Driving and Protection of High Density High Temperature Power Module for Electric Vehicle Application

There has been an increasing trend for the commercialization of electric vehicles (EVs) to reduce greenhouse gas emissions and dependence on petroleum. However, a key technical barrier to their wide application is the development of high power density electric drive systems due to limited space within EVs. High temperature environment inherent in EVs further introduces a new level of complexity. Under high power density and high temperature operation, system reliability and safety also become important. This dissertation deals with the development of advanced driving and protection technologies for high temperature high density power module capable of operating under the harsh environment of electric vehicles, while ensuring system reliability and safety under short circuit conditions. Several related research topics will be discussed in this dissertation. First, an active gate driver (AGD) for IGBT modules is proposed to improve their overall switching performance. The proposed one has the capability of reducing the switching loss, delay time, and Miller plateau duration during turn-on and turn-off transient without sacrificing current and voltage stress. Second, a board-level integrated silicon carbide (SiC) MOSFET power module is developed for high temperature and high power density application. Specifically, a silicon-on-insulator (SOI) based gate driver board is designed and fabricated through chip-on-board (COB) technique. Also, a 1200 V / 100 A SiC MOSFET phase-leg power module is developed utilizing high temperature packaging technologies. Third, a comprehensive short circuit ruggedness evaluation and numerical investigation of up-to-date commercial silicon carbide (SiC) MOSFETs is presented. The short circuit capability of three types of commercial 1200 V SiC MOSFETs is tested under various conditions. The experimental short circuit behaviors are compared and analyzed through numerical thermal dynamic simulation. Finally, according to the short circuit ruggedness evaluation results, three short circuit protection methods are proposed to improve the reliability and overall cost of the SiC MOSFET based converter. A comparison is made in terms of fault response time, temperature dependent characteristics, and applications to help designers select a proper protection method

High-Efficiency MOSFET-based MMC Design for LVDC Distribution Systems

LVDC distribution networks have the potential to release larger capacity without having to upgrade the existing cables. One of the main challenges of LVDC networks is the extra customer-end DC-AC conversion stage. This paper proposes and evaluates a 5-level Si MOSFET-based MMC as a promising alternative to the conventional 2-level IGBT-based converter. This is due to the comparatively higher efficiency, power quality and reliability, and reduced EM emissions. A comprehensive analysis of a Si MOSFET 5-level MMC converter design is performed to investigate the suitability of the topology for LVDC applications. Detailed theoretical analysis of the 5-level MMC is presented, with simulated and experimental results to demonstrate circuit performance. To suppress the AC circulating current, especially the dominant 2nd harmonics, this paper presents a double line-frequency PI with orthogonal imaginary axis control method. Comparison of simulation and experimental results with those for double line-frequency PR control shows that the proposed PI controller has better performance. In addition, it is simpler to implement and more immune to sampling/discretisation errors

Design and Evaluation of High Power, High Efficiency and High Power Density Motor Drives for More Electric Aircrafts

More-electric aircraft (MEA) is an attractive concept as it can reduce carbon dioxide emission, relieve fossil-fuel consumption, improve the overall efficiency of aircraft, and reduce the operational costs. However, it poses substantial challenges in designing a high-performance motor drive system for such applications. In the report of Aircraft Technology Roadmap to 2050, the propulsion converter is required to be ultra-high efficiency, high power density, and high reliability. Though the wide band-gap devices, such as the Silicon-carbide based Metal Oxide Silicon Field Effect (SiC-MOSFET), shows better switching performance and improved high-temperature performance compared to the silicon counterparts, applying it to the MEA-related application is still challenging. The high switching speed of SiC-MOSFET reduces switching loss and enables the design of high-density converters. However, it poses intense challenges in limiting the stray inductance in the power stage. The fast switching behavior of SiC-MOSFET also challenges the design scalability by multi-chip parallel, which is essential in high-power-rating converters. Moreover, the partial discharge can happen at the lower voltage when the converter is operated at high altitude, low air-pressure conditions, which threatens the converter lifetime by the accelerated aging of the insulation system. This dissertation addresses these issues at the paper-design level, power-module level, and converter level, respectively. At the paper-design level, the proposed model-based design and optimization enables shoulder-by-shoulder performance comparison between different candidate topology and then generates optimal semiconductor design space for the selected topology. At the power-module level, this dissertation focuses on the development of an ultra-low inductance module by using a novel packaging structure that integrates the printed circuit board (PCB) with direct-bounding copper (DBC). The detailed power-loop optimization, thermal analysis, and fabrication guidance are discussed to demonstrate its performance and manufacturability. At the converter level, this dissertation provides a comprehensive design strategy to improve the performance of the laminated busbar. In the design of the busbar conduction layer, this work analyzed the impacts of each stray inductance item and then proposed a novel double-side decoupled conduction-layer structure with minimized stray inductance and improved dynamic current sharing. In the design of the insulation system of the busbar, this dissertation investigates the design strategy to ensure the busbar is free of partial discharge without sacrificing the parasitic control. Through the dissertation, a single-phase 150 kVA converter, a three-phase 450 kVA converter, and a 1.2 kV, 300 A power module are designed, fabricated, and tested to demonstrate the proposed design strategies

Discussion on Electric Power Supply Systems for All Electric Aircraft

The electric power supply system is one of the most important research areas within sustainable and energy-efcient aviation for more- and especially all electric aircraft. This paper discusses the history in electrication, current trends with a broad overview of research activities, state of the art of electrication and an initial proposal for a short-range aircraft. It gives an overviewof the mission prole, electrical sources, approaches for the electrical distribution system and the required electrical loads. Current research aspects and questions are discussed, including voltage levels, semiconductor technology, topologies and reliability. Because of the importance for safety possible circuit breakers for the proposed concept are also presented and compared, leading to a initial proposal. Additionally, a very broad review of literature and a state of the art discussion of the wiring harness is given, showing that this topic comes with a high number of aspects and requirements. Finally, the conclusion sums up the most important results and gives an outlook on important future research topics

Electrical Design of a Portable Pure Sine Wave Inverter Using Ferrite Core Transformer and Double Stage Technique

The size of the iron core transformer in an inverter is large and heavy because it has more conductor turns and works at low frequencies. In contrast, ferrite core transformers are designed to work at high frequencies, so the number of turns of the conductor is less, and the transformer size is relatively small and light. Device portability is a significant challenge in designing high-power inverters. This research uses a ferrite core transformer to design a portable pure sine wave inverter. A two-stage technique is proposed in designing the inverter so that the dc-link voltage and capacitor size can be flexibly selected, and the device size can be compacted. The design consists of two stages. First, a circuit to generate a 400-Volt DC voltage is designed using IC SG3525, a MOSFET power amplifier, and a ferrite core step-up transformer. Second, a pure sine wave generator circuit is constructed using an EGS002 module, MOSFETs, and a filter circuit. Experiments are performed by measuring the output voltage, monitoring power and frequency, and observing the waveform with an oscilloscope. The results reveal that the designed inverter can generate a 220-volt pure sine wave output, a maximum power of 500 Watts, a frequency of 50 Hz, and an efficiency between 91.4% to 98.1%

Contributions to the design of power modules for electric and hybrid vehicles: trends, design aspects and simulation techniques

314 p.En la última década, la protección del medio ambiente y el uso alternativo de energías renovables están tomando mayor relevancia tanto en el ámbito social y político, como científico. El sector del transporte es uno de los principales causantes de los gases de efecto invernadero y la polución existente, contribuyendo con hasta el 27 % de las emisiones a nivel global. En este contexto desfavorable, la electrificación de los vehículos de carretera se convierte en un factor crucial. Para ello, la transición de la actual flota de vehículos de carretera debe ser progresiva forzando la investigación y desarrollo de nuevos conceptos a la hora de producir vehículos eléctricos (EV) y vehículos eléctricos híbridos (HEV) más eficientes, fiables, seguros y de menor coste. En consecuencia, para el desarrollo y mejora de los convertidores de potencia de los HEV/EV, este trabajo abarca los siguientes aspectos tecnológicos: - Arquitecturas de la etapa de conversión de potencia. Las principales topologías que pueden ser implementadas en el tren de potencia para HEV/EV son descritas y analizadas, teniendo en cuenta las alternativas que mejor se adaptan a los requisitos técnicos que demandan este tipo de aplicaciones. De dicha exposición se identifican los elementos constituyentes fundamentales de los convertidores de potencia que forman parte del tren de tracción para automoción.- Nuevos dispositivos semiconductores de potencia. Los nuevos objetivos y retos tecnológicos solo pueden lograrse mediante el uso de nuevos materiales. Los semiconductores Wide bandgap (WBG), especialmente los dispositivos electrónicos de potencia basados en nitruro de galio (GaN) y carburo de silicio (SiC), son las alternativas más prometedoras al silicio (Si) debido a las mejores prestaciones que poseen dichos materiales, lo que permite mejorar la conductividad térmica, aumentar las frecuencias de conmutación y reducir las pérdidas.- Análisis de técnicas de rutado, conexionado y ensamblado de módulos de potencia. Los módulos de potencia fabricados con dies en lugar de dispositivos discretos son la opción preferida por los fabricantes para lograr las especificaciones indicadas por la industria de la automoción. Teniendo en cuenta los estrictos requisitos de eficiencia, fiabilidad y coste es necesario revisar y plantear nuevos layouts de las etapas de conversión de potencia, así como esquemas y técnicas de paralelización de los circuitos, centrándose en las tecnologías disponibles.Teniendo en cuenta dichos aspectos, la presente investigación evalúa las alternativas de semiconductores de potencia que pueden ser implementadas en aplicaciones HEV/EV, así como su conexionado para la obtención de las densidades de potencia requeridas, centrándose en la técnica de paralelización de semiconductores. Debido a la falta de información tanto científica como comercial e industrial sobre dicha técnica, una de las principales contribuciones del presente trabajo ha sido la propuesta y verificación de una serie de criterios de diseño para el diseño de módulos de potencia. Finalmente, los resultados que se han extraído de los circuitos de potencia propuestos demuestran la utilidad de dichos criterios de diseño, obteniendo circuitos con bajas impedancias parásitas y equilibrados eléctrica y térmicamente. A nivel industrial, el conocimiento expuesto en la presente tesis permite reducir los tiempos de diseño a la hora de obtener prototipos de ciertas garantías, permitiendo comenzar la fase de prototipado habiéndose realizado comprobaciones eléctricas y térmicas

Survey on Photo-Voltaic Powered Interleaved Converter System

Renewable energy is the best solution to meet the growing demand for energy in the country. The solar energy is considered as the most promising energy by the researchers due to its abundant availability, eco-friendly nature, long lasting nature, wide range of application and above all it is a maintenance free system. The energy absorbed by the earth can satisfy 15000 times of today’s total energy demand and its hundred times more than that our conventional energy like coal and other fossil fuels. Though, there are overwhelming advantages in solar energy, It has few drawbacks as well such as its low conversion ratio, inconsistent supply of energy due to variation in the sun light, less efficiency due to ripples in the converter, time dependent and, above all, high capitation cost. These aforementioned flaws have been addressed by the researchers in order to extract maximum energy and attain hundred percentage benefits of this heavenly resource. So, this chapter presents a comprehensive investigation based on photo voltaic (PV) system requirements with the following constraints such as system efficiency, system gain, dynamic response, switching losses are investigated. The overview exhibits and identifies the requirements of a best PV power generation system