is advantageous to minimize the ripple on the bus current and voltage by proper phase shifting of the pulse-width modulation (PWM) pulses among the converters via a method known as interleaving. Existing approaches use either a centralized controller or separate communication lines among the stacked converters to control their relative PWM switch transitions. The key drawbacks are that these methods entail significant wiring, the central controller acts as a single point of failure, and implementation on very large numbers of units is impractical. In this paper, we introduce a decentralized interleaving control (DIC) strategy that acts on local current measurements at every converter and achieves communication-free PWM interleaving among the series-stacked converters. The proposed controller is simple in structure and is shown to converge asymptotically to the interleaved state irrespective of clock drifts among the digital signal processors. Experimental results are provided for a system of five series-connected converters showing a 10× reduction in the current ripple compared to normal operation.

cascaded converter↗
DOE OSTI2023

Medium Voltage Solid State Transformer for Extreme Fast Charging Applications

A modular and scalable solid state transformer (SST) with direct medium voltage (MV) AC connectivity is proposed to enable DC extreme fast charging (XFC) of electric vehicles. Single-phase-modules (SPMs), each consisting of an active-front-end (AFE) stage and an isolated DC-DC stage, are connected in input-series-output-parallel (ISOP) configuration. The modular hardware is co-designed with decentralized control of the DC-DC stages where voltage and power balancing are achieved by each SPM using only its local sensor feedback; a centralized controller (CC) regulates the low voltage (LV) DC bus through the AFE stages without any sensor feedback form the SPMs. The controller architecture contrasts sharply with the prior art for MV AC to LV DC SSTs where high-speed bidirectional communication among SPMs and a CC are required for module-level voltage and power balancing, which severely limits the scalability and practical realization of higher voltage and higher power units. Detailed small-signal analysis and controller design guidelines are developed. Furthermore, a soft start-up strategy is presented. The proposed converter and control structure are validated through simulation and experimental results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Comparative Evaluation of the Single-Phase Shift and Extended-Phase Shift Control for Isolated DC-DC Converter

Abstract: This paper presents a comparative evaluation of the Single-Phase Shift (SPS) and Extended-Phase Shift (EPS) controls for the isolated DC-DC Converter. The analysis is based on the power regulation range, flexibility of operation, current stress on power devices, system efficiency while focusing on the issue of backflow power, control complexity, design and implementation overhead, and stability of the entire system. It is also examined how the backflow influences power circulation and increases current stress. Here, the Dual Active Bridge (DAB) Converter is employed to assess the performance of the control methods. Compared to SPS control, EPS offers a wider power regulation range, greater flexibility, lower current stress, and better system efficiency. However, EPS has increased control complexity, design and implementation overhead, and often requires sophisticated feedback control loops. The comparison is made through mathematical modeling of power transfer, backflow, and current stress. Simulation results validate the comparative analysis presented.

Amir, Aamir [The University of Alabama (UA)]↗
DOE OSTI2020

Control of SiC Based Integrated DC-DC Powertrain Charger for Electric Vehicles

In this paper, an automated controller for an integrated, reconfigurable dc-dc converter for plugin electric vehicles (EVs) is presented. The integrated converter combines both an interleaved boost converter and dual active bridge (DAB) converter, sharing magnetics and switching devices. The converter switches between operating modes using the existing battery management system (BMS) contactors. The integrated converter operates in isolated DAB mode during battery charging operation. During traction operation, the integrated converter is operated in interleaved boost mode for heavy load and DAB mode during light load, high voltage operation. An online transition algorithm is used to transition from interleaved boost mode to DAB mode with minimal bus distortion. The automated controller selects the operating mode and inverter bus voltage at different torque-speed conditions to get maximum overall traction drive efficiency. An experimental prototype of the integrated converter demonstrates the automated controller functionality.

Anwar, Saeed↗
DOE OSTI2021

An Active Detection Scheme for Sensor Spoofing in Grid-tied PV Systems

In this paper an active detection scheme for sensor spoofing (manipulated externally via a cyber attack) in grid-tied PV systems is discussed. The core of the proposed active detection scheme is to introduce a private (secret) watermarking signal into the control inputs of the DC-DC converter and DC-AC inverter stages to detect any malicious spoofing (manipulation) of voltage/current sensor measurements controlling both the DC-DC converter maximum power point tracking (MPPT) stage and the DC-AC inverter of the grid-tied PV system. Several types of possible spoofing mechanisms (attack models) are discussed. The proposed sensor spoofing attack detector system consists of injecting a small magnitude of digital watermarking signal (DWS) and conduct three statistical watermark tests on the reported sensor measurements to determine if a) the proposed system is healthy and operating as expected b) if sensor signals were spoofed (manipulated) externally or c) if a particular sensor is malfunctioning due to a faulty hardware. It is shown via extensive simulations that the proposed DWS approach is robust in detecting malicious external manipulation of sensors controlling the grid tied PV system. A testing platform is currently under development and the experimental results will be discussed in the conference presentation.

Ibrahim, Hasan↗
DOE OSTI2022

3.5 kW/in3 Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter

Planar magnetics design has been widely used in power electronics field because of the low profile, ease of manufacturability, and high power density. This paper first proposes a 3-level four-switch buck-boost (3L-FSBB) converter for the dc-dc applications where the zero common-mode (CM) voltage emissions, step-up and step-down are all required. With the consideration of power density, efficiency, and cost, a 15oz heavy copper coupled inductor for 3-level FSBB converter was designed and optimized with the low-cost commercial core and planar windings. According to the soft-switching quadrangle modulation for 3-L FSBB, the turns number and stacked core number are optimized first. And then, a two-board design is proposed to reduce the fringing effect and improve the thermal performance. Finally, a 75 kVA two-stage ac-dc-dc converter including a 3-level FSBB converter was built to verify the electrical design.

Cao, Yuliang↗
DOE OSTI2022

A 75 kVA Intelligent Power Stages (IPS) Unit Design for Future Grid-interface Application

The demand for grid-interface converter with flexible dc bus is driven by the fast development of energy storage system (ESS), electric vehicle (EV) charging system, and versatile residential load. This paper first proposes a two-stage intelligent power stage (IPS) unit for future grid-interface applications. To achieve zero common-mode (CM) voltage emissions, step-up and step-down voltage gain, a 3-level four-switch buck-boost (3-L FSBB) dc-dc converter is adopted with fully zero voltage switching (ZVS). In one IPS unit, an advanced fiberoptic communication with sub-nanosecond synchronization is developed for different enhanced gate drivers. Moreover, an enhanced gate driver integrated current and voltage sensors is designed for monitoring and diagnostics. To achieve a whole low-profile design, three 12 oz heavy copper planar ac inductors are designed and implemented. Finally, a 75 kVA IPS unit was built to verify both the thermal and electrical design.

Cao, Yuliang↗
DOE OSTI2022

A Self-Organizing Nano Grid (SONG) for Energy Access Clusters

In this paper, a bottom-up dc Self-Organizing Nano Grid (SONG) for rural electrification at ultra-low-cost through a flexible and scalable topology is presented. The proposed nano grid requires no communication and uses dc-bus signaling to convey excess energy in the system through the bus voltage, allowing independent agents to conduct energy transactions based on their needs in a decentralized manner. Moreover, this article proposes a concept that uses a novel multi-source, multi-segment droop control strategy with demand coordination, allowing for dynamic self-balancing of the system under fluctuating operating conditions. The unique use of a surplus photovoltaic (PV) power droop mode precisely estimates energy availability to minimize load chattering that helps in stabilizing the dc-bus. In addition, this architecture uses standard dc/dc converters for a low-cost, modular, Plug and Play ( PnP ) solution with highly automated operation, enabling local assembly, operation, and maintenance by non-technical personnel. The proposed SONG concept was validated in simulation and with a 700W, laboratory-scale, custom made nano grid system. The simulation and experimental test cases show the feasibility of the SONG system by demonstrating the proposed multi-source, multi-segment droop control strategy without load chattering under varying operating conditions.

dc-dc converter↗
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↗
DOE OSTI2023

Zero Voltage Switching AC-DC Converter Based on Zero State Modulation (ZSM)

In this paper, a half-bridge building block that can achieve soft switching across the complete operating range while operating under fixed frequency is proposed. In addition, dead-beat model predictive controls to control the same are also proposed. The proposed converter, referred to as zero-state modulated (ZSM) converter, uses a zero state, enabled by a small auxiliary switch, to achieve soft-switching. The approach allows lower switching loss, controlled dv/dt, small filter inductor, fixed frequency operation allowing interleaving to reduce filter capacitor. A single half-bridge building block can used to realize a ZVS DC-DC converter or multiple of these building blocks can be used to achieve soft switching 1-phase or 3-phase AC-DC converters.

Kandula, Prasad↗
DOE OSTI2025

System Identification of a DC-DC Buck Converter Based on Two-Channel Relay Method

This work presents a system identification approach based on a two-channel relay applied to a DC-DC buck converter operating in closed-loop with a PI controller to regulate its output voltage. The implemented two-relay method allows system identification while the system is running online. Moreover, the algorithm works in a closed-loop configuration while introducing a minimal perturbation in the converter's operation. The presented algorithm was used to identify the frequency response of the converter with no-prior knowledge about the system structure. Furthermore, the identified transfer function parameters has a good agreement with the mathematical model of the converter. Simulation results of the comparison between the switching model, mathematical model and the identified model are provided to validate the theoretical analysis.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗