Browsing by Author "Dong, Dong"
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- 3D Commutation-Loop Design Methodology for a SiC Based Matrix Converter run in Step-up mode with PCB Aluminum Nitride Cooling InlayBaker, Victoria Isabelle (Virginia Tech, 2021-07-22)This work investigates three-dimensional power loop layout for application to a SiC based matrix converter, providing a symmetric, low-inductance solution. The thesis presents various layout types to achieve this design target, and details the implementation of a hybrid layout to the matrix converter phase-leg. This layout is more easily achievable with a surface-mount device package, which also offers benefits such as ease in manufacturing, and a compact package. In order to implement a surface-mount device, a PCB thermal management strategy should be utilized. An evaluation of these methods is also presented in the work. The final power loop solution that implements an aluminum nitride inlay is evaluated through simulated parasitic extraction and experimental double pulse tests. The layout achieves small, symmetric loop inductances. Finally, the full power, three-phase matrix converter demonstrates the successful implementation of this power loop layout.
- Ac-dc Bus-interface Bi-directional Converters in Renewable Energy SystemsDong, Dong (Virginia Tech, 2012-07-25)This dissertation covers several issues related to the ac-dc bus-interface bi-directional converters in renewable energy systems. The dissertation explores a dc-electronic distribution system for residential and commercial applications with a focus on the design of an ac-dc bi-directional converter for such application. This converter is named as the "Energy Control Center" due to its unique role in the system. First, the impact of the unbalanced power from the ac grid, especially the single-phase grid, on the dc system operation is analyzed. Then, a simple ac-dc two-stage topology and an advanced digital control system is proposed with a detailed design procedure. The proposed converter system significantly reduces the dc-link capacitor volume and achieves a dynamics-decoupling operation between the interfaced systems. The total volume of the two-stage topology can be reduced by upto three times compared with the typical design of a full-bridge converter. In addition, film capacitors can be used instead of electrolytic capacitors in the system, and thus the whole system reliability is improved. A set of ac passive plus active filter solutions is proposed for the ac-dc bus-interface converter which significantly reduces the total power filter volume but still eliminate the total leakage current and the common-mode conducted EMI noises by more than 90%. The dc-side low-frequency CM voltage ripple generated by the unbalanced ac voltages can be eliminated as well. The proposed solution features a high reliability and fits three types of the prevalent low-voltage ac distribution systems. Grid synchronization, a critical interface control in ac-dc bus-interface converters, is discussed in detail. First, a novel single-phase grid synchronization solution is proposed to achieve the rejection of multiple noises as well as the capability to track the ac voltage amplitude. Then, a comprehensive modeling methodology of the grid synchronization for three-phase system is proposed to explain the output frequency behaviors of grid-interface power converters at the weak grid, at the islanded condition, and at the multi-converter condition. The proposed models provide a strong tool to predict the grid synchronization instabilities raised from industries under many operating conditions, which is critical in future more-distributed-generation power systems. Islanding detection issues in ac-dc bus-interface converters are discussed in detail. More than five frequency-based islanding detection algorithms are proposed. These solutions achieve different performances and are suitable for different applications, which are advantageous over existing solutions. More importantly, the detailed modeling, trade-off analysis, and design procedures are given to help completely understand the principles. In the end, the effectiveness of the proposed solutions in a multiple-converter system are analyzed. The results drawn from the discussion can help engineers to evaluate other existing solutions as well.
- Anti-islanding detection for three-phase distributed generation(United States Patent and Trademark Office, 2017-04-25)Wobbling the operating frequency of a phase-locked loop (PLL), preferably by adding a periodic variation is feedback gain or delay in reference signal phase allows the avoidance of any non-detection zone that might occur due to exact synchronization of the phase locked loop operating frequency with a reference signal. If the change in PLL operating frequency is periodic, it can be made of adequate speed variation to accommodate and time requirement for islanding detection or the like when a reference signal being tracked by the PLL is lost. Such wobbling of the PLL operating frequency is preferably achieved by addition a periodic variable gain in a feedback loop and/or adding a periodically varying phase delay in a reference signal and/or PLL output.
- A Compact Three-Phase Multi-stage EMI Filter with Compensated Parasitic-Component EffectsChen, Shin-Yu (Virginia Tech, 2023-09-14)With the advent of wide bandgap (WBG) semiconductor devices, the electromagnetic interference (EMI) emissions are more pronounced due to high slew rates in the form of high dv/dt and high di/dt at higher switching frequencies compared to the traditional silicon technology. To comply with the stringent conducted emission requirements, EMI filters are adopted to attenuate the high frequency common mode (CM) and differential mode (DM) noise through the propagation path. However, self and mutual parasitic components are known to degrade the EMI filter performance. While parasitic cancellation techniques have been discussed at length in prior literature, most of them have focused mainly on single phase applications. As such this work focuses on extending the preexisting concepts to three-phase systems. Novel component placement, winding strategy as well as shielding and grounding techniques were developed to desensitize the influence of the parasitic effects on a three-phase multi-stage filter. The effectiveness of the three-phase filter structure employing the proposed methodologies has been validated via noise measurements at the line impedance stabilization network (LISN) in a 15kW rated motor drive system. Consequently, general design guidelines have been formulated for filter topologies with different inductor and capacitor form-factors.
- DC-side leakage current reduction for single phase full-bridge power converter/inverter(United States Patent and Trademark Office, 2015-06-02)Leakage current through stray or parasitic capacitance (which is particularly large in devices such as photovoltaic cell arrays and which are damaged by such leakage currents) due to common mode switching noise in a full bridge single phase power converter is reduced at high frequencies by magnetically coupling the two phase legs on the AC side of the power converter and connecting mid points of the AC and DC sides of the power converter and is reduced at low frequencies by use of a feedback arrangement that modifies sinusoidal modulation of the switches of the full bridge converter to function as an active filter. The magnetic coupling for the two phase legs is designed in a simple manner to avoid saturation based on volt-second considerations.
- Design and implementation of Silicon-Carbide-based Four-Switch Buck-Boost DCDC Converter for DC Microgrid ApplicationsBai, Yijie (Virginia Tech, 2023-02-07)With the increasing demand for clean and renewable energy, new distribution network concepts, such as DC microgrids and distributed power generation networks, are being developed. One key component of such networks is the grid-interfacing DC-DC power converter that can transfer power bi-directionally while having a wide range of voltage step-up and step-down capabilities. Also, with the proliferated demand for electric vehicle chargers, battery energy storage systems, and solid-state transformers (SST), the bi-directional high-power DC-DC converter plays a more significant role in the renewable energy industry. To satisfy the requirements of the high-power bi-directional wide-range DC-DC converter, different topologies have been compared in this thesis, and the four-switch buck-boost (FSBB) converter topology has been selected as the candidate. This work investigates the operation principle of the FSBB converter, and a digital real-time low-loss quadrangle current mode(QCM) control implementation, which satisfies the zero-voltage-switching (ZVS) requirements, is proposed. With the QCM control method, the FSBB converter efficiency can be further increased by reducing the inductor RMS current and device switching loss compared to traditional continuous current mode(CCM) control and discontinuous current mode(DCM) control. Although the small signal model has been derived for FSBB under CCM control, the small ripple approximation that was previously used in the CCM model no longer applies in the QCM model and causing the model to be different. To aid the control system compensator design, QCM small signal model is desired. In this thesis, a small signal model for FSBB under QCM control is proposed. A 50 kW silicon carbide (SiC) based grid-interfacing converter prototype was constructed to verify the QCM control implementation and small signal model of the FSBB converter. For driving the 1.2kV SiC modules, an enhanced gate driver with fiber optic (FO) based digital communication capability was designed. Digital on-state and off-state drain-source voltage sensors and Rogowski coil-based current sensors are embedded in the gate driver to minimize the requirement for external sensors, thus increasing the power density of the converter unit. Also, Rogowski-coil-based current protection and drain-source voltage-based current protection is embedded in the gate driver to prevent SiC switching device from damage.
- Design and Integration Techniques for High-Frequency PCB-Based Magnetics in Resonant ConvertersAhmed, Ahmed Salah Nabih (Virginia Tech, 2023-07-11)In today's industrial power converters, converter reliability is essential, and converter topologies are well-established. Without a doubt, the power electronic industry continues to seek efficient power delivery and high power density. Resonant converters, especially LLC converters, have been intensively studied and applied in DC-DC converters. One of the most demanding applications for LLC converters is data centers. To date, LLC Resonant converters, are deployed in many applications for improved efficiency, density, and reliability. With the introduction of WBG devices coupled with the soft switching feature, the switching frequency can be extended beyond Mega-Hertz. With the significant increase in operating frequency, complicated magnetic components can be broken down into a cellular structure, each with a few number of turns. They can be easily implemented using 4-6 layers of PCB windings. Moreover, integrating the cellular cores using flux cancellation can further improve the power density. The proposed integrated magnetics can be automated in the manufacturing process. The magnetic size is reduced at this frequency, and planar magnetics using PCB winding become more relevant. PCB magnetics feature multiple advantages over Litz wire. The benefits are summarized as follows: The labor-intensive manufacturing process can be automated, thus reduction of cost. There is much reduced CM noise by using the shield layer. They have parasitics with much-improved reproducibility in large quantities. PCB windings feature less leakage between transformer windings because of the flexibility of the winding interleaving and the reduced number of turns. There is better thermal management due to the increased surface-to-body ratio. The design has a low profile and high-power density. However, it is not without its own limitations. There are challenges for high frequency PCB-magnetic magnetic design for the LLC converter. Firstly, With the recently developed high frequency core material, a phenomenon referred to as the dimensional resonant is observed. The effects of dimensional resonance were discussed in the literature when using an unusually large core structure; however, it can be observed more frequently under high excitation frequency, particularly with integrated magnetics. This dissertation discusses the dimensional effects of core loss on a PCB-based magnetics structure. A case study is presented on a 3-kW 400-to-48-V LLC prototype running at 1 MHz. The converter utilizes a low-profile matrix of two integrated transformers with a rectangular and thin cross-section area for reduced core loss. Specific solutions are presented. % Secondly, The matrix transformer is suitable for an LLC converter with high output current. However, the matrix transformer also increases the core size and core losses. The core loss degrades the LLC converter's light load and peak efficiency. In this dissertation, We discuss the design process and implementation of the DC-DC stage of the power supply unit for narrow range 48 V data center bus architecture. The optimization takes into account the number of elemental transformers, number of transformer turns, switching frequency, and transformer dimensions, namely winding width and core cross-section area. The optimization process results in a nearly 99% efficient 400-to-48-V LLC with a very high-power density and low profile fully integrated on PCB. A matrix of four transformers is used to reduce the termination loss of the secondary synchronous rectifier and achieve better thermal management. The number of secondary turns is optimized to achieve the best trade-off between winding loss, core loss, and power density. Another challenge arises for magnetic integration when multiple magnetic components with different characteristics come together. For instance, in the case of a transformer and an inductor on the same PCB. The PCB transformer is designed with perfectly interleaved primary and secondary layers to utilize the full PCB layer thickness. As a rule of thumb, the transformer winding layer is designed within 1 to 2 times the skin depth. On the other hand, the inductor's winding lacks interleaving and suffers from high MMF stress on layers. This makes the inductor prone to high eddy currents and eddy loss. Furthermore, this dissertation addresses the challenges associated with the high winding and core loss in the Integrated Transformer-Inductor (ITL). To overcome these challenges, we propose an improved winding design of the ITL by utilizing idle shielding layers for inductor integration within the matrix transformer. This method offers full printed circuit board (PCB) utilization, where all layers are consumed as winding, resulting in a significant reduction in the winding loss of the ITL. Moreover, we propose an improved core structure of the ITL that offers better flux distribution of the leakage flux within the magnetic core. This method reduces the core loss by more than 50% compared to the conventional core structure. We demonstrate the effectiveness of our proposed concepts by presenting the design of the ITL used in a high-efficiency, high-power-density 3-kW 400-to-48-V LLC module. The proposed converter achieves a peak efficiency of 98.7% and a power density of 1500 W/in3. This dissertation presents the concept of matrix inductors to solve such problems. A matrix of four resonant inductors is also designed to reduce the proximity effect between inductor windings and reduce inductor PCB winding loss. The matrix inductor provides a solution for high thermal stress in PCB-based inductors and reduces the inter-winding capacitance between inductor layers. This dissertation solves the challenges in magnetic design in high-frequency DC-DC converters in offline power supplies and data centers. This includes the transformer and inductor of the LLC converter. With the academic contribution in this dissertation, Wide-bandgap devices WBG can be successfully utilized in high-frequency DC-DC converters with Mega-Hertz switching frequency to achieve high efficiency, high power density, and automated manufacturing. The cost will be reduced, and the performance will be improved significantly.
- Design of a 10 kV SiC MOSFET-based high-density, high-efficiency, modular medium-voltage power converterMocevic, Slavko; Yu, Jianghui; Fan, Boran; Sun, Keyao; Xu, Yue; Stewart, Joshua; Rong, Yu; Song, He; Mitrovic, Vladimir; Yan, Ning; Wang, Jun; Cvetkovic, Igor; Burgos, Rolando; Boroyevich, Dushan; DiMarino, Christina; Dong, Dong; Motwani, Jayesh Kumar; Zhang, Richard (IEEE, 2022-03)Simultaneously imposed challenges of high-voltage insulation, high dv/dt, high-switching frequency, fast protection, and thermal management associated with the adoption of 10 kV SiC MOSFET, often pose nearly insurmountable barriers to potential users, undoubtedly hindering their penetration in medium-voltage (MV) power conversion. Key novel technologies such as enhanced gatedriver, auxiliary power supply network, PCB planar dc-bus, and high-density inductor are presented, enabling the SiC-based designs in modular MV converters, overcoming aforementioned challenges. However, purely substituting SiC design instead of Sibased ones in modular MV converters, would expectedly yield only limited gains. Therefore, to further elevate SiC-based designs, novel high-bandwidth control strategies such as switching-cycle control (SCC) and integrated capacitor-blocked transistor (ICBT), as well as high-performance/high-bandwidth communication network are developed. All these technologies combined, overcome barriers posed by state-of-the-art Si designs and unlock system level benefits such as very high power density, high-efficiency, fast dynamic response, unrestricted line frequency operation, and improved power quality, all demonstrated throughout this paper.
- Design of High-Density Filter Building Blocks for SiC-based Three-Phase Power ConvertersPhukan, Ripunjoy (Virginia Tech, 2023-06-16)The advent of wide-bandgap (WBG) devices like silicon carbide (SiC) MOSFETs has resulted in a paradigm shift toward high-density and high-efficiency integration of power electronics systems. This being the result of relatively high switching frequencies (>10 kHz) compared to conventional Si IGBT counterparts, which reportedly can minimize the size of passive components such as DC-link capacitors and line harmonic filters. Unfortunately, with faster switching speeds and high slew rates, the common-mode (CM) and differential-mode (DM) conducted emissions interference (EMI) noise is worsened. The effects are manifested at the utility interface with grid-tied applications (three-phase rectifiers or back-to-back converters) in the form of high CM and DM emissions, total harmonic distortion (THD) and current harmonics. While at the motor end, long cable and bearing/leakage current effects are prevalent. As such, typically bulky passive filters are recommended to comply with industry regulations and allow safe and reliable system operation, which can be detrimental on the overall system power density. Hence, it is imperative to minimize the filter volume/weight contribution to fully utilize the benefits of WBG power converters. As an added feature, modular filter building block (FBB) configurations inspired by the building block nature of power electronics converters are needed to address scalability to higher power levels (through interleaving or paralleling) without the need for significant filter redesign. As such, for grid-tied applications (AC-DC converters), the interleaving of parallel converters adopted to achieve superior harmonic attenuation for grid-side currents at the expense of low harmonic filter volume. Therefore, interleaved converters are explored in Chapters 2 and 3. However, to block inter-channel circulation, additional use of coupled inductors (CI) can outweigh the benefits of interleaving. Therefore, modular FBB architectures with unique methods to handle circulating currents are proposed. At the same time, the FBB is designed to meet power quality and EMI limits for any given number of channels, up to the maximum number of channels, N, allowed at the point of common coupling (PCC). Consequently, a qualitative and quantitative comparison of FBB candidates is performed, and the indirectly coupled FBB using a secondary loop interconnection is proposed as a viable modular FBB candidate. Correspondingly, for DC-AC inverters, modular filters can be realized using a masked impedance and decoupling approach. The test case being a DC-fed motor drive for aircraft propulsion systems. Techniques, such as optimized parallel RC dampers to reduce the peak bearing current and CM/DM magnetic integration of a DC side filter with an embedded DC current sensor and embedded decoupling path with gate driver for high frequency commutation, are implemented to reduce the overall weight of the system. The challenges with low temperature rise margin due to high ambient temperature and low peak Partial Discharge Inception Voltage (PDIV) are addressed. In addition, a novel pulse with modulation (PWM) scheme is proposed to further enhance the bandwidth of the proposed AC filter, specifically targeted to reduce the peak bearing current and improve the specific power and motor lifetime. A negative consequence of high-density filter integration is the impact of self and mutual parasitic couplings of filter sub-components on filter attenuation, which is studied on a back-to-back converter system (AC-AC). Simplified lumped models that are representative of the high frequency filter behavior are developed to desensitize the impact of individual filter sub-components. Thereafter, unique winding and placement techniques are proposed to compensate for the impact of self and mutual parasitic couplings on the noise spectrum. Overall, this work presents potential FBB topologies for varying modes of power conversion (AC-DC, DC-AC, and AC-AC), ultimately aimed at reducing the volume/weight of the system. Methods to minimize the passive component volume/weight from the point of view of topology, magnetic integration, and PWM techniques are discussed, while the implications of a high-density integration at high frequency is presented. Generalized practical design guidelines are formulated to aid in accurate high-density filter design for WBG converters.
- Design Optimizations of LLC Resonant Converters with Planar Matrix TransformersPrakash, Pranav Raj (Virginia Tech, 2021-12)LLC resonant converters have been a popular choice for DC-DC converters due to their high efficiency, high power density, and hold-up capability in power supplies for communication systems, datacenters, consumer electronics, and automobiles. With the rapid development of wide-bandgap devices and novel magnetic materials, the push for higher switching frequencies to achieve higher power densities at lower costs is gaining traction. To demonstrate high efficiency and high power density, the Center for Power Electronics Systems (CPES) at Virginia Tech designed an 800W, 1MHz 400V/12V LLC converter for future datacenters, which could achieve a peak efficiency of 97.6% and a power density of 900 W/in3. However, with the ever-increasing demand for online services, the performance of power delivery must also be simultaneously improved to keep pace with the demand. The focus of this thesis is improving the performance of CPES’ previous 400V/12V LLC converter by investigating different aspects of its design and operation. Ultimately, design guidelines are proposed, and improvements are demonstrated to effectively achieve higher efficiency and higher power density than the previous CPES converter. Multiple aspects of the LLC converter’s design and structure are investigated to further improve its performance, and three main areas are the focus of this thesis. The output-side termination design of the planar transformer is investigated and modeled, and design guidelines for filter capacitor selection are provided for optimal efficiency. Next, the existing shielding technique for matrix transformers, which helps reduce common-mode (CM) noise without compromising on efficiency, is investigated for asymmetry and current-sharing issues, and modifications have been proposed to improve its efficiency. Thirdly, the LLC converter’s switching frequency is optimized to improve its performance over the previous CPES converter. Finally, the hardware results with the proposed improvements are demonstrated, and the converter’s performance is compared with the previous CPES converter as well as other recent proposed solutions.
- Device Voltage Balancing from Device-level to Converter-level in High Power Density Medium Voltage Converter using 10 kV SiC MOSFETsLin, Xiang (Virginia Tech, 2023-01-25)The electric power system is undergoing a paradigm change on how electric energy is generated, transmitted, and delivered. Power electronics systems which can provide medium-voltage (MV) to high-voltage (HV) output (>13.8 kV ac, > 20 kV dc) with much faster dynamic response (> 10 kHz bandwidth) or high switching-frequency will enable new electronic energy network architectures, like MVDC power delivery, underground solid-state power substation (SSPS), and high-density power electronics building block (PEBB); help drive the levelized cost of electricity (LCOE) of renewable energy on par with conventional power generation; deliver precise and clean power to loads like high-speed electric motors; push the future power system toward 100% renewable energy and energy storage supplied. In the MV to HV area, the power conversion solution is dominated by silicon devices, like SCR, IGCT, and IGBT, which are slow in nature, posing significant switching losses and bulky auxiliary components like turn-on snubbers. Devices in series are required to reach higher voltage. High-frequency HV converter in two-level or three-level bridges running 20 kHz or higher in many emerging applications, like MVDC networks with high-frequency transformers and energy storage integration is hard to be built by silicon solutions. The emerging HV wide-bandgap (WBG) power semiconductors, e.g., 10 kV SiC MOSFETs offer higher blocking capability, faster and more efficient switching performances. This makes the high-frequency power conversion technology feasible for the MV area. To build a MV high-frequency power converter with high-power density, 10 kV SiC MOSFETs in series are required to reach >10 kV operation dc voltage as the single device rating is still limited by the semiconductor process and packaging capability. However, the knowledge of dynamic voltage sharing of high-speed HV SiC devices under high dv/dt rate and effective balancing methods are not fully explored. Both the voltage imbalance and the robust device voltage balancing control are not studied clearly in the existing literature. This dissertation evaluates the voltage imbalance of series-connected 10 kV SiC MOSFETs thoroughly. The parasitic capacitors connected with device terminals are found to be a unique factor for the voltage imbalance of series-connected SiC MOSFETs, which have a significant impact on the dv/dt of different devices based on the detailed analysis. The unbalanced dv/dt and the gate signal mismatch together result in the voltage imbalance of series-connected SiC MOSFETs and a set of new voltage balancing control methods are proposed. Passive capacitor compensation and closed-loop short pulse gate signal control are proposed to solve the voltage imbalance caused by the unbalanced dv/dt. Closed-loop gate delay time control is proposed to solve the voltage imbalance caused by the gate signal mismatch. Two gate driver prototypes are designed and verified for the proposed voltage balancing control methods. As the number of devices increases, the voltage balancing methods under the device-level will be complex and risky to coordinate. Therefore, the converter-level device voltage balancing methods are desired when over three devices are in stack. Therefore, this dissertation proposes to use the 3-level (3L) neutral-point-clamped (NPC) converter structure as a converter-level approach to simplify the voltage balancing control of series-connected SiC MOSFETs. A new modulation strategy is proposed to control the loss of clamping diodes, so compact MV SiC Schottky diodes can be selected to reduce the impact of extra components on the power density. Compared to the phase-leg with direct series-connected SiC MOSFETs, the phase-leg designed with the converter-level approach achieves similar power density, easier voltage balancing control, and better efficiency, which is attractive for both two and four devices in series connection. Finally, this dissertation studies the impact of series-connected 10 kV SiC MOSFETs on MV phase-leg volume reduction with the example of multi-level flying capacitor (FC) converters. The relation between the capacitances of FCs and the device voltage is studied and a new design procedure for FCs is developed to achieve minimum FC energy and regulate the maximum device voltage. With the design procedure, the total FC volumes of a 22 kV 5-level FC converter and a 22 kV 3-level FC converter with series-connected 10 kV SiC MOSFETs are calculated and compared. Series-connected 10 kV SiC MOSFETs are found to help significantly reduce the total FC volume (> 85 %). In summary, this dissertation demonstrates that the direct series connection of 10 kV SiC MOSFETs is a reliable solution for the MV converter design, and the converter-level approach is a better voltage balancing control method. This dissertation also presents a quantitative analysis of the volume reduction enabled by the series-connected 10 kV SiC MOSFETs in MV converter phase-leg design.
- DQ-Frame Small-Signal Stability Analysis of AC Systems with Single-Phase and Three-Phase ConvertersLin, Qing (Virginia Tech, 2024-06-21)The widespread integration of power converters in applications such as microgrids and data centers has introduced significant stability challenges. This dissertation presents a novel approach to modeling and comprehensive stability analysis for both single-phase and three-phase converters, addressing vital gaps in the existing literature. The first part of the dissertation (Chapters 2 to 4) focuses on single-phase power supply units, proposing an impedance model and a loop gain model based on dq-frame analysis. These models have been validated through extensive experimental testing, demonstrating their effectiveness in stability analysis across a range of system configurations, including single-phase, three-phase three-wire, and three-phase four-wire systems. The second part (Chapters 5 and 6) examines three-phase converters used for integrating renewable energy into microgrids. It introduces a grid-forming control, followed by a detailed investigation into its impedance modeling and stability assessment. This part specifically tackles the challenges posed by the appearance of right-half-plane poles in stability analysis, proposing a new stability margin index to address these issues. The efficacy of these research findings is further substantiated by the development and implementation of a Power-Hardware-in-the-Loop testbed, providing practical validation. Overall, this dissertation has enhanced the modeling, understanding, and management of stability issues in power electronics systems, offering valuable insights and methodologies that are likely to influence future research and development in the field.
- EMI Suppression and Performance Enhancement for Truly Differential Gate DriversMiranda-Santos, Jesi (Virginia Tech, 2023-06-30)The increasing market demand for wideband gap (WBG) power switches has led to heightened competition to increase converter power density, switching frequencies, and reduce form factor, among other factors. However, this technology has also brought about an increase in encounters with electromagnetic interference (EMI), posing significant challenges. Nevertheless, the maturation of power switches has been accompanied by an improvement in gate drive technology aimed at resolving EMI challenges, albeit at a higher component and cost expense. This thesis aims to design, analyze, and implement a recent innovative differential gate driver for a 1.2 kV SiC MOSFET full bridge module. The purpose of this design is to mitigate EMI, improve performance, and reduce the number of filtering elements that are typically required. The investigation into the impact of EMI on electrical systems involves exploring factors such as testing equipment, power supplies, and gate drive layout. Based on these considerations, system and sub-system level analyses are conducted to derive practical design recommendations for implementing the differential gate driver. Three gate drive PCBs are designed and evaluated through extensive double pulse tests (DPTs). Furthermore, continuous switching of the driver presents its own set of challenges that are not apparent during the DPTs, requiring further exploration of low-cost solutions. Finally, a comparison between custom and discrete module solutions employing 1.2 kV SiC MOSFETs is conducted, highlighting the advantages and disadvantages of each approach. The solutions proposed in this work are intended to be extended to other gate drive ICs, with the goal of providing valuable insights and guidelines for EMI suppression and gate driver performance enhancement.
- Evaluation and Development of Medium-Voltage Converters Using 3.3 kV SiC MOSFETs for EV Charging ApplicationGill, Lee (Virginia Tech, 2019-08-05)The emergence of wide-bandgap-based (WBG) devices, such as silicon carbide (SiC) and gallium nitride (GaN), have unveiled unprecedented opportunities, enabling the realization of superior power conversion systems. Among the potential areas of advancement are medium-voltage (MV) and high-voltage (HV) applications, due to the growing demand for high-power-density and high-efficiency power electronics converters. These advancements have propelled a wide adoption of electric vehicles (EV), which in the future will require great improvements in the charging time of these vehicles. Thereby, this thesis attempts to address such a challenge and bring about technological improvements, enabling faster, more efficient, and more effective ways of charging an electric vehicle through the application of MV 3.3 kV SiC MOSFETs. The current fast-charging solution involves heavy and bulky MV-LV transformers, which add installation complexity for EV charging stations. However, this thesis presents an alternative power-delivery solution utilizing an MV dual-active-bridge (DAB) converter. The proposed architecture is designed to directly interface with the MV grid for high-power, fast-charging capabilities while eliminating the need for an installation of the MV-LV transformer. The MV DAB converter utilizes 3.3 kV SiC MOSFETs to realize the next 800 V EV charging system, along with an extended zero-voltage-switching (ZVS) scheme, in order to provide an efficient charging strategy across a wide range of battery voltage levels. Lastly, a detailed design comparison analysis of an MV Flyback converter, targeted for the auxiliary power supply for the proposed MV EV charging architecture, is presented.
- Evaluation of Voltage-Controlled Active Gate-Drivers for SiC MOSFET Power SemiconductorsMourges, Paul Michael (Virginia Tech, 2022-09-26)With the development and use of Silicon-Carbide [Silicon-Carbide (SiC)] devices come a host of advantages, including higher switching frequency, improved thermal performance, and higher voltage rating. This higher switching frequency can reduce the size of the con- verter system, but is typically associated with higher dv/dt voltage slew rates that further increase electromagnetic interference (EMI) related phenomena. Conventional gate-drivers are very limited in the way that they can control this high dv/dt, and this leads to the use of active gate-drivers. This thesis will explore the use of an active voltage-controlled gate-driver for SiC devices, utilizing transiently a voltage closer to the Miller plateau than the nominal turn-on and turn-off voltage to introduce control over the switching transient. Various ap- plied voltages, and voltage sequences will be evaluated to determine their effectiveness for controlling dv/dt and their impact on switching loss. Through this work, a better under- standing of the advantages and drawbacks of an active gate-driver can be found. The main result from this work is the effective reduction in the dv/dt generated by MOSFET devices, which was attained at a lower switching loss penalty compared to conventional resistive gate-drivers operating at similar dv/dt rates. Simulation and experimental results obtained with a prototype active gate-driver circuitry were used for this evaluation.
- Global Intergrid for Sustainable Energy AbundanceBoroyevich, Dushan; Cvetkovic, Igor; Dong, Dong (IEEE Power Electronics Society, 2022-06-04)Invited Poster for Session on Brainstorming for Game-Changing Ideas.
- High-frequency Current-transformer Based Auxiliary Power Supply for SiC-based Medium Voltage Converter SystemsYan, Ning (Virginia Tech, 2020)Auxiliary power supply (APS) plays a key role in ensuring the safe operation of the main circuit elements including gate drivers, sensors, controllers, etc. in medium voltage (MV) silicon carbide (SiC)-based converter systems. Such a converter requires APS to have high insulation capability, low common-mode coupling capacitance (Ccm ), and high-power density. Furthermore, considering the lifetime and simplicity of the auxiliary power supply system design in the MV converter, partial discharge (PD) free and multi-load driving ability are the additional two factors that need to be addressed in the design. However, today’s state-of-the-art products have either low power rating or bulky designs, which does not satisfy the demands. To improve the current designs, this thesis presents a 1 MHz isolated APS design using gallium nitride (GaN) devices with MV insulation reinforcement. By adopting LCCL-LC resonant topology, the proposed APS is able to supply multiple loads simultaneously and realize zero voltage switching (ZVS) at any load conditions. Since high reliability under faulty load conditions is also an important feature for APS in MV converter, the secondary side circuit of APS is designed as a regulated stage. To achieve MV insulation (> 20 kV) as well as low Ccm value (< 5 pF), a current-based transformer with a single turn structure using MV insulation wire is designed. Furthermore, by introducing different insulated materials and shielding structures, the APS is capable to achieve different partial discharge inception voltages (PDIV). In this thesis, the transformer design, resonant converter design, and insulation strategies will be detailly explained and verified by experiment results. Overall, this proposed APS is capable to supply multiple loads simultaneously with a maximum power of 120 W for the sending side and 20 W for each receiving side in a compact form factor. ZVS can be realized regardless of load conditions. Based on different insulation materials, two different receiving sides were built. Both of them can achieve a breakdown voltage of over 20 kV. The air-insulated solution can achieve a PDIV of 6 kV with Ccm of 1.2 pF. The silicone-insulated solution can achieve a PDIV of 17 kV with Ccm of 3.9 pF.
- High-Frequency Design Consideration and EMI Mitigation in SiC-based Multilevel ConvertersYu, Jianghui (Virginia Tech, 2022-05-23)Medium Voltage (MV) power conversion systems are essential in high power applications to address the increasing demand of energy and the increasing penetration of renewable energy sources. MV power electronics converters are the key elements for power conversion in MV systems and are the focus of this study. Multilevel converter topologies are promising topologies in MV applications because of their reduced voltage stress on devices, excellent output quality, reduced semiconductor losses, lower common mode voltage among other advantages. However, they may suffer from the large number of switching devices and capacitors, as well as the need to regulate capacitor voltages. SiC MOSFETs can achieve higher switching speeds, higher switching frequencies, higher voltage ratings, higher operation temperatures compared to traditional Si devices. They have shown promise to increase the efficiency and power density of the converters, but may suffer from higher voltage overshoots, increased Electromagnetic Interference (EMI) emission and so on. In SiC-based multilevel converters, the features of multilevel topologies, and the features of SiC MOSFETs are coupled together. The benefits, challenges, and solutions of using SiC MOSFETs in multilevel converters are studied explicitly in this work. With the high switching speeds and high switching frequencies of SiC MOSFETs, and the large number of switches and capacitors in multilevel topologies, SiC-based multilevel converters need to be studied while considering high-frequency voltage and current behaviors and the interactions among them at different locations. Firstly, the use of SiC-based multilevel converter in the high-speed motor drive application is explored. A three-phase inverter is designed and built employing five-level Stacked Multicell Converter topology and SiC MOSFETs. The benefits and challenges of using multilevel converter topology and using SiC MOSFETs for this application are explored. A fitting topology is selected, and a prototype is designed, both with attentions paid to deal with the high switching speeds of SiC MOSFETs. The inverter is verified through experiments to meet all specifications with a high efficiency. Then a unique type of converter, converters with Integrated Capacitor Blocked Transistor (ICBT) cells are studied. Unlike the traditional methods, there are no fast-developing voltage unbalances, or high cell capacitor voltage ripples in ICBT-based converters. The ideal operation principle is analyzed and verified by the simulation results. Then the impacts of non-idealities on the operation are analyzed, and a control method is proposed for this type of converter. The operation and control of ICBT-based converters are verified by experimental results to achieve low cell capacitor voltage ripples and excellent voltage balance in Medium Voltage high power applications. Lastly, the conducted EMI emission in SiC-based multilevel converters are studied. Four SiC-based multilevel converters are studied, with the focus on the power circuit in one converter and the auxiliary circuits in the other three converters. The complexity of noise generation and propagation in multilevel converters is presented. The conducted EMI disturbances are experimentally evaluated, analyzed, and effectively mitigated in all four cases.
- Hybrid Modular Multilevel Converter Family and Modular DC Circuit Breaker for Medium-voltage DC (MVDC) ApplicationsLiu, Jian (Virginia Tech, 2023-09-12)With the increasing maturity and flexibility of power electronics-based voltage conversion techniques, DC grids, and distribution systems have gained significant interest. These systems offer advantages such as improved power quality, efficiency, and flexibility. Medium-voltage DC (MVDC) applications, including shipboard, railway systems, distribution networks, and microgrids, are emerging as critical areas of interest. To integrate MVDC systems with existing power grids, MV AC/DC conversion techniques are crucial. Moreover, the lack of mature protection strategies and equipment, particularly DC circuit breakers (DCCB), poses a significant challenge to the development of MVDC systems. Therefore, this thesis aims to address two primary challenges in the field: the improved topologies of MV AC/DC conversion techniques for interfacing MVDC systems with power grids and the development of high power density DCCB for MVDC systems. The traditional modular multilevel converter (MMC) is widely used for medium voltage (MV) AC/DC conversion due to its modularity, scalability, and reliability. However, the presence of numerous semiconductor devices and capacitors in MMCs results in challenges such as low power efficiency and density. To enhance the performance of MMCs, this thesis proposes several novel hybrid MMC (HMMC) topologies, including the three-level HMMC, flying capacitor HMMC, and hybrid-leg MMC. These topologies aim to leverage the advantages of both conventional multilevel converters and MMCs. By replacing the low-voltage (LV) submodule (SM) in MMCs with a simple high-voltage (HV) switch, higher efficiency, a smaller footprint, and lower cost can be achieved. The HV switch operates at line frequency, simplifying device-switching and addressing the challenges of series-connected devices. The introduction of additional HV switches enables alternative connections compared to traditional MMCs, reducing the number of required SMs. Consequently, there is a significant reduction in the number of semiconductor devices, capacitor energy storage, and power losses. Furthermore, an average model is developed for the three-level HMMC to illustrate the additional power flow path between the AC and DC sides, as well as the reduced SM capacitor energy storage requirement. As a result, the proposed HMMCs exhibit substantial potential to replace traditional MMCs, offering higher efficiency and power density. Unidirectional high-voltage (HV) and medium-voltage (MV) rectifiers are essential for applications where power flows exclusively from the AC to the DC side. Examples of such applications include HVDC transmission, front-end converters for electric vehicle (EV) charging stations, and data centers. Therefore, hybrid modular multilevel rectifiers (HMMRs) are proposed for these unidirectional AC/DC applications. Instead of utilizing active devices for HV switches, the HMMR employs HV diode to achieve step-up HMMR, step-down HMMR, and flying capacitor HMMR configurations. As diodes are passive devices that do not require gate driver units, the HMMR design becomes simpler, resulting in cost and volume savings. Additionally, voltage sharing among the HV diode stack becomes more manageable as concerns regarding gate signal mismatch are eliminated. However, it is important to note that diodes lack current interruption capability. This limitation requires further investigation, particularly in non-unity power factor (PF) operations, which may impose restrictions on the operational range of the rectifiers. In terms of medium voltage (MV) DC circuit breakers (DCCB), this paper introduces the concept and design procedure of a high-power-density, modular, and scalable power electronic interrupter (PEI) for MV hybrid circuit breakers (HCB). The analysis includes trade-offs and limiting factors of various components within a single PEI module. A prototype of a 12 kV, 1 kA breaking-capable PEI is constructed, and new staged turn-off strategies are proposed to ensure the balanced distribution of metal-oxide varistor (MOV) energy. The developed PEI achieves a peak power density of 7.4 kW/cm$^3$, much higher than the solution based on the IGBT modules. After integrating the developed PEI into a full-scale HCB, the breaking capability of the developed PEI and the effectiveness of the staged turn-off strategy are validated. Furthermore, the scalability of the HCB is evaluated, which can simplify the design process from a low-voltage HCB to a higher-voltage version. For series-connected devices in SSCB or HCB configurations, the conventional gate driver structure necessitates an individual gate driver unit, fiber-optic, and isolated power supplies for each device. This design increases cost and volume, particularly for this single-pulse application. To address this issue, two new single gate driver structures are proposed to reduce component count and system complexity. The first solution, namely the MOV-coupled structure, employs a metal-oxide varistor (MOV) for the turn-off path. On the other hand, the transformer-coupled structure combines the auxiliary power and gate signal, enabling both simultaneous and staged turn-off schemes. Moreover, the cascaded high- and lower-voltage transformer structure simplifies insulation design and demonstrates improved scalability. These proposed gate driver structures aim to streamline the system, reduce component numbers, and simplify control for series-connected devices, leading to cost savings and improved overall performance.
- Hybrid Modular Multilevel Converters for High-AC/Low-DC Medium-Voltage ApplicationsMotwani, Jayesh Kumar; Liu, Jian; Boroyevich, Dushan; Burgos, Rolando; Zhou, Zhi; Dong, Dong (IEEE, 2024-02-12)With ever-increasing power-density requirements, technologies such as energy storage systems and electric-vehicles can benefit greatly from interfacing medium-voltage (MV)-AC grid like 13.8kV or 30kV using high-AC/low-DC voltage converter. Using modular high-AC/low-DC voltage converter can help increase power-density and efficiency, while reducing total conversion steps and providing flexibility. Full-bridge modular multilevel converters (FB-MMC) and solid-state transformers are existing solutions for such operations, but suffer from limitations of high semiconductor requirements, large submodule capacitors and/or many high-frequency transformers. Three new hybrid-MMC (HMMC) topologies are proposed in this paper as alternative solutions for such high-AC/low-DC voltage operations. Each of the three developed HMMCs utilizes a unique combination of low-frequency high-voltage switches and fast-switching lowvoltage switch based submodules to generate multilevel-AC voltage. HMMCs are compared extensively to state-of-the-art FB-MMC and are shown to have semiconductor savings of over 27%, 38% lower submodule capacitor size, and 53% lower losses for 13.8-kV-AC/6-kV-DC operation. Due to these benefits like higher efficiency, significantly smaller submodule capacitance requirements, and fewer semiconductors, HMMCs can be an excellent option for high-AC/low-DC applications. Practical considerations like snubber and DC split-capacitor requirement are also elaborated for developing and commercializing HMMCs. Comparison results are verified using a 17.5 kW three-phase MV laboratory prototype.
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