Key technologies of active power filter for aircraft: a review

Active Power Filter (APF) is not only an advanced technology to improve power quality and purify power system pollution but also a good approach to solve electrical problems of an advanced aircraft such as harmonic, reactive power and unbalanced load. However, there are still some specific problems for the application of aeronautic APF in practice. Based on current research on aeronautic APF, this paper reviews three key technologies where APF can be used in aircraft AC power supply system, including the acquisition method of reference current, the strategy of APF current control and the main circuit topology.  Consecutively, the features of current aeronautic APF research are summarized, and the future research directions are also suggested

Towards High Efficiency and High Power Density Converter: System Level Design, Modulation, and Active EMI Filters

Power converter exposes strong challenges to its efficiency, power density and reliability. For the grid-connected inverter application, three-level (3-L) T-type neutral-point-clamped (TNPC) inverters has higher efficiency and lower total harmonic distortion (THD) compared to two-level inverter. Hybrid switch concept combines the benefit of both silicon carbide (SiC) MOSFET and Si IGBT. By applying hybrid switch structure in 3-L T-type inverter, the total power density of 3-L TNPC inverter will be higher while the cost will be lower than that of all-SiC 3-L T-type inverter. The hybrid switch based 3-L TNPC inverter also imposes challenge to its modulation and control, a propoer modulation and control shceme need to be chosen to enable better inverter performance in terms of efficiency, neutral point balancing and electromagnetic interference (EMI). Morever, to shrink the EMI filter size for the power converter, an active EMI filter (AEF) structure is proposed. The proposed AEF provides superior performance than any of the conventional passive EMI filter and the existing AEFs. In this work, the system level design and testing of a 30 kW grid-connected 3-L T-type inverter with hybrid switch structure is discussed. Then, an improved space vector modulation (SVM) has been proposed, which enables neutral-point balancing (NPB) control in the proposed hybrid-switch-based TNPC inverters with loss and common-mode voltage reduction. Finally, the design, modelling, and testing of the proposed AEF is demonstrated

Design and Control of Power Converters for High Power-Quality Interface with Utility and Aviation Grids

Power electronics as a subject integrating power devices, electric and electronic circuits, control, and thermal and mechanic design, requires not only knowledge and engineering insight for each subarea, but also understanding of interface issues when incorporating these different areas into high performance converter design.Addressing these fundamental questions, the dissertation studies design and control issues in three types of power converters applied in low-frequency high-power transmission, medium-frequency converter emulated grid, and high-frequency high-density aviation grid, respectively, with the focus on discovering, understanding, and mitigating interface issues to improve power quality and converter performance, and to reduce the noise emission.For hybrid ac/dc power transmission,• Analyze the interface transformer saturation issue between ac and dc power flow under line unbalances.• Proposed both passive transformer design and active hybrid-line-impedance-conditioner to suppress this issue.For transmission line emulator,• Propose general transmission line emulation schemes with extension capability.• Analyze and actively suppress the effects of sensing/sampling bias and PWM ripple on emulation considering interfaced grid impedance.• Analyze the stability issue caused by interaction of the emulator and its interfaced impedance. A criterion that determines the stability and impedance boundary of the emulator is proposed.For aircraft battery charger,• Investigate architectures for dual-input and dual-output battery charger, and a three-level integrated topology using GaN devices is proposed to achieve high density.• Identify and analyze the mechanisms and impacts of high switching frequency, di/dt, dv/dt on sensing and power quality control; mitigate solutions are proposed.• Model and compensate the distortion due to charging transition of device junction capacitances in three-level converters.• Find the previously overlooked device junction capacitance of the nonactive devices in three-level converters, and analyze the impacts on switching loss, device stress, and current distortion. A loss calculation method is proposed using the data from the conventional double pulse tester.• Establish fundamental knowledge on performance degradation of EMI filters. The impacts and mechanisms of both inductive and capacitive coupling on different filter structures are understood. Characterization methodology including measuring, modeling, and prediction of filter insertion loss is proposed. Mitigation solutions are proposed to reduce inter-component coupling and self-parasitics

Modeling and Optimization Algorithm for SiC-based Three-phase Motor Drive System

More electric aircraft (MEA) and electrified aircraft propulsion (EAP) becomes the important topics in the area of transportation electrifications, expecting remarkable environmental and economic benefits. However, they bring the urgent challenges for the power electronics design since the new power architecture in the electrified aircraft requires many benchmark designs and comparisons. Also, a large number of power electronics converter designs with different specifications and system-level configurations need to be conducted in MEA and EAP, which demands huge design efforts and costs. Moreover, the long debugging and testing process increases the time to market because of gaps between the paper design and implementation. To address these issues, this dissertation covers the modeling and optimization algorithms for SiC-based three-phase motor drive systems in aviation applications. The improved models can help reduce the gaps between the paper design and implementation, and the implemented optimization algorithms can reduce the required execution time of the design program. The models related to magnetic core based inductors, geometry layouts, switching behaviors, device loss, and cooling design have been explored and improved, and several modeling techniques like analytical, numerical, and curve-fitting methods are applied. With the developed models, more physics characteristics of power electronics components are incorporated, and the design accuracy can be improved. To improve the design efficiency and to reduce the design time, optimization schemes for the filter design, device selection combined with cooling design, and system-level optimization are studied and implemented. For filter design, two optimization schemes including Ap based weight prediction and particle swarm optimization are adopted to reduce searching efforts. For device selection and related cooling design, a design iteration considering practical layouts and switching speed is proposed. For system-level optimization, the design algorithm enables the evaluation of different topologies, modulation schemes, switching frequencies, filter configurations, cooling methods, and paralleled converter structure. To reduce the execution time of system-level optimization, a switching function based simulation and waveform synthesis method are adopted. Furthermore, combined with the concept of design automation, software integrated with the developed models, optimization algorithms, and simulations is developed to enable visualization of the design configurations, database management, and design results

Conducted EMI Mitigation in Power Converters using Active EMI Filters

Wide bandgap devices enable high power density power converters. Despite the advantages of increased switching frequency, the passive components are still a major bottleneck towards enabling high power density. Among the passive components in the converter, the passive EMI filters are unavoidable to ensure compliance with conducted EMI standards. Active EMI filters help reduce the volume of the passive components and have been around for three decades now. Firstly, this work presents a summary of all the different active EMI filters based on the type of noise-sensing, noise-processing, the type of active circuits used and the type of control methods. This is followed by modeling, design and stability analysis of three different active EMI filters for DM noise attenuation. The first active EMI filter is a conventional active EMI filter. The key bottlenecks to improving performance of the conventional active EMI filter are identified while still achieving volume reduction of passive components. Following this two novel active EMI filters are presented that overcome the bottlenecks of conventional active EMI filter. The second active EMI filter is based on a analog twin-circuit. This novel filter uses a twin-circuit which enables the use of low-voltage surface-mount components for compensation. The third active EMI filter uses zero-phase filtering implemented in an FPGA. While all the filters are demonstrated for differential-mode noise, their use can be extended for common-mode noise attenuation

REGULATED TRANSFORMER RECTIFIER UNIT FOR MORE ELECTRIC AIRCRAFTS

The impending trends in the global demand of more-electric-aircrafts with higher efficiency, high power density, and high degree of compactness has opened up numerous opportunities in front of avionic industries to develop innovative power electronic interfaces. Traditionally, passive diode-bridge based transformer rectifier units (TRU) have been used to generate a DC voltage supply from variable frequency and variable voltage AC power out of the turbo generators. These topologies suffer from bulky and heavy low-frequency transformer size, lack of DC-link voltage regulation flexibility, high degree of harmonic contents in the input currents, and additional cooling arrangement requirements. This PhD research proposes an alternative approach to replace TRUs by actively controlled Regulated Transformer Rectifier Units (RTRUs) employing the advantages of emerging wide band gap (WBG) semiconductor technology. The proposed RTRU utilizing Silicon Carbide (SiC) power devices is composed of a three-phase active boost power factor correction (PFC) rectifier followed by an isolated phase-shifted full bridge (PSFB) DC-DC converter. Various innovative control algorithms for wide-range input frequency operation, ultra-compact EMI filter design methodology, DC link capacitor reduction approach and novel start-up schemes are proposed in order to improve power quality and transient dynamics and to enhance power density of the integrated converter system. Furthermore, a variable switching frequency control algorithm of PSFB DC-DC converter has been proposed for tracking maximum conversion efficiency at all feasible operating conditions. In addition, an innovative methodology engaging multi-objective optimization for designing electromagnetic interference (EMI) filter stage with minimized volume subjected to the reactive power constraints is analyzed and validated experimentally. For proof-of-concept verifications, three different conversion stages i.e. EMI filter, three-phase boost PFC and PSFB converter are individually developed and tested with upto 6kW (continuous) / 10kW (peak) power rating, which can interface a variable input voltage (190V-240V AC RMS) variable frequency (360Hz – 800Hz) three-phase AC excitation source, emulating the airplane turbo generator and provide an AC RMS voltage of 190V to 260V. According to the experimental measurements, total harmonic distortion (THD) as low as 4.3% and an output voltage ripple of ±1% are achieved at rated output power. The proposed SiC based RTRU prototype is ~8% more efficient and ~50% lighter than state-of-the art TRU technologies