power conditioning research at arl adelphipearton.mse.ufl.edu/mwe_init_rev/epri99.pdf · power...
TRANSCRIPT
Power Conditioning Research at ARL Adelphi
T.F. Podlesak
A.G. Stewart
Presented at the DARPA/EPRI Megawatt Review
Monterey, CA
12-13 January 1999Approved for Public Release: Distribution is Unlimited
Outline
• Overall Power Conditioning Program Plan
• Matrix Converter Vehicle Program – Needs
– Current Technology Shortfalls
– Proposed Solutions and Objectives
– Teaming
• Facility Update
• Large Semiconductor Research
Compact Power
ConditioningAC - DC - Pulsed
Compact Power
ConditioningAC - DC - Pulsed
FutureCombat Systems
Technology Base R&D Enabled Technology System Applications
98 99 00 01 02 03 04 05 06 -25
CERDEC
ARDEC
MICOMHard SwitchingHard Switching
Soft SwitchingSoft Switching
Mobile Electric Power
High-Power Radars
Hybrid SwitchingHybrid Switching
Algorithm Development
High-Energy Conv.High-Energy Conv.
Circuit TopologiesCircuit Topologies
High-Temp. Conv.High-Temp. Conv.
Matrix Converters
PEBB SwitchesPEBB Switches
High Voltage Dev.High Voltage Dev.
Wide Bandgap Dev.Wide Bandgap Dev.
Switch Technology
Large Area DevicesLarge Area Devices
RF / DEW
UAVs, Robotic Systems
Hybrid Electric Vehicles
FSV FCS
Reactive Armor
EML / ETC Gun
Smart Munitions
AAN
TARDEC
ARL Power Conditioning Roadmap
ARL Power Conditioning Program Architecture
Mission Tech-Base Program
High-risk, generic, enabling technology
Laboratory demonstrations: IGBTs(10-100 kW matrix converter) MCTs
PEBBs
Partnering with Academia:Visiting Scholars - Nottingham University
Wide bandgap program liaison: TPAsFOCsSTOs
Customer Programs
FOCUS : Matrix Converter Applicationsand Integration
FOCUS : Matrix Converter Technology R&D
DARPA / TARDECElectric Vehicle Programs
Industry & Academia Partnering Projects
FOCUS : Device Characterization/Design Development
• Novel Switch R&D • Training Opportunities• Simulation and Modeling • Marketing Support
Foreign Technology• IGBT/IGCT Switches• Fast Dynistor Switch• Fast Turn-on Thyristor
IAT EM Gun
Parallel 125-mmThyristor Evaluation
BRAC
High-power Dyna-mometer Controller
A
C
B
Application of matrix converter to electric vehicle drive
• PEBB• M113 & HMMWV test beds
Joint program by Rockwell, ARL, Nottingham University, Berkeley Research Associates, and SPCO
Army ResearchLaboratory
• Highly Compact, high power converters are a critical part of electric propulsion and on-board power generation systems for Electric Combat Vehicles (ECV)
• Size reduction paramount for ECV - interior space under armor at high premium• ECV electric propulsion drives (and over 45% of other applications) require truly
inherent line regeneration capability for braking and steering• Overall system operates in a harsh environment at elevated temperatures
Critical Need for High Power Density Converters
• Electric actuation systems for MEA• HPD power converters for EHA, PGS• Low weight, compact motor drives• High temperature electronics
Dual needs for MEA & MES
All-Electric D rive Train• H ig her en gine efficien cy• Increased ran ge• Im proved log istics
Active Su spension
EM / ETC Gu n• Increased ran ge/lethal ity• D eeper m ag azine
Active A rm o r• R edu ced weigh t• Increased protectio n
DEW A pp licatio ns• H ig h/m edium pow er laser• H ig h po w er m icr ow ave
Ad vanced Senso rs• N arrow/wid eband EM• N BC• T herm al/ IR
Co un term easu res
P ower Elec tron ics A pp lica tio ns for Arm y M iss ion s
• All previously proposed converters for ECVs are DC link type large reactive filter components
• C and L are largest components; produce heat, but not real power– Electrolytic caps have shortest lifetime and limited temperature range
Not suitable for harsh environment, high temperature operation– Poor braking capability due to low performance, bulky & heavy
regeneration system – Premature failures of motor winding and device caused by hard-
switching and high dv/dt stresses – Poor PF, harmonics negatively impact fuel efficiency & on-board pwr– High EMI and switching losses
• Added large volume, weight by low frequency excitation (60 Hz) of motor system and conventional cooling
• Overall volume, weight, lifetime and perf unacceptable for future DoD sys
Current Technology Shortfalls
• Highly compact, low weight, high power matrix converters
• 400 Hz motor and 4-quadrant HF drive system with variable frequency input.
• New cooling technology
Proposed Technology Solutions
Power conditioning and propulsion systemfor future combat vehicles and tanks
High Speed
Generator
High
FrequencyGenerator
Propulsion
Weapon
High VAC
480/277 VAC
28 VDC
e.g. 270 VDC
Hf
Xfmr
MatrixConverter
MatrixConverter
MatrixConverter
MatrixConverter
MatrixConverter
Suspension
Actuation
Protection
Vetronics
NBC
Loader
Automotive
Active Armor
Main Armament
Active Suspension
Advanced SensorsDEW Applications
Countermeasures
Electric Drive
• Highly compact and low weight matrix converters– Eliminate large reactive elements– Eliminates bulky & heavy front-end rectifiers by inherent
regeneration – Eliminate temperature sensitive electrolytic components, elevate
operating temperature, extend system lifetime – 60-75% reduction in volume – 50% weight reduction– Much improved braking and steering– Improve fuel efficiency, clean power, low EMI
• 400 Hz motor & drive system further reduces size and weight• New cooling technology
– Using available vehicle fluid (engine cooling water, lubricatingoil or fuel) eliminates bulky dedicated cooling system.
Proposed Technology Solutions
Program Objectives• Develop revolutionary AC-AC power converter that is highly-
compact, low-weight, and modular for DoD systems
– Achieve 60-75% volume reduction
– Achieve 50% weight reduction
– Improve regeneration for braking, steering
– Increase operating temperature range
• 200-225ºC (electronics controller)
• 90-100°C (motor and power).
– Extend the system lifetime
• Demonstrate AC-AC converter for high power regulation, power conditioning and motor control (5, 25, 100, 150 HP) on a HMMWV and an M-113 vehicle
• Experimentally verify performance of AC-AC converter for HMMWV and M-113 vehicle missions.
Management PlanRockwell Team:• Rockwell Science Center • Collins Avionics & Communications • Oak Ridge National Laboratory• Boeing North American.
ARL Team:• Army Research Laboratory• Nottingham University• Berkeley Research Associates, Inc.
• SPCO
C onsu ltan t: D ave B land ing(B oe ing)
(B N A )
C onsu ltan ts :D enn is B raun,B ruce Be iho ff,
P erry D e lVecch io(R ockw e ll Au tom ation)
D r. H seuh-R ong C hang,D r. C .L . C hen
(R S C )
C onsu ltan ts :D r. Je ff G o lden,
Jerry F rank, R obert M organ(B erke ley R esearch
A ssoc ia tes)
D r. Jon C lare ,D r. P a t W hee ler,
D r. M . S um ner, P ost D oc (T BN )(N ottingham U nv ie rs ity )
S ubcon trac to rs :John D risco ll (PT S C o .),
D r. B ill N unna lly (U n iv . M issouri-C o lum b ia),D ick B oothe (V A Pow er T ech. S ystem s)
C onsu ltan t:D r. F ang Peng
(O ak R idge N a tiona lLabora tiry , D O E )
D an M itche ll(C A C D ),
D r. J ian S un(R ockw e ll)
S teve C h iu ,C harles N eft,R ichard Tan,
C . W in te rha lte r(R S C )
D r. E d S canne l(A R L)
D r. S u jee t C hand(R S C )
A lex S tew artA R L Team Leade r
D r. J ie C hangR S C Team Leader &P rinc ipa l Investiga to r
D r. T om Pod lesakP rinc ipa l Investiga to r
(sys tem )
D r. R .A . K ehs,K laus K erris ,
E ric T u ttle(A R L)
AC-AC Power Converter Design
Snubber
a
b
c
M
On-board VVVFpower
generatione
a
eb
ec
G
High
speed
engine
4-quadrant high
performancepropulsion drive
Modular
integrated phasebank circuit
Modular high power AC-AC converter (100Hp) and 400Hz electric drive system
New Electric Drive System
125 mm Involute Data10 milliohm PFN (21mF) into 1.45 milliohm load
Rep Rate Data
Charging Voltage
500 V/division
Charge Current
100 A/division
20 second/division