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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 OSTI2023

Additive Manufacturing of Coreless Flyback Transformers Using Aerosol Jet Printing and Electrochemical Deposition

An additive manufacturing approach combining aerosol jet printing (AJP) and electrodeposition opens a new pathway to the production of lightweight coreless flyback transformer devices for power electronics. AJP of seed layers with resolution on the order of 30 μm is combined with electrodeposition of Cu and Ni for decreased resistance. This combined approach addresses known shortcomings of AJP and electrodeposition. Nanoparticle inks used in AJP of metals have low conductivity versus bulk materials due to their high grain boundary resistance. There is a lack of readily available high-resolution patterning techniques for electrodeposition outside of expensive clean-room-based lithography techniques. Combining these two techniques enables the patterning of high-resolution, high-conductivity components. Here in this manuscript, we report on the construction of coreless flyback transformers consisting of two-layer primary and two-layer secondary spiral inductors separated by layers of a printed UV-curable dielectric. An input voltage of 17 V at 400 kHz was amplified to an output of 1250 V corresponding to a gain of 73.5. COMSOL modeling at the individual inductor level and at the transformer level was used to compare expected inductance, equivalent series resistance (ESR), and coupling with experimentally measured values.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Multiplexing-Based Flyback Converter for Multi-Port USB Power Delivery with True Power-Sharing

Universal serial bus power delivery (USB-PD) chargers are more attractive to consumers with multiple output ports. Existing multiple port charger designs take multi-stage approach thus increase power loss and charger size. Also, ports are normally designed with different power capability thus the high-power port becomes under-used if the connected device is fully charged while the other lower power ports cannot take over the unused power. This is mainly limited by the power architecture design. This paper addresses this issue by presenting a multiplexing based multi-port quasi-resonant flyback converter. The design achieves true power-sharing with high efficiency, small size, and simple analog implementation. This paper discusses the operating principle and design considerations. A GaN-based 60 W dual port charger verifies the proposed scheme while achieving 76% size reduction and 1% efficiency improvement than state-of-the-art.

Xue, Lincoln↗
DOE OSTI2021

New Modulation and Impact of Transformer Leakage Inductance on Current-Source Solid-State Transformer

This article presents a novel modulation scheme for device voltage stress mitigation and comprehensive analysis of the impact of transformer leakage inductance in a current-source solid-state transformer (SST). Different from dual active bridge (DAB) SST, the operation of the current-source SST is similar to that of a flyback converter. The device bridge on only one side of the transformer is active to store energy into or release energy from the magnetizing inductance which acts as a current-source dc link. Such flyback operation with reverse-blocking switches can lead to additional device voltage stress and incomplete zero-voltage switching (ZVS) on the current-source soft-switching solid-state transformer (S4T) under conventional modulation. A new modulation scheme is proposed to address this issue. Moreover, different from the DAB, the leakage inductance of the medium-frequency transformer (MFT) in the S4T is a parasitic element similar to that in a matrix SST and can cause additional device voltage stress. Though the resonant capacitors, originally added to achieve ZVS, can absorb and recycle the leakage energy in the S4T, these capacitors need to be increased with larger leakage inductances to limit the voltage stress. However, large resonant capacitors can result in more lost duty cycles and reduced efficiency. The impact of such leakage inductance on device voltage stress is analyzed comprehensively, which is critical to guide future research and design of the S4T. Experimental results from S4T prototypes for DC-DC, multiport AC-DC, and AC-AC conversion with 1:1 and 4:1 MFT comprehensively verify the proposed concepts. Lastly, a case study of a three-phase AC-AC S4T over a power range from 1 kVA to 100 kVA each module reveals that the MFT leakage inductance should be less than 1% of the magnetizing inductance for safe operation.

14 SOLAR ENERGY↗
DOE OSTI2022

Device Voltage Stress from Ground Leakage Current in Medium-Voltage Solid-State Transformer

Grounding related issues are critical for safe and reliable operation of solid-state transformer (SST) in medium-voltage (MV) applications, e.g., solar photovoltaic and energy storage integration, date center, electric vehicle fast charging, etc. This article presents for the first time the issue of additional device voltage stress due to grounding-loop current in current-source SST, using the soft-switching solid-state transformer (S4T) as an example. The S4T features single-stage isolated AC-AC, AC-DC, or DC-DC conversion with full-range ZVS, derived from flyback converter or current-source converter (CSC). However, the flyback operation for CSC-based SST means that magnetizing current flows through the reverse-blocking devices on only one side of the medium-frequency transformer (MFT) at a time. Then, the voltages across the devices, especially those on the other side of the MFT, can be influenced by parasitic current. A parasitic model of a modular S4T (M-S4T) prototype is developed from direct measurements and datasheets. Using the developed parasitic model and equivalent circuits, the causes of the voltage stress are analyzed. A voltage-stress mitigation scheme of connecting additional grounding capacitors is proposed. Damping resistors are also installed to damp out the grounding-loop resonance. A robust parameter design of the proposed scheme is given. The existence of the voltage stress issue and the effectiveness of the proposed scheme are verified experimentally on an MV SiC M-S4T prototype with inherent parameter variations among the five modules in the prototype. Here, both single-module and stacked-module operation are demonstrated during steady state and dynamic conditions up to 4 kV peak.

42 ENGINEERING↗
DOE OSTI2022

Laminated Permanent Magnets Enable Compact Magnetic Components in Current-Source Converters

Magnetic components have become one of the primary barriers to high power density converters, especially to current-source converters (CSCs). In CSCs, the inductors/transformers have a predominantly dc flux to store energy, which can be offset by standard permanent magnets (PMs). However, eddy currents in standard PMs induce significant losses and thermal stress for medium-frequency applications. This article proposes using laminated PMs to offset the dc flux while reducing eddy currents, leading to significant reductions in the size, cost, and losses of inductors/transformers. Furthermore, the laminated PMs’ optimal location, orientation, and distribution are investigated to generalize this approach for maximum benefits. Here, three-dimensional finite-element analysis simulation and hardware experiments are presented to validate the effectiveness of the proposed approach in a medium-frequency transformer (MFT) for CSCs. Compared with standard PMs, the proposed use of laminated PMs reduces aggregate core-plus-PM losses by 85% in experiments, and thus, relaxes the MFT thermal design. Finally, the proposed approach is experimentally validated in a 40 kVA flyback-type MFT for a soft-switching solid-state transformer. Compared to the traditional design without any PMs, the proposed design increases the saturation current by 46% while inducing only 5% more losses, leading to significant savings in magnetics cost and size.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2013

Integrated Power Chip Converter for Solid State Lighting (Final Report)

The overall goal of the project was to develop an integrated power converter chip for solid-state lighting. We developed a low component count circuit topology, fast and low loss switching devices, compact and low loss passive components, and integration methodology to enable an integrated LED driver, where cost, size and efficiency are paramount. The converter was designed to operate directly from ac line voltage, nominally providing 24 V output at 25 W with features of dimming and control for light uniformity. We developed a power circuit and control suitable for chip-scale integration, low loss and high frequency GaN power devices with a new vertical architecture that reduces parasitics and lowers cost by decreasing the chip real estate, and high-density passives, including a chip-scale flyback transformer that integrates inductor and transformer action into a single component.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

High Efficiency OLED Light Engine

LED Specialists has accomplished the program objective in designing a high efficiency OLED light engine combining high-performance OLED panels in the 5W-8W range. We achieved our goal by using an Active-Clamp Flyback circuit topology using state-of-the-art electronics. Evaluation testing of our second-generation prototype PC board has demonstrated an efficiency rating of 93% and dimming capability between 100% and 5% of OLED brightness. A reliability analysis of the design shows it to have a predicted Mean Time Between Failures (MTBF) of approximately 1,000,000 hours.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2016

The influence of electron discharge and magnetic field on calcium carbonate (CaCO{sub 3}) precipitation

The influences of electron discharge and magnetic field on calcium carbonate (CaCO{sub 3}) precipitation in water have been successfully investigated. The study used three pairs of magnetic field 0.1 T whilst the electron discharge was generated from television flyback transformer type BW00607 and stainless steel SUS 304 as an electrode. The water sample with an initial condition of 230 mg/L placed in the reactor with flow rate 375 mL/minutes, result showed that the electron discharge can be reduced contain of calcium carbonate the water sample around 17.39% within 2 hours. Meanwhile for the same long period of treatment and flow rate, around 56.69% from initial condition of 520 mg/L of calcium carbonate in the water sample can be achieved by three pairs of magnetic field 0.1 T. When the combination of three pairs of magnetic field 0.1 T and the electron discharge used for treatment, the result showed that the combination of electron discharge and magnetic field methods can be used to precipitate calcium carbonate in the water sample 300 mg/L around 76.66% for 2 hours of treatment. The study then investigated the influence of the polar position of the magnetic field on calcium carbonate precipitation. Two positions of magnetic field were tested namely the system with alternated polar magnetics and the system without inversion of the polar magnetics. The influence of the polar position showed that the percentage reduction in levels of calcium carbonate in the water sample (360 mg/L) is significant different. Result showed that the system without inversion of the polar magnetics is generally lower than the system with alternated polar magnetics, with reduction level at 30.55 and 57.69%, respectively.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Adaptive Time-Division Multiplexing Driving System for Solid State Lighting with Multiple Tunable Channels

Next generation solid state lighting enables unlimited control of light and serve much broader functions beyond the basic lighting for illuminance. The emerging lighting for productivity, well-being, healthcare, and growth have revolutionized the scope of lighting. To empower this unlimited controllability, a multi-channel tunable power-electronics driver is essential but has not been satisfactorily addressed so far. Existing solutions are lossy, large, and expensive, due to introduction of additional buck power conversion stages. This paper proposes a time-division multiplexing (TDM) LED driving system which eliminates those buck stages. The proposed design can directly pair with off-the-shelf pulse width modulated (PWM) controllers and since it inherits entire feature sets, it can achieve low loss at standby and at dimmed condition. The simple analog implementation avoids usage of expensive DSPs/MCU. GaN’s high switching frequency capability can push up the multiplexing frequency so a GaN-based flyback was built and proved the concept.

Xue, Lincoln↗
DOE OSTI2014

Automated qualification and analysis of protective spark gaps for DC accelerators

Protective spark gaps are used in the high voltage multiplier column of a 3 MeV DC Accelerator to prevent excessive voltage build-ups. Precise gap of 5 mm is maintained between the electrodes in these spark gaps for obtaining 120 kV± 5 kV in 6 kg/cm{sup 2} SF{sub 6} environment which is the dielectric medium. There are 74 such spark gaps used in the multiplier. Each spark gap has to be qualified for electrical performance before fitting in the accelerator to ensure reliable operation. As the breakdown voltage stabilizes after a large number of sparks between the electrodes, the qualification process becomes time consuming and cumbersome. For qualifying large number of spark gaps an automatic breakdown analysis setup has been developed. This setup operates in air, a dielectric medium. The setup consists of a flyback topology based high voltage power supply with maximum rating of 25 kV. This setup works in conjunction with spark detection and automated shutdown circuit. The breakdown voltage is sensed using a peak detector circuit. The voltage breakdown data is recorded and statistical distribution of the breakdown voltage has been analyzed. This paper describes details of the diagnostics and the spark gap qualification process based on the experimental data. (author)

43 PARTICLE ACCELERATORS↗
DOE OSTI2013

Architectures and Control of Submodule Integrated DC-DC Converters for Photovoltaic Applications

This paper describes photovoltaic (PV) module architectures with parallel-connected submodule-integrated dc-dc converters (subMICs) that improve efficiency of energy capture in the presence of partial shading or other mismatch conditions. The subMICs are bidirectional isolated dc-dc converters capable of injecting or subtracting currents to balance the module substring voltages. When no mismatches are present, the subMICs are simply shut down, resulting in zero insertion losses. It is shown that the objective of minimum subMIC power processing can be solved as a linear programming problem. A simple close-to-optimal distributed control approach is presented that allows autonomous subMIC control without the need for a central controller or any communication among the subMICs. Furthermore, the proposed control approach is well suited for an isolated-port architecture, which yields additional practical advantages including reduced subMIC power and voltage ratings. The architectures and the control approach are validated by simulations and experimental results using three bidirectional flyback subMICs attached to a standard 180-W, 72-cell PV module, yielding greater than 98% module-level power processing efficiency for a mismatch less than 25%.

Olalla, C↗
DOE OSTI2019

A Hybrid Modulation Method for Single-Stage Soft-Switching Inverter Based on Series Resonant Converter

Pseudo-dc-link inverters are promising due to the single-stage configuration. The inverters can be isolated by high-frequency transformers, which also provide the freedom of step-up/down through winding turns ratio. Conventionally, a pseudo-dc-link inverter is based upon a pulsewidth modulation converter like flyback converter, but the accompanying switching losses can degrade efficiency and overall system performance. Alternatively, resonant converters (e.g., series resonant converter) seem to fit the need as they typically display soft-switching characteristics. However, the relevant research results are scarce because of two main reasons: high resonant current and limited soft-switching range. To overcome the difficulties, a hybrid modulation method is proposed in this article for a pseudo-dc-link inverter based on series resonant converter. In high-line region, the inverter operates with variable-frequency modulation, which leads to zero-voltage switching and relatively low-resonant current. In low-line region, the inverter operates with a short-pulse density modulation so that switching losses are greatly curtailed without excessive resonant current. The merits in both regions together contribute toward the high efficiency of the inverter. This article presents the operational principle of the proposed modulation as well as a comparison with other modulation methods. In addition, a 400 V-230 Vac, 2-kW prototype was built to verify the proposed modulation and the peak efficiency reaches 98.0%.

42 ENGINEERING↗
DOE OSTI2021

A Bulk-Capacitance Reduction Method Using Self-Driven Thyristor for AC-DC Converters

Universal serial bus power delivery (USB-PD) fast chargers equipped with wide-bandgap devices are driven to higher power density and efficiency. Furthermore, the indispensable high-voltage bulk capacitors used to smooth the rectifier output could take 40% of the total system volume due to the large capacitance value required. This paper discussed a capacitor reduction method using a self-driven thyristor scheme comprised of only three components in total. No extra control circuit is needed. Circuit analysis and design equations are presented, and the design results are implemented in a 60-W GaN-based active-clamp flyback converter. The measurement results on the prototype show a 36.4% reduction of the bulk-capacitor size with similar efficiency compared to the conventional solution.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2016

Dynamic scan control in STEM: spiral scans

Abstract Scanning transmission electron microscopy (STEM) has emerged as one of the foremost techniques to analyze materials at atomic resolution. However, two practical difficulties inherent to STEM imaging are: radiation damage imparted by the electron beam, which can potentially damage or otherwise modify the specimen and slow-scan image acquisition, which limits the ability to capture dynamic changes at high temporal resolution. Furthermore, due in part to scan flyback corrections, typical raster scan methods result in an uneven distribution of dose across the scanned area. A method to allow extremely fast scanning with a uniform residence time would enable imaging at low electron doses, ameliorating radiation damage and at the same time permitting image acquisition at higher frame-rates while maintaining atomic resolution. The practical complication is that rastering the STEM probe at higher speeds causes significant image distortions. Non-square scan patterns provide a solution to this dilemma and can be tailored for low dose imaging conditions. Here, we develop a method for imaging with alternative scan patterns and investigate their performance at very high scan speeds. A general analysis for spiral scanning is presented here for the following spiral scan functions: Archimedean, Fermat, and constant linear velocity spirals, which were tested for STEM imaging. The quality of spiral scan STEM images is generally comparable with STEM images from conventional raster scans, and the dose uniformity can be improved.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2012

High Efficiency Driving Electronics for General Illumination LED Luminaires

New generation of standalone LED driver platforms developed, which are more efficient These LED Drivers are more efficient (≥90%), smaller in size ( 0.15 in3/watt), lower in cost (12 cents/watt in high volumes in millions of units). And these products are very reliable having an operating life of over 50,000 hours. This technology will enable growth of LED light sources in the use. This will also help in energy saving and reducing total life cycle cost of LED units. Two topologies selected for next generation of LED drivers: 1) Value engineered single stage Flyback topology. This is suitable for low powered LED drivers up to 50W power. 2) Two stage boost power factor correction (PFC) plus LLC half bridge platform for higher powers. This topology is suitable for 40W to 300W LED drivers. Three new product platforms were developed to cover a wide range of LED drivers: 1) 120V 40W LED driver, 2) Intellivolt 75W LED driver, & 3) Intellivolt 150W LED driver. These are standalone LED drivers for rugged outdoor lighting applications. Based on these platforms number of products are developed and successfully introduced in the market place meeting key performance, size and cost goals.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Magnetics, Inc. 0077894A7 (Datasheet)

Description of Core Under Test (CUT). Magnetics, Inc. 0077894A7 is a powder core material having low loss and high saturation fields. Known for the marketing name Kool Mu, was transformed by taking the known magnetic material, Sendust, and altered the manufacturing process to lower core losses. Possessing these specific properties makes it ideal for power factor correction circuits as well Pulse and Flyback Transformers. In-Line Noise Filters and Inductors are also common due to the near zero magnetostriction. Exhibits a potential saturation induction of 1 T.

36 MATERIALS SCIENCE↗