Publications

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Abstract: Advantages of the 2.5D HI (Heterogeneous Integration) electronics packaging of the power electronics compared to PCB packaging will be presented. Current 2.5D packaging effort using TSV (Through Silicon Via) will be presented in terms of fabrication, microstructural analysis, reliability, and thermal simulation.

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This project is intended to support the development of new traction drive systems that meet the targets of 100 kW/L for power electronics and 50 kW/L for electric machines with reliable operation to 300,000 miles. To meet these goals, new designs must be identified that make use of state-of-the-art and next-generation electronic materials and design methods. Designs must exploit synergies between components, for example converters designed for high-frequency switching using wide band gap devices and ceramic capacitors. This project includes: (1) a survey of available technologies; (2) the development of design tools that consider the converter volume and performance; (3) exercising the design software to evaluate performance gaps and predict the impact of certain technologies and design approaches, i.e. GaN semiconductors, ceramic capacitors, and select topologies; and (4) building and testing hardware prototypes to validate models and concepts. Early instantiations of the design tools enable co-optimization of the power module and passive elements and provide some design guidance; later instantiations will enable the co-optimization of inverter and machine. Prototype testing begins with evaluation of simpler conversion topologies (i.e. the half-bridge boost converter) and progresses with fabrication of prototype inverter drives.

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DC microgrids envisioned with high bandwidth communications may well expand their application range by considering autonomous strategies as resiliency contingencies. In most cases, these strategies are based on the droop control method, seeking low voltage regulation and proportional load sharing. Control challenges arise when coordinating the output of multiple DC microgrids composed of several Distributed Energy Resources. This paper proposes an autonomous control strategy for transactional converters when multiple DC microgrids are connected through a common bus. The control seeks to match the external bus voltage with the internal bus voltage balancing power. Three case scenarios are considered: standalone operation of each DC microgrid, excess generation, and generation deficit in one DC microgrid. Results using Sandia National Laboratories Secure Scalable Microgrid Simulink library, and models developed in MATLAB are compared.

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With evolving landscape of DC power transmission and distribution, a reliable and fast protection against faults is critical, especially for medium- and high-voltage applications. Thus, solid-state circuit breakers (SSCB), consisting of cascaded silicon carbide (SiC) junction field-effect transistors (JFET), utilize the intrinsic normally-ON characteristic along with their low ON-resistance. This approach provides an efficient and robust protection solution from detrimental short-circuit events. However, for applications that require high-voltage blocking capability, a proper number of JFETs need be connected in series to achieve the desired blocking voltage rating. Ensuring equal voltage balancing across the JFETs during the switching transitions as well as the blocking stage is critical and hence, this paper presents a novel passive balancing network for series connected JFETs for DC SSCB applications. The dynamic voltage balancing network to synchronize both the turn ON and OFF intervals is described analytically. Moreover, the static voltage balancing network is implemented to establish equal sharing of the total blocking voltage across the series connection of JFETs. The proposed dynamic and steady-state balancing networks are validated by SPICE simulation and experimental results.

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In spite of several advantages of SiC JFETs over enhancement mode SiC MOSFETs, the intrinsic normally-ON characteristic of the JFETs can be undesirable for many industrial power conversion applications due to the negative turn-OFF voltage requirement. This prevents normally-ON JFETs from being widely accepted in industry. However, a cascode configuration, which uses a low voltage (LV) Si MOSFET can be used to enable a normally-OFF behavior, making this approach an attractive solution to utilize the benefits of SiC JFETs. For medium-, and high-voltage applications that require larger blocking voltage than the rating of each JFET, additional devices can be connected in series to increase the overall blocking voltage capability, creating a super-cascode configuration. This paper provides a review of several super-cascode topology variations and presents a comprehensive comparative study, evaluating similarities and differences in operating principles, equivalent circuits, and design considerations and limitations.

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Optimized designs were achieved using a genetic algorithm to evaluate multi-objective trade space, including Mean-Time-Between-Failure (MTBF) and volumetric power density. This work provides a foundational platform that can be used to optimize additional power converters, such as an inverter for the EV traction drive system as well as trade-offs in thermal management due to the use of different device substrate materials.

In power electronic applications, reliability and power density are a few of the many important performance metrics that require continual improvement in order to meet the demand of today's complex electrical systems. However, due to the complexity of the synergy between various components, it is challenging to visualize and evaluate the effects of choosing one component over another and what certain design parameters impose on the overall reliability and lifetime of the system. Furthermore, many areas of electronics have realized remarkable innovation in the integration of new materials of passive and active components; wide-bandgap semiconductor devices and new magnetic materials allow higher operating temperature, blocking voltage, and switching frequency; all of which enable much more compact power converter designs. However, uncertainty remains in the overall electronics reliability in different design variations. Hence, in order to better understand the relationship between reliability and power density in a power electronic system, this paper utilizes a genetic algorithm (GA) to provide pareto optimal solution sets in a multi-variate trade space that relates the Mean Time Between Failures (MTBF) and volumetric power density for the design of a 5 kW synchronous boost converter. Different designs of the synchronous boost converter based on the variation of the electrical parameters and material types for the passive (input and output capacitors, the boost inductor, and the heatsink) and active components (switches) have been studied. A few candidate designs have been evaluated and verified through hardware experiments.

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This paper describes the design of a very high power density inverter drive module using aggressive high-frequency design methods and multi-objective optimization tools. This work is part of a larger effort to develop electric drive designs with >97% efficiency, power densities of 100 kW/L for the power electronics, and with predicted reliable operation to 300, 000 miles. The approach taken in this work is to develop designs that utilize wide band gap devices (SiC or GaN) and ceramic capacitors to enable high-frequency switching and a compact integrated design. The multi-objective optimization is employed to select key parameters for the design.

Power systems with highly flexible architectures (i.e. permitting many configurations) may allow for more economic operation as well as improved reliability and resiliency. The greater number of configurations enable optimization for attaining the former benefit and redundancy for achieving the latter. Flexibility is of great importance in electric ship power systems wherein the system must ensure delivery of power to vital loads. The United States (US) Navy is currently investigating new architectures that enable a greater number of interconnection permutations. Among the new features considered are generators that may supply two buses; this may be done using conventional (single winding set) generators and two rectifiers or a dual wound machine with two rectifiers. In systems supplied by dual-wound machines, buses may not be tied directly but are linked dynamically through the shared generator dynamics. In systems with conventional generation supplying two rectifiers, the two buses are tied through a common AC bus supplying both rectifiers. This paper presents a comparison of these two approaches of supplying two buses from one generator; the evaluation considers issues associated with dynamic coupling through these two candidate architectures, including the coupled response due to faults and systems with pulsed loads. Results are based on analysis, simulation results, and hardware experiment.

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Forced oscillations in power systems are of particular interest when they interact and reinforce inter-area oscillations. This paper determines how a previously proposed inter-area damping controller mitigates forced oscillations. The damping controller modulates active power on the Pacific DC Intertie (PDCI) based on phasor measurement units (PMU) frequency measurements. The primary goal of the controller is to improve the small signal stability of the north south B mode in the North American Western Interconnection (WI). The paper presents small signal stability analysis in a reduced order system, time-domain simulations of a detailed representation of the WI and actual system test results to demonstrate that the PDCI damping controller provides effective damping to forced oscillations in the frequency range below 1 Hz.

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The U.S. Navy is investing in the development of new technologies that broaden warship capabilities and maintain U.S. naval superiority. Specifically, Naval Sea Systems Command (NAVSEA) is supporting the development of power systems technologies that enable the Navy to realise an all-electric warship. A challenge to fielding an all-electric power system architecture includes minimising the size of energy storage systems (ESS) while maintaining the response times necessary to support potential pulsed loads. This work explores the trade-off between energy storage size requirements (i.e. mass) and performance (i.e. peak power, energy storage, and control bandwidth) in the context of a power system architecture that meets the needs of the U.S. Navy. In this work, the simulated time domain responses of a representative power system were evaluated under different loading conditions and control parameters, and the results were considered in conjunction with sizing constraints of and estimated specific power and energy densities of various storage technologies. The simulation scenarios were based on representative operational vignettes, and a Ragone plot was used to illustrate the intersection of potential energy storage sizing with the energy and power density requirements of the system. Furthermore, the energy storage control bandwidth requirements were evaluated by simulation for different loading scenarios. Two approaches were taken to design an ESS: one based only on time domain power and energy requirements from simulation and another based on bandwidth (specific frequency) limitations of various technologies.

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This paper describes the design and implementation of a proof-of-concept Pacific dc Intertie (PDCI) wide area damping controller and includes system test results on the North American Western Interconnection (WI). To damp inter-area oscillations, the controller modulates the power transfer of the PDCI, a ±500 kV dc transmission line in the WI. The control system utilizes real-time phasor measurement unit (PMU) feedback to construct a commanded power signal which is added to the scheduled power flow for the PDCI. After years of design, simulations, and development, this controller has been implemented in hardware and successfully tested in both open and closed-loop operation. The most important design specifications were safe, reliable performance, no degradation of any system modes in any circumstances, and improve damping to the controllable modes in the WI. The main finding is that the controller adds significant damping to the modes of the WI and does not adversely affect the system response in any of the test cases. The primary contribution of this paper, to the state of the art research, is the design methods and test results of the first North American real-time control system that uses wide area PMU feedback.

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The purpose of the International Technology Roadmap for Wide-Bandgap Power Semiconductors (ITRW) Materials and Devices Working Group, which considers the materials science of Wide-and Ultra-Wide-Band-Gap (WBG and UWBG) semiconductors, in addition to device design, fabrication, and evaluation, is to formulate a long-term, international roadmap for WBG and UWBG materials and devices, consistent with the packaging and applications working groups of ITRW. The working group is co-chaired by Victor Veliadis (primarily representing silicon carbide (SiC) and related materials) and Robert Kaplar (primarily representing gallium nitride (GaN) and related materials, as well as emerging ultra-WBGs) and is split into four sub-working-groups, which are: 1) SiC materials and devices (co-chairs Jon Zhang and Mietek Bakowski). 2) Lateral GaN materials and devices (co-chairs Sameh Khalil and Peter Moens). 3) Vertical GaN materials and devices (co-chairs TBD). 4) Emerging UWBG materials and devices (co-chairs Mark Hollis). The first two subgroups represent technology that is far more mature than that of the latter two, and devices are available as commercial products in power applications. The primary focus of this article will be on developments in subgroups 1 and 2, with only brief descriptions of the latter two sub-groups, including future activities as they mature technologically.

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This report presents a complete listing, as of May 2019, of the damping controller (DCON) project accomplishments including a project overview, project innovations, awards, patent application, journal papers, conference papers, project reports, and project presentations. The purpose of the DCON is to mitigate inter-area oscillations in the WI by active improvement of oscillatory mode damping using phasor measurement unit (PMU) feedback to modulate power flow in the PDCI. The DCON project is the result of a collaboration between Sandia National Laboratories (SNL), Montana Technological University (MTU), Bonneville Power Administration (BPA), and the Department of Energy Office of Electricity (DOE-OE).

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This project is part of a multi-lab consortium that leverages U.S. research expertise and facilities at national labs and universities to significantly advance electric drive power density and reliability, while simultaneously reducing cost. The final objective of the consortium is to develop a 100 kW traction drive system that achieves 33 kW/L, has an operational life of 300,000 miles, and a cost of less than $\$6$/kW. One element of the system is a 100 kW inverter with a power density of 100 kW/L and a cost of $\$2.7$/kW. New materials such as widebandgap semiconductors, soft magnetic materials, and ceramic dielectrics, integrated using multi-objective cooptimization design techniques, will be utilized to achieve these program goals. This project focuses on a subset of the power electronics work within the consortium, specifically the design, fabrication, and evaluation of vertical GaN power devices suitable for automotive applications.

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This paper presents simulation results of a control scheme for damping inter-area oscillations using high-voltage DC (HVDC) power modulation. The control system utilizes realtime synchrophasor feedback to construct a supplemental commanded power signal for the Pacific DC Intertie (PDCI) in the North American Western Interconnection (WI). A prototype of this controller has been implemented in hardware and, after multiple years of development, successfully tested in both open and closed-loop operation. This paper presents simulation results of the WI during multiple severe contingencies with the damping controller in both open and closed-loop. The primary results are that the controller adds significant damping to the controllable modes of the WI and that it does not adversely affect the system response in any of the simulated cases. Furthermore, the simulations show that a feedback signal composed of the frequency difference between points of measurement near the Washington-Oregon border and the California-Oregon border can be employed with similar results to a feedback signal constructed from measurements taken near the Washington-Oregon border and southern California. This is an important consideration because it allowed the control system to be designed without relying upon cross-system measurements, which would have introduced significant additional delay.

Distributed control compensation based on local and remote sensor feedback can improve small-signal stability in large distributed systems, such as electric power systems. Long distance remote measurements, however, are potentially subject to relatively long and uncertain network latencies. In this work, the issue of asymmetrical network latencies is considered for an active damping application in a two-area electric power system. The combined effects of latency and gain are evaluated in time domain simulation and in analysis using root-locus and the maximum singular value of the input sensitivity function. The results aid in quantifying the effects of network latencies and gain on system stability and disturbance rejection.

Distributed control compensation based on local and remote sensor feedback can improve small-signal stability in large distributed systems, such as electric power systems. Long distance remote measurements, however, are potentially subject to relatively long and uncertain network latencies. In this work, the issue of asymmetrical network latencies is considered for an active damping application in a two-area electric power system. The combined effects of latency and gain are evaluated in time domain simulation and in analysis using root-locus and the maximum singular value of the input sensitivity function. The results aid in quantifying the effects of network latencies and gain on system stability and disturbance rejection.

Lightly damped electromechanical oscillations are a source of concern in the western interconnect. Recent development of a reliable real-time wide-area measurement system (WaMS) has enabled the potential for large-scale damping control approaches for stabilizing critical oscillation modes. a recent research project has focused on the development of a prototype feedback modulation controller for the Pacific DC Intertie (PDCI) aimed at stabilizing such modes. The damping controller utilizes real-time WaMS signals to form a modulation command for the DC power on the PDCI. This paper summarizes results from the first actual-system closed-loop tests. Results demonstrate desirable performance and improved modal damping consistent with previous model studies.

This letter presents a new frequency control strategy that takes advantage of communications and fast responding resources such as photovoltaic generation, energy storage, wind generation, and demand response, termed collectively as converter interfaced generators (CIGs). The proposed approach uses an active monitoring of power imbalances to rapidly redispatch CIGs. This approach differs from previously proposed frequency control schemes in that it employs feed-forward control based on a measured power imbalance rather than relying on a frequency measurement. Time-domain simulations of the full Western Electricity Coordinating Council system are conducted to demonstrate the effectiveness of the proposed method, showing improved performance.

Many candidate power system architectures are being evaluated for the Navy’s next generation all-electric warship. One proposed power system concept involves the use of dual-wound generators to power both the Port and Starboard side buses using different 3-phase sets from the same machine (Doerry, 2015). This offers the benefit of improved efficiency through reduced engine light-loading and improved dispatch flexibility, but the approach couples the two busses through a common generator, making one bus vulnerable to faults and other dynamic events on the other bus. Thus, understanding the dynamics of cross-bus coupling is imperative to the successful implementation of a dual-wound generator system. In (Rashkin, 2017), a kilowatt-scale system was analysed that considered the use of a dual-wound permanent magnet machine, two passive rectifiers, and two DC buses with resistive loads. For this system, dc voltage variation on one bus was evaluated in the time domain as a function of load changes on the other bus. Therein, substantive cross-bus coupling was demonstrated in simulation and hardware experiments. The voltage disturbances were attributed to electromechanical (i.e. speed disturbances) as well as electromagnetic coupling mechanisms. In this work, a 25 MVA dual-wound generator was considered, and active rectifier models were implemented in Matlab both using average value modelling and switching (space vector modulation) simulation models. The frequency dynamics of the system between the load on one side and the dc voltage on the other side was studied. The coupling is depicted in the frequency domain as a transfer function with amplitude and phase and is shown to have distinct characteristics (i.e. frequency regimes) associated with physical coupling mechanisms such as electromechanical and electromagnetic coupling as well as response characteristics associated with control action by the active rectifiers. In addition, based on requirements outlined in draft Military Standard 1399-MVDC, an approach to derive specifications will be discussed and presented. This method will aid in quantifying the allowable coupling of energy from one bus to another in various frequency regimes as a function of other power system parameters. Finally, design and control strategies will be discussed to mitigate cross-bus coupling. The findings of this work will inform the design, control, and operation of future naval warship power systems.

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A system is presented that is capable of measuring subnanosecond reverse recovery times of diodes in wide-bandgap materials over a wide range of forward biases (0 - 1 A) and reverse voltages (0 - 10 kV). The system utilizes the step recovery technique and comprises a cable pulser based on a silicon (Si) Photoconductive Semiconductor Switch (PCSS) triggered with an Ultrashort Pulse Laser, a pulse charging circuit, a diode biasing circuit, and resistive and capacitive voltage monitors. The PCSS-based cable pulser transmits a 130 ps rise time pulse down a transmission line to a capacitively coupled diode, which acts as the terminating element of the transmission line. The temporal nature of the pulse reflected by the diode provides the reverse recovery characteristics of the diode, measured with a high bandwidth capacitive probe integrated into the cable pulser. This system was used to measure the reverse recovery times (including the creation and charging of the depletion region) for two Avogy gallium nitride diodes; the initial reverse recovery time was found to be 4 ns and varied minimally over reverse biases of 50-100 V and forward current of 1-100 mA.

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Demand for enhanced cooling technologies within various commercial and consumer applications has increased in recent decades due to electronic devices becoming more energy dense. This study demonstrates jumping-droplet based electric-field-enhanced (EFE) condensation as a potential method to achieve active hot spot cooling in electronic devices. To test the viability of EFE condensation, we developed an experimental setup to remove heat via droplet evaporation from single and multiple high power gallium nitride (GaN) transistors acting as local hot spots (4.6 mm x 2.6 mm). An externally powered circuit was developed to direct jumping droplets from a copper oxide (CuO) nanostructured superhydrophobic surface to the transistor hot spots by applying electric fields between the condensing surface and the transistor. Heat transfer measurements were performed in ambient air (22-25°C air temperature, 20-45% relative humidity) to determine the effects of gap spacing (2-4 mm), electric field (50-250 V/cm), and heat flux (demonstrated to 13 W/cm²). EFE condensation was shown to enhance the heat transfer from the local hot spot by ≈ 200% compared to cooling without jumping and by 20% compared to non-EFE jumping. Dynamic switching of the electric field for a two-GaN system reveals the potential for active cooling of mobile hot spots. The opportunity for further cooling enhancement by the removal of non-condensable gases promises hot spot heat dissipation rates approaching 120 W/cm². This work provides a framework for the development of active jumping droplet based vapor chambers and heat pipes capable of spatial and temporal thermal dissipation control.

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