Browsing by Author "Ghassemi, Mona"

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    Characterization of Partial Discharge Activities in WBG Power Converters under Low-Pressure Condition
    Borghei, Moein; Ghassemi, Mona (MDPI, 2021-08-30)
    Many sectors, such as transportation systems, are undergoing rapid electrification due to the need for the mitigation of CO2 emissions. To ensure safe and reliable operation, the electrical equipment must be able to work under various environmental conditions. At high altitudes, the low pressure can adversely affect the health of insulating materials of electrical systems in electric aircraft. A well-known, primary aging mechanism in dielectrics is partial discharge (PD). This study targets internal PD evaluation in an insulated-gate bipolar transistor (IGBT) module under low-pressure conditions. The estimation of electric field distribution is conducted through 3D finite element analysis (FEA) using COMSOL Multiphysics®. The procedure of PD detection and transient modeling is performed in MATLAB for two pressure levels (atmospheric and half-atmospheric). The case study is the IGBT module with a void or two voids in the proximity of triple joints. The single-void case demonstrates that at half-atmospheric pressure, the intensity of discharges per voltage cycle increases by more than 40% compared to atmospheric pressure. The double-void case further shows that a void that is harmless at sea level can turn into an additional source of aging and couple with the other voids to escalate PD intensity by a factor of two or more.
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    Effects of Frequency and Temperature on Electric Field Mitigation Method via Protruding Substrate Combined with Applying Nonlinear FDC Layer in Wide Bandgap Power Modules
    Tousi, Maryam Mesgarpour; Ghassemi, Mona (MDPI, 2020-04-18)
    Our previous studies showed that geometrical techniques including (1) metal layer offset, (2) stacked substrate design and (3) protruding substrate, either individually or combined, cannot solve high electric field issues in high voltage high-density wide bandgap (WBG) power modules. Then, for the first time, we showed that a combination of the aforementioned geometrical methods and the application of a nonlinear field-dependent conductivity (FDC) layer could address the issue. Simulations were done under a 50 Hz sinusoidal AC voltage per IEC 61287-1. However, in practice, the insulation materials of the envisaged WBG power modules will be under square wave voltage pulses with a frequency of up to a few tens of kHz and temperatures up to a few hundred degrees. The relative permittivity and electrical conductivity of aluminum nitride (AlN) ceramic, silicone gel, and nonlinear FDC materials that were assumed to be constant in our previous studies, may be frequency- and temperature-dependent, and their dependency should be considered in the model. This is the case for other papers dealing with electric field calculation within power electronics modules, where the permittivity and AC electrical conductivity of the encapsulant and ceramic substrate materials are assumed at room temperature and for a 50 or 60 Hz AC sinusoidal voltage. Thus, the big question that remains unanswered is whether or not electric field simulations are valid for high temperature and high-frequency conditions. In this paper, this technical gap is addressed where a frequency- and temperature-dependent finite element method (FEM) model of the insulation system envisaged for a 6.5 kV high-density WBG power module will be developed in COMSOL Multiphysics, where a protruding substrate combined with the application of a nonlinear FDC layer is considered to address the high field issue. By using this model, the influence of frequency and temperature on the effectiveness of the proposed electric field reduction method is studied.
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    Electric Field Grading and Electrical Insulation Design for High Voltage,  High Power Density Wide Bandgap Power Modules
    Mesgarpour Tousi, Maryam (Virginia Tech, 2020-10-19)
    The trend towards more and all-electric apparatuses and more electrification will lead to higher electrical demand. Increases in electrical power demand can be provided by either higher currents or higher voltages. Due to "weight" and "voltage" drop, a raise in the current is not preferred; so, "higher voltages" are being considered. Another trend is to reduce the size and weight of apparatuses. Combined, these two trends result in the high voltage, high power density concept. It is expected that by 2030, 80% of all electric power will flow through "power electronics systems". In regards to the high voltage, high power density concept described above, "wide bandgap (WBG) power modules" made from materials such as "SiC and GaN (and, soon, Ga2O3 and diamond)", which can endure "higher voltages" and "currents" rather than "Si-based modules", are considered to be the most promising solution to reducing the size and weight of "power conversion systems". In addition to the trend towards higher "blocking voltage", volume reduction has been targeted for WBG devices. The blocking voltage is the breakdown voltage capability of the device, and volume reduction translates into power density increase. This leads to extremely high electric field stress, E, of extremely nonuniform type within the module, leading to a higher possibility of "partial discharge (PD)" and, in turn, insulation degradation and, eventually, breakdown of the module. Unless the discussed high E issue is satisfactorily addressed and solved, realizing next-generation high power density WBG power modules that can properly operate will not be possible. Contributions and innovations of this Ph.D. work are as follows. i) Novel electric field grading techniques including (a) various geometrical techniques, (b) applying "nonlinear field-dependent conductivity (FDC) materials" to high E regions, and (c) combination of (a) and (b), are developed; ii) A criterion for the electric stress intensity based upon accurate dimensions of a power device package and its "PD measurement" is presented; iii) Guidelines for the electrical insulation design of next-generation high voltage (up to 30 kV), high power density "WBG power modules" as both the "one-minute insulation" and PD tests according to the standard IEC 61287-1 are introduced; iv) Influence of temperature up to 250°C and frequency up to 1 MHz on E distribution and electric field grading methods mentioned in i) is studied; and v) A coupled thermal and electrical (electrothermal) model is developed to obtain thermal distribution within the module precisely. All models and simulations are developed and carried out in COMSOL Multiphysics.
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    A Finite Element Analysis Model for Partial Discharges in Silicone Gel under a High Slew Rate, High-Frequency Square Wave Voltage in Low-Pressure Conditions
    Borghei, Moein; Ghassemi, Mona (MDPI, 2020-05-01)
    Wide bandgap (WBG) devices made from materials such as SiC, GaN, Ga2O3 and diamond, which can tolerate higher voltages and currents compared to silicon-based devices, are the most promising approach for reducing the size and weight of power management and conversion systems. Silicone gel, which is the existing commercial option for encapsulation of power modules, is susceptible to partial discharges (PDs). PDs often occur in air-filled cavities located in high electric field regions around the sharp edges of metallization in the gel. This study focuses on the modeling of PD phenomenon in an air filled-cavity in silicone gel for the combination of (1) a fast, high-frequency square wave voltage and (2) low-pressure conditions. The low-pressure condition is common in the aviation industry where pressure can go as low as 4 psi. To integrate the pressure impact into PD model, in the first place, the model parameters are adjusted with the experimental results reported in the literature and in the second place, the dependencies of various PD characteristics such as dielectric constant and inception electric field on pressure are examined. Finally, the reflections of these changes in PD intensity, duration and inception time are investigated. The results imply that the low pressure at high altitudes can considerably affect the PD inception and extinction criterion, also the transient state conditions during PD events. These changes result in the prolongation of PD events and more intense ones. As the PD model is strongly dependent upon the accurate estimation electric field estimation of the system, a finite-element analysis (FEA) model developed in COMSOL Multiphysics linked with MATLAB is employed that numerically calculates the electric field distribution.
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    Fully Soft-Switching Modulation Methods for SRC-Unfolding Inverter
    Yeh, Chih-Shen (Virginia Tech, 2020-12-16)
    Isolated inverters feature the freedom in voltage step-up/down, electrical safety, and modularity. Among them, pseudo-dc-link inverters have the advantage of high efficiency due to their single-stage structure. Traditionally, pseudo-dc-link inverters are based on pulse-width-modulated converters, which suffer from hard switching, the need for auxiliary components, and/or high current stresses. Meanwhile, the series resonant converter has been prevalent in past decades due to its simplicity and high efficiency. Therefore, it is intriguing to design a single-stage inverter based on a series resonant converter. However, there are limited papers regarding such an inverter topology. To figure out the reason, basic modulation methods proposed or implied in the literature are summarized and evaluated through circuit simulation software. It turns out each basic modulation method has at least one critical drawback in modulation range, hard switching, and/or high current stresses. Given the deficiencies in the basic modulation methods, a hybrid modulation method is proposed here. The proposed method combines variable-frequency modulation in the high-output region and short pulse-density modulation in the low-output region. In this way, all the aforementioned critical drawbacks can be greatly alleviated. The hybrid modulation method is compared to the basic modulation methods based on three design metrics: the rms value of the resonant current, the magnetic flux of the transformer, and the turn-off current. By these design metrics that directly related to power losses, the benefit of the proposed method in terms of efficiency can be explained. Moreover, a power loss model is also established to provide more insights into the inverter's efficiency performance. It helps demonstrate how the selection of resonant tank and other factors affects the power loss distribution. Also, an inverter design procedure is introduced and a prototype is built to verify the proposed modulation method. The results show that the switching losses, especially the turn-on loss, can be well suppressed, and the losses in other passive components are well restrained. This implies the proposed method is suitable for high-frequency applications. Other than efficiency, output waveform quality is also important for an inverter. However, the changing plant model makes the controller design difficult. Therefore, a third-order model established by other researchers has been adopted to identify the pole locations. In addition, a gain-varying method is proposed for the compensator to reduce the gain variance caused by different operating conditions. The experimental results show that without the gain-varying method, the inverter may have issues in slow tracking and/or instability. Finally, in some scenarios, the inverter based on a series resonant converter can be regarded as a module. A multi-modular inverter can be formed by connecting the modules in an input-parallel-output-series configuration. In this case, a technique termed sequential waveform synthesis can be applied. The proposed technique can extend the region of variable-frequency modulation and shorten the region of short pulse-density modulation. This is beneficial to efficiency based on an analysis. With more than a certain amount of modules connected, the short pulse-density modulation can even be waived, which means the multi-modular inverter can be free from turn-on loss. In summary, this dissertation focuses on developing modulation methods for inverters based on the series resonant converter. Soft-switching feature and high efficiency are the two top priorities. The analytic and experimental results are provided based on standalone applications.
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    High power density technologies for large generators and motors for marine applications with focus on electrical insulation challenges
    Ghassemi, Mona (2020-02)
    High power density generators and motors are envisaged in modern all-electric ships where electrical power for both propulsion and service loads is provided through a common electrical platform known as an integrated power system. Three recent high-power density technologies for generators and motors proposed for marine applications are reviewed, and the author focuses on their electrical insulation challenges. These technologies are high-frequency (high-speed) generators (200400 Hz), superconducting generators, and novel insulation materials and systems. For high-speed generators, high loss in magnetic materials may shorten its insulation life. Thus, these generators should be designed to be cooled by water instead of air. For superconducting generators, the most significant concern is the integrity of the insulation system over the large thermal excursion whenever the system is cycled between room temperature and operating temperature. In novel insulation materials and systems section: (i) using mica paper tapes containing boron nitride filler in the binding resin of the glass backing insulation, developed by Toshiba and Von Roll, resulted in a 15% increase in the MVA of generators for the same slot dimensions and operating temperatures, (ii) GE developed an enhanced polyethylene glycol terephthalate-mica tape having superior voltage-endurance characteristics, (iii) Isovolta has introduced a mica paper tape using a flat glass fibre backing material, called Powerfab, rather than the more common woven structure, leading to a 15% reduced mica tape, and (iv) adding novel nanocomposites as fillers to ground wall insulation, introduced by Siemens, is a promising technique towards more high power density designs. Furthermore, accelerated aging of insulation systems especially those in electrical rotating machines exposed to voltage pluses with high slew rates up to hundreds of kV/mu s and high-repetition rates ranging from hundreds of kHz to MHz is discussed. These voltage pulses are generated by wide bandgap-based converters envisaged in the medium voltage DC architecture for future U.S. naval ships.
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    The Modeling of Partial Discharge under Fast, Repetitive Voltage Pulses Using Finite-Element Analysis
    Razavi Borghei, Seyyed Moein (Virginia Tech, 2020-04)
    By 2030, it is expected that 80% of all electric power will flow through power electronics systems. Wide bandgap power modules that can tolerate higher voltages and currents than silicon-based modules are the most promising solution to reducing the size and weight of power electronics systems. These wide-bandgap power modules constitute powerful building blocks for power electronics systems, and wide bandgap-based converter/power electronics building blocks are envisaged to be widely used in power grids in low- and medium-voltage applications and possibly in high-voltage applications for high-voltage direct current and flexible alternating current transmission systems. One of the merits of wide bandgap devices is that their slew rates and switching frequencies are much higher than silicon-based devices. However, from the insulation side, frequency and slew rate are two of the most critical factors of a voltage pulse, influencing the level of degradation of the insulation systems that are exposed to such voltage pulses. The shorter the rise time, the shorter the lifetime. Furthermore, lifetime dramatically decreases with increasing frequency. Thus, although wide bandgap devices are revolutionizing power electronics, electrical insulating systems are not prepared for such a revolution; without addressing insulation issues, the electronic power revolution will fail due to dramatically increased failure rates of electrification components. In this regard, internal partial discharges (PDs) have the most effect on insulation degradation. Internal PDs which occur in air-filled cavities or voids are localized electrical discharges that only partially bridge the insulation between conductors. Voids in solid or gel dielectrics are challenging to eliminate entirely and may result simply during manufacturing process. The objective of this study is to develop a Finite-Element Analysis (FEA) PD model under fast, repetitive voltage pulses, which has been done for the first time. The model is coded and implemented in COMSOL Multiphysics linked with MATLAB, and its simulation results are validated with experimental tests. Using the model, the influence of different parameters including void shape, void size, and void air pressure on PD parameters are studied.
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    Partial Discharge Analysis under High-Frequency, Fast-Rise Square Wave Voltages in Silicone Gel: A Modeling Approach
    Borghei, Moein; Ghassemi, Mona (MDPI, 2019-11-28)
    Wide bandgap (WBG) power modules able to tolerate high voltages and currents are the most promising solution to reduce the size and weight of the power management and conversion systems. These systems are envisioned to be widely used in the power grid and the next generation of more (and possibly all) electric aircraft, ships, and vehicles. However, accelerated aging of silicone gel when being exposed to high frequency, fast rise-time voltage pulses that can offset or even be an obstacle for using WBG-based systems. Silicone gel is used to insulate conductor parts in the module and encapsulate the module. It has less electrical insulation strength than the substrate and is susceptible to partial discharges (PDs). PDs often occur in the cavities located close to high electric field regions around the sharp edges of metallization in the gel. The vulnerability of silicone gel to PDs occurred in the cavities under repetitive pulses with a high slew rate investigated in this paper. The objective mentioned above is achieved by developing a Finite-Element Analysis (FEA) PD model for fast, repetitive voltage pulses. This work has been done for the first time to the best of our knowledge. By using the model, the influence of frequency and slew rate on the magnitude and rate of PD events is studied.
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    Partial Discharges: Experimental Investigation, Model Development, and Data Analytics
    Razavi Borghei, Seyyed Moein (Virginia Tech, 2022-02-11)
    Insulation system is an inseparable part of electrical equipment. In this study, one of the most important aging factors in insulation systems known as partial discharge (PD) is targeted. PD phenomenon has been studied for more than a century and yet new technologies still demand the investigation of PD impact. Nowadays, electrification is penetrating into various fossil-fuel-based industries such as transportation system that demands the reliability of electrical equipment under various harsh environmental conditions. Due to the lack of knowledge on the behavior of insulation systems, research in this area is intensively needed. The current study probes into the partial discharge phenomenon from two aspects and the groundwork for both aspects are provided by experimentation of multiple PD types. In the first goal, a finite-element analysis (FEA) approach is developed based on measurement data to estimate electric field distribution. The FEA model is coupled with a programming scheme to evaluate PD conditions, calculate PD metrics, and perform statistical analysis of the results. For the second target, it is aimed to use deep neural networks to identify and discriminate different sources of PD. The measurement data are used to generate thousands of phase-resolved PD (PRPD) images that will be used for training deep learning models. To meet the characteristics of the dataset, a deep residual neural network is designed and optimized to discriminate PD sources in an accurate, stable, and time-efficient way. The outcome of this research enhances the reliability of electrical apparatus through a better understanding of the PD behavior and lays a foundation for automatic monitoring of PD sources.
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    Precise Evaluation of Repetitive Transient Overvoltages in Motor Windings in Wide-Bandgap Drive Systems
    Barzkar, Ashkan; Ghassemi, Mona (MDPI, 2022-07-19)
    The increasing interest in employing wide-bandgap (WBG) drive systems has brought about very high power, high-frequency inverters enjoying switching frequencies up to hundreds of kilohertz. However, voltage surges with steep fronts, caused by turning semiconductor switches on/off in inverters, travel through the cable and are reflected at interfaces due to impedance mismatches, giving rise to overvoltages at motor terminals and in motor windings. The phenomena typically associated with these repetitive overvoltages are partial discharges and heating in the insulation system, both of which contribute to insulation system degradation and may lead to premature failures. In this article, taking the mentioned challenges into account, the repetitive transient overvoltage phenomenon in WBG drive systems is evaluated at motor terminals and in motor windings by implementing a precise multiconductor transmission line (MCTL) model in the time domain considering skin and proximity effects. In this regard, first, a finite element method (FEM) analysis is conducted in COMSOL Multiphysics to calculate parasitic elements of the motor; next, the vector fitting approach is employed to properly account for the frequency dependency of calculated elements, and, finally, the model is developed in EMTP-RV to assess the transient overvoltages at motor terminals and in motor windings. As shown, the harshest situation occurs in turns closer to motor terminals and/or turns closer to the neutral point depending on whether the neutral point is grounded or floating, how different phases are connected, and how motor phases are excited by pulse width modulation (PWM) voltages.