A Multifunctional SiC DC-DC Converter Topology with Normalized Fault Detection Strategy for Electric Vehicle Applications

The automotive industry is experiencing a monumental shift in technology and propulsion strategies. More than ever before, car manufacturers and suppliers are shifting development and funding away from combustion engines in favor of electrified powertrains. One of the main obstacles contributing to customers reluctance to buy EVs is the lack of infrastructure for charging. Traditional 110/220VAC outlets equipped at residential buildings are relatively low power compared to the batteries used in EVs today. These AC chargers, classified as level 1 and level 2, will take approximately 12-24 hours to completely charge a battery, depending on battery size and state-of-charge. Additionally, because this method of charging uses alternating current, vehicles must have chargers on-board to convert the energy from AC to DC to recharge the battery because EV batteries are direct current energy sources. Millions of dollars from the government and private companies are being invested to create an adequate DC fast charging infrastructure. The advantages of DC charging are two-fold, much quicker charging times and the elimination of onboard chargers. However, there is one blatant problem with current investments into a DC charging infrastructure – technological advancement. Most electric vehicles in production have battery pack voltages between 300V and 400V and current DC fast chargers are being developed for the current technology. This will likely change rather quickly; the development of wide-bandgap devices will allow for higher voltage devices. Furthermore, the energy densities of batteries will also likely improve, allowing for higher bus voltages. Higher bus voltages will offer several advantages over current architectures – more power, smaller devices, improved efficiencies, and more. The problem is, once higher bus voltages are achieved and popularized, the current fast charging infrastructure will be deemed obsolete. An intermediate solution needs to be developed to allow higher bus voltage vehicles to continue to utilize the current fast chargers being deployed nation-wide. The proposed DC-DC converter is a practical design that offers multiple purposes when implemented in electric vehicles that utilize permanent magnet synchronous machines (PMSM) and bus voltages of ~800V. It consists of a bi-directional interleaved DC-DC cascaded with an isolated full bridge converter. This configuration provides a 12V source with galvanic isolation during normal propulsion. The interleaved converter can boost in reverse to allow for charging of the 800V bus with current generation DC fast chargers operating at ~400V. Finally, an inverter fault detection methodology has been realized to take advantage of the interleaved DC-DC structure. If an open switch fault is detected on any of the 3-phases driving the PMSM, the appropriate phase-leg is isolated, and a phase-leg from the interleaved DC-DC is used to maintain propulsion. This is realized by monitoring the phase currents of the AC motor and analyzing the difference in value between all three. A threshold value is implemented in C-code, not contingent on the system parameters. A difference of phase currents greater than the threshold value is a clear indication that an open switch fault has occurred. The proposed power conversion structure and the motor inverter fault detection, isolation, and compensation approaches are verified by a PSIM simulation. The simulation results successfully validate the feasibility of proposed electric powertrain structure and inverter switch fault detection and compensation methods.Master of Science in EngineeringEnergy Systems Engineering, College of Engineering & Computer ScienceUniversity of Michigan-Dearbornhttp://deepblue.lib.umich.edu/bitstream/2027.42/156398/1/Brandon Pieniozek Final Thesis.pdfDescription of Brandon Pieniozek Final Thesis.pdf : Thesi

Industrial and Technological Applications of Power Electronics Systems

The Special Issue "Industrial and Technological Applications of Power Electronics Systems" focuses on: - new strategies of control for electric machines, including sensorless control and fault diagnosis; - existing and emerging industrial applications of GaN and SiC-based converters; - modern methods for electromagnetic compatibility. The book covers topics such as control systems, fault diagnosis, converters, inverters, and electromagnetic interference in power electronics systems. The Special Issue includes 19 scientific papers by industry experts and worldwide professors in the area of electrical engineering

A review of modular electrical sub-systems of electric vehicles

Climate change risks have triggered the international community to find efficient solutions to reduce greenhouse gas (GHG) emissions mainly produced by the energy, industrial, and transportation sectors. The problem can be significantly tackled by promoting electric vehicles (EVs) to be the dominant technology in the transportation sector. Accordingly, there is a pressing need to increase the scale of EV penetration, which requires simplifying the manufacturing process, increasing the training level of maintenance personnel, securing the necessary supply chains, and, importantly, developing the charging infrastructure. A new modular trend in EV manufacturing is being explored and tested by several large automotive companies, mainly in the USA, the European Union, and China. This modular manufacturing platform paves the way for standardised manufacturing and assembly of EVs when standard scalable units are used to build EVs at different power scales, ranging from small light-duty vehicles to large electric buses and trucks. In this context, modularising EV electric systems needs to be considered to prepare for the next EV generation. This paper reviews the main modular topologies presented in the literature in the context of EV systems. This paper summarises the most promising topologies in terms of modularised battery connections, propulsion systems focusing on inverters and rectifiers, modular cascaded EV machines, and modular charging systems

Degradation modeling and degradation-aware control of power electronic systems

The power electronics market is valued at $23.25 billion in 2019 and is projected to reach$ 36.64 billion by 2027. Power electronic systems (PES) have been extensively used in a wide range of critical applications, including automotive, renewable energy, industrial variable-frequency drive, etc. Thus, the PESs\u27 reliability and robustness are immensely important for the smooth operation of mission-critical applications. Power semiconductor switches are one of the most vulnerable components in the PES. The vulnerability of these switches impacts the reliability and robustness of the PES. Thus, switch-health monitoring and prognosis are critical for avoiding unexpected shutdowns and preventing catastrophic failures. The importance of the prognosis study increases dramatically with the growing popularity of the next-generation power semiconductor switches, wide bandgap switches. These switches show immense promise in the high-power high-frequency operations due to their higher breakdown voltage and lower switch loss. But their wide adaptation is limited by the inadequate reliability study. A thorough prognosis study comprising switch degradation modeling, remaining useful life (RUL) estimation, and degradation-aware controller development, is important to enhance the PESs\u27 robustness, especially with wide bandgap switches. In this dissertation, three studies are conducted to achieve these objectives- 1) Insulated Gate Bipolar Transistor (IGBT) degradation modeling and RUL estimation, 2) cascode Gallium Nitride (GaN) Field-Effect Transistor (FET) degradation modeling and RUL estimation, and 3) Degradation-aware controller design for a PES, solid-state transformer (SST). The first two studies have addressed the significant variation in RUL estimation and proposed degradation identification methods for IGBT and cascode GaN FET. In the third study, a system-level integration of the switch degradation model is implemented in the SST. The insight into the switch\u27s degradation pattern from the first two studies is integrated into developing a degradation-aware controller for the SST. State-of-the-art controllers do not consider the switch degradation that results in premature system failure. The proposed low-complexity degradation-aware and adaptive SST controller ensures optimal degradation-aware power transfer and robust operation over the lifetime

FY2011 Oak Ridge National Laboratory Annual Progress Report for the Power Electronics and Electric Machinery Program

The U.S. Department of Energy (DOE) announced in May 2011 a new cooperative research effort comprising DOE, the U.S. Council for Automotive Research (composed of automakers Ford Motor Company, General Motors Company, and Chrysler Group), Tesla Motors, and representatives of the electric utility and petroleum industries. Known as U.S. DRIVE (Driving Research and Innovation for Vehicle efficiency and Energy sustainability), it represents DOE's commitment to developing public-private partnerships to fund high risk-high reward research into advanced automotive technologies. The new partnership replaces and builds upon the partnership known as FreedomCAR (derived from 'Freedom' and 'Cooperative Automotive Research') that ran from 2002 through 2010 and the Partnership for a New Generation of Vehicles initiative that ran from 1993 through 2001. The Oak Ridge National Laboratory's (ORNL's) Power Electronics and Electric Machines (PEEM) subprogram within the DOE Vehicle Technologies Program (VTP) provides support and guidance for many cutting-edge automotive technologies now under development. Research is focused on developing revolutionary new power electronics (PE), electric motor (EM), and traction drive system technologies that will leapfrog current on-the-road technologies. The research and development (R&D) is also aimed at achieving a greater understanding of and improvements in the way the various new components of tomorrow's automobiles will function as a unified system to improve fuel efficiency. In supporting the development of advanced vehicle propulsion systems, the PEEM subprogram has enabled the development of technologies that will significantly improve efficiency, costs, and fuel economy. The PEEM subprogram supports the efforts of the U.S. DRIVE partnership through a three phase approach intended to: (1) identify overall propulsion and vehicle related needs by analyzing programmatic goals and reviewing industry's recommendations and requirements and then develop the appropriate technical targets for systems, subsystems, and component R&D activities; (2) develop and validate individual subsystems and components, including EMs and PE; and (3) determine how well the components and subsystems work together in a vehicle environment or as a complete propulsion system and whether the efficiency and performance targets at the vehicle level have been achieved. The research performed under this subprogram will help remove technical and cost barriers to enable the development of technology for use in such advanced vehicles as hybrid electric vehicles (HEVs), plug-in HEVs (PHEVs), battery electric vehicles, and fuel-cell-powered automobiles that meet the goals of the VTP. A key element in making these advanced vehicles practical is providing an affordable electric traction drive system. This will require attaining weight, volume, efficiency, and cost targets for the PE and EM subsystems of the traction drive system. Areas of development include: (1) novel traction motor designs that result in increased power density and lower cost; (2) inverter technologies involving new topologies to achieve higher efficiency with the ability to accommodate higher temperature environments while achieving high reliability; (3) converter concepts that use methods of reducing the component count and integrating functionality to decrease size, weight, and cost; (4) new onboard battery charging concepts that result in decreased cost and size; (5) more effective thermal control through innovative packaging technologies; and (6) integrated motor-inverter traction drive system concepts. ORNL's PEEM research program conducts fundamental research, evaluates hardware, and assists in the technical direction of the VTP Advanced Power Electronics and Electric Motors (APEEM) program. In this role, ORNL serves on the U.S. DRIVE Electrical and Electronics Technical Team, evaluates proposals for DOE, and lends its technological expertise to the direction of projects and evaluation of developing technologies. ORNL also executes specific projects for DOE. DOE's continuing R&D into advanced vehicle technologies for transportation offers the possibility of reducing the nation's dependence on foreign oil and the negative economic impacts of crude oil price fluctuations. It also supports the Administration's goal of deploying 1 million PHEVs by 2015

Power quality improvement utilizing photovoltaic generation connected to a weak grid

Microgrid research and development in the past decades have been one of the most popular topics. Similarly, the photovoltaic generation has been surging among renewable generation in the past few years, thanks to the availability, affordability, technology maturity of the PV panels and the PV inverter in the general market. Unfortunately, quite often, the PV installations are connected to weak grids and may have been considered as the culprit of poor power quality affecting other loads in particular sensitive loads connected to the same point of common coupling (PCC). This paper is intended to demystify the renewable generation, and turns the negative perception into positive revelation of the superiority of PV generation to the power quality improvement in a microgrid system. The main objective of this work is to develop a control method for the PV inverter so that the power quality at the PCC will be improved under various disturbances. The method is to control the reactive current based on utilizing the grid current to counteract the negative impact of the disturbances. The proposed control method is verified in PSIM platform. Promising results have been obtaine

A review of modular electrical sub-systems of electric vehicles

Climate change risks have triggered the international community to find efficient solutions to reduce greenhouse gas (GHG) emissions mainly produced by the energy, industrial, and transportation sectors. The problem can be significantly tackled by promoting electric vehicles (EVs) to be the dominant technology in the transportation sector. Accordingly, there is a pressing need to increase the scale of EV penetration, which requires simplifying the manufacturing process, increasing the training level of maintenance personnel, securing the necessary supply chains, and, importantly, developing the charging infrastructure. A new modular trend in EV manufacturing is being explored and tested by several large automotive companies, mainly in the USA, the European Union, and China. This modular manufacturing platform paves the way for standardised manufacturing and assembly of EVs when standard scalable units are used to build EVs at different power scales, ranging from small light-duty vehicles to large electric buses and trucks. In this context, modularising EV electric systems needs to be considered to prepare for the next EV generation. This paper reviews the main modular topologies presented in the literature in the context of EV systems. This paper summarises the most promising topologies in terms of modularised battery connections, propulsion systems focusing on inverters and rectifiers, modular cascaded EV machines, and modular charging systems