Solid-State Transformers for Interfacing Solar Panels to the Power Grid: An Optimum Design Methodology of a High Frequency Transformer for dc-dc Converter Applications

Nowadays the use of power electronic interfaces to integrate distributed generation with the power grid is becoming relevant due to the increased penetration of renewable energy sources like solar, and the continued interest to move to a smarter and more robust electric grid. Those interfaces, which also provide a voltage step-up or step-down function, are of particular interest because renewable energy sources do not always have voltages compatible with the connecting grid. Among them, the so-called “power electronic transformer” or “solid-state transformer” (SST) is the focus of significant research. Advantages such as bidirectional power flow, improved system control, reduced size, and premium power quality at the output terminals, increase the interest of the SST for future electric grids. The SST consists mainly of two components: a high-frequency transformer (made out of advanced magnetic materials) and power converters (employing efficient power semiconductor devices like those based on silicon carbide (SiC)) to enable operation at frequencies higher than the grid frequency. This paper presents an optimum design method that can be employed to build a high-frequency transformer for a SST intended to interface a renewable energy source (e.g., a photovoltaic system) to the electric grid. Core material, geometry, and size will be analyzed in order to provide an optimum balance between cost, efficiency, thermal management, and size. Special consideration will also be given to the selection of the winding conductors given the skin effect associated with operation at high frequencies

Isolated and Bidirectional DC-DC Converter for Electric Vehicles

O estado da arte iniciou com a análise na literatura de topologias de conversores DC-DC. Técnicas de modulação são estudadas com vista a melhorar a eficiência de conversão, realçando as vantagens e limitações inerentes das mesmas. Após a análise da literatura, o foco projeto passou a ser a topologias de dupla ponte com dispositivos ativos e com isolamento galvânico intermédio entre as duas pontes (conhecido em inglês por dual active bridge). Algumas técnicas de modulação que permitem o funcionamento do conversor são analisadas no documento e suportadas com resultados obtidos em ambiente de simulação. O dimensionamento do transformador de potência é realizado assim como a descrição dos passos. É relizado uma análise de mercado de dispositivos de comutação com a tecnologia "Silicon Carbide" e são apresentados estimativas de perdas e eficiência de operação na utilização de transistores com a techonoloa SiC no conversor analisado. Os resultados são obtidos com recurso a simulações computacionais que através de modelos de aproximação permitem aproximar o conversor a uma situação mais proxima da real. Em termos de implementação, é esperado a implementação um circuito de comando para dois MOSFETS com tecnologia SiC com a configuração em meia ponte ligada a uma carga

Development of a Hybrid-Electric Aircraft Propulsion System Based on Silicon Carbide Triple Active Bridge Multiport Power Converter

Constrained by the low energy density of Lithium-ion batteries with all-electric aircraft propulsion, hybrid-electric aircraft propulsion drive becomes one of the most promising technologies in aviation electrification, especially for wide-body airplanes. In this thesis, a three-port triple active bridge (TAB) DC-DC converter is developed to manage the power flow between the turbo generator, battery, and the propulsion motor. The TAB converter is modeled based on the emerging Silicon Carbide (SiC) Metal-Oxide-Semiconductor Field Effect Transistor (MOSFET) modules operating at high switching frequency, so the size of the magnetic transformer can be significantly reduced. Different operation modes of this hybrid-electric propulsion drive based on the SiC TAB converter are modeled and simulated to replicate the takeoff mode, cruising mode, and regenerative charging mode of a typical flight profile. Additionally, soft switching is investigated for the TAB converter to further improve the efficiency and power density of the converter, and zero voltage switching is achieved at heavy load operating conditions. The results show that the proposed TAB converter is capable of achieving high efficiency during all stages of the flight profile

High Power, Medium Frequency, and Medium Voltage Transformer Design and Implementation

Many industrial applications that require high-power and high-voltage DC-DC conversion are emerging. Space-borne and off-shore wind farms, fleet fast electric vehicle charging stations, large data centers, and smart distribution systems are among the applications. Solid State Transformer (SST) is a promising concept for addressing these emerging applications. It replaces the traditional Low Frequency Transformer (LFT) while offering many advanced features such as VAR compensation, voltage regulation, fault isolation, and DC connectivity. Many technical challenges related to high voltage stress, efficiency, reliability, protection, and insulation must be addressed before the technology is ready for commercial deployment. Among the major challenges in the construction of SSTs are the strategies for connecting to Medium Voltage (MV) level. This issue has primarily been addressed by synthesizing multicellular SST concepts based on modules rated for a fraction of the total MV side voltage and connecting these modules in series at the input side. Silicon Carbide (SiC) semiconductor development enables the fabrication of power semiconductor devices with high blocking voltage capabilities while achieving superior switching and conduction performances. When compared to modular lower voltage converters, these higher voltage semiconductors enable the construction of single-cell SSTs by avoiding the series connection of several modules, resulting in simple, reliable, lighter mass, more power dense, higher efficiency, and cost effective converter structures. This dissertation proposes a solution to this major issue. The proposed work focuses on the development of a dual active bridge with high power, medium voltage, and medium frequency control. This architecture addresses the shortcomings of existing modular systems by providing a more power dense, cost-effective, and efficient solution. For the first time, this topology is investigated on a 700kW system connected to a 13kVdc input to generate 7.2kVdc at the output. The use of 10kV SiC modules and gate drivers in an active neutral point clamped to two level dual active bridge converter is investigated. A special emphasis will be placed on a comprehensive transformer design that employs a multi-physics approach that addresses all magnetic, electrical, insulation, and thermal aspects. The transformer is designed and tested to ensure the system’s viability

A Novel Three-Level Isolated AC-DC PFC Power Converter Topology with Reduced Number of Switches

The three-level isolated AC-DC power factor corrected (PFC) converter provides safe and more efficient power conversion. In comparison with two-level, three-level PFC converter has the advantages of low total harmonic distortion, low device voltage rating, low di/dt, better output performance, high power factor, and low switching losses at higher switching frequencies. The high frequency transformer (HFT) grants galvanic isolation, steps up or down secondary voltage, and limits damage in case of a fault current. The existing three-level converter based on solid-state transformer (SST) topologies convert ac power from the electrical grid to a dc load while maintaining at least the minimum requirements set by the international standards (i.e., high power factor and low total harmonic distortion). The SST topologies with the capability of controlling intermediate dc-bus and output voltage simultaneously require two full bridges at the primary and secondary side of the HFT. As the power level increases, the number of cascaded bridges increases accordingly, and the price associated with these semiconductor devices becomes highly expensive. As result, the demand of converting high power level led to emphasis on high performance and cost-effective power conversion topology. The aim of this dissertation is to develop a new low-cost and high-performance three-level isolated AC-DC (PFC) converter topology. The proposed topology replaces the conventional three-level inverter in the secondary side of the HFT by only two switches and four diodes while still maintaining the basic functionality of a three-level converter (i.e., regulating the output voltage, controlling the dc-bus voltage to be within desired limits). The advantages of this new topology are: (1) low conduction losses; (2) low-cost; (3) no need to consider the issue of the power backflow; (4) zero-voltage switching (ZVS) and zero-current switching (ZCS) at turn ON are inherently guaranteed without any extra control effort. Two isolated three-level AC-DC power converter topologies are developed and investigated through the dissertation. First topology is based on the neutral point clamping (NPC) converter, and the second topology composed of the T-type converter. Two scale-down prototypes rated at 900-W and 1kW, 200 V are built to test the overall performance of the proposed topologies. The first and second topologies exhibit 94.5 % and 95.8 % efficiency scaled at a nominal power, respectively. The secondary bridge (novel circuit) in both topologies, which consists of two switches and four diodes, has 99.34 % practical efficiency

Solid state transformer technologies and applications: a bibliographical survey

This paper presents a bibliographical survey of the work carried out to date on the solid state transformer (SST). The paper provides a list of references that cover most work related to this device and a short discussion about several aspects. The sections of the paper are respectively dedicated to summarize configurations and control strategies for each SST stage, the work carried out for optimizing the design of high-frequency transformers that could adequately work in the isolation stage of a SST, the efficiency of this device, the various modelling approaches and simulation tools used to analyze the performance of a SST (working a component of a microgrid, a distribution system or just in a standalone scenario), and the potential applications that this device is offering as a component of a power grid, a smart house, or a traction system.Peer ReviewedPostprint (published version

Design and Optimization of a Modular DC-DC Power Converter for Medium Voltage Shipboard Applications

Power electronic converters rated for medium voltage direct current (MVDC) are promising for electrification of future ships. In shipboard electrification, due to limitation of space, energy and technical maintenance, the high-power density, high efficiency and modularity of the power electronic converters are desired. Utilizing power modules made from wide band gap (WBG) semiconductors like silicon carbide (SiC) and high frequency power transformer (HFPT) can be beneficial for obtaining the high-power density, high efficiency and isolation that is required for the power electronic converters. To provide power for the low voltage (LV) DC loads, a conversion of the power from MVDC main bus to LVDC is needed. Therefore, a DC-DC converter is an essential component of a DC power system. DC-DC converter is a multipurpose element in Unit-based protection architecture (UBPA) which is an architecture that eliminates the need for DC circuit breaker (CB) and instead relies on isolated power electronic converters for protection of the system. Topologies based on Dual active bridge (DAB), Neutral point clamp (NPC) and Modular Multi-level Converter (MMC) are suggested for such a DC-DC converter rated for megawatt (MW) power level. Switching at MV level with high frequency in the ship environment is challenging because of the parasitic coupling that appears between the power module, MV side of the transformer and the ship haul which is made from the materials capable of conducting electricity. Moreover, the transformer used in the isolated DC-DC converter is one of the main contributors to the weight and power density of the converter. In this study, the DAB converter is suggested as a building block for an input series output parallel (ISOP) connected converter and analytical equations are provided for the design. A novel design for the HFPT is proposed and analytical formula is derived for the thermal loss and the leakage inductance of the HFPT. Optimization methodology using evolutionary algorithms method like genetic algorithm is applied to the design to extract the optimal values for a design. A case study is also provided in this study

Design Approaches to Enhance Power Density in Power Converters for Traction Applications

This dissertation presents a design strategy to increase the power density for automotive Power Conversion Units (PCUs) consisting of DC-DC and DC-AC stages. The strategy significantly improves the volumetric power density, as evident by a proposed PCU constructed and tested having 55.6 kW/L, representing an 11.2 % improvement on the Department of Energy’s 2025 goal of 50 kW/L for the same power electronics architecture. The dissertation begins with a custom magnetic design procedure, based on optimization of a predetermined C-core geometrical relationship and custom Litz wire. It accounts for electrical and thermal tradeoffs to produce a magnetic structure to best accomplish volume and thermal constraints. This work is coupled with a control strategy for the DC-DC converter whereby a variable-frequency Discontinuous Conduction Mode (DCM) control is used to further reduce the required values of the passive components, to provide an increase in power density and a large improvement of low-power-level efficiency, experimentally demonstrated at full power through an 80 kW Interleaved Boost Converter. Integration of this enhanced DC-DC stage to the DC-AC stage requires a DC-Link capacitor, which hinders achieving power density targets. Increasing the switching frequency is an established method of reducing the size of passives. However, it is the RMS current sizing requirements that diminishes any gains achieved by raising the switching frequency. A synchronous carrier phase shift-based control algorithm, that aligns the output current of the boost stage with the input current of an inverter, is proposed to reduce the RMS current in the DC-Link capacitor by up to 25% and an average 20% smaller capacitor volume. Lastly, a new electrothermal platform based on paralleled discrete devices is presented for a 50 kW traction inverter. Embedded capacitors within the vacant volume of the hybrid material thermal management structure enables higher power density (155 kW/L) and significantly reduces cost

Design Approaches to Enhance Power Density in Power Converters for Traction Applications

This dissertation presents a design strategy to increase the power density for automotive Power Conversion Units (PCUs) consisting of DC-DC and DC-AC stages. The strategy significantly improves the volumetric power density, as evident by a proposed PCU constructed and tested having 55.6 kW/L, representing an 11.2 % improvement on the Department of Energy’s 2025 goal of 50 kW/L for the same power electronics architecture. The dissertation begins with a custom magnetic design procedure, based on optimization of a predetermined C-core geometrical relationship and custom Litz wire. It accounts for electrical and thermal tradeoffs to produce a magnetic structure to best accomplish volume and thermal constraints. This work is coupled with a control strategy for the DC-DC converter whereby a variable-frequency Discontinuous Conduction Mode (DCM) control is used to further reduce the required values of the passive components, to provide an increase in power density and a large improvement of low-power-level efficiency, experimentally demonstrated at full power through an 80 kW Interleaved Boost Converter. Integration of this enhanced DC-DC stage to the DC-AC stage requires a DC-Link capacitor, which hinders achieving power density targets. Increasing the switching frequency is an established method of reducing the size of passives. However, it is the RMS current sizing requirements that diminishes any gains achieved by raising the switching frequency. A synchronous carrier phase shift-based control algorithm, that aligns the output current of the boost stage with the input current of an inverter, is proposed to reduce the RMS current in the DC-Link capacitor by up to 25% and an average 20% smaller capacitor volume. Lastly, a new electrothermal platform based on paralleled discrete devices is presented for a 50 kW traction inverter. Embedded capacitors within the vacant volume of the hybrid material thermal management structure enables higher power density (155 kW/L) and significantly reduces cost

Design and Implementation of a Multi-port Solid State Transformer for Flexible Der Integration

Conventional power system includes four major sections, bulk generation, transmission network, distribution network, and loads. The main converter in the conventional electric grid is the low-frequency passive transformer providing galvanic isolation and voltage regulation for various voltage zones. In this configuration, small-scale renewable energy resources are generally connected to the power system at low voltage zones or inside microgrids. Recent developments in the design of power electronic elements with higher voltage and power ratings and medium/high frequency enable making use of solid state transformer at different voltage levels in the distribution system and microgrid design. In this work, the concept of a Multi-Port Solid State Transformer (MPSST) for distribution network application is introduced. MPSST provides a compact, integrated and galvanically isolated multi-port node for microgrid and distribution applications and reduces the number and size of the converters in the concept of efficient smart distribution systems. A new architecture for distribution systems integrating distributed generation (DG) at different voltage zones using MPSST is proposed, studied and simulated. The developed concept interconnects different voltage types and levels using one compact converter with a centralized control logic. In addition, a general method is developed and mathematically analyzed to provide active and reactive power support using the local alternative power sources through MPSST. MPSST is a combination of high-frequency power electronic converters and a multi-winding high-frequency transformer. The total size of the MPSST is dramatically smaller than the conventional transformers with the same voltage and power rating. MPSST also enables online measurement and data collection and active control of the parameters at all connected ports. A two-layer control technique, which is a combination of duty cycle control and a modified phase shift control is used to regulate the voltage and power flow of the different ports. Since the converter has several independent and dependent variables, a transfer matrix between variables of the converter is calculated and used in system control. Finally, the implementation process of the converter including, component selection, modeling, software development, and transformer design is presented and the first prototype of the MPSST is developed and tested in the lab. Chapter five includes the hardware test results and the discussion and comparison of the results with the design expectations