[신간의 별자리x] 우리/미술, 그리고 ‘슬픔의 박물관’

While 10-kV silicon-carbide (SiC) MOSFETs are gradually penetrating medium-voltage (MV) applications, intertwined challenges concerning high-voltage insulation, high ${dv}/{dt}$ , protections, and thermal management are simultaneously imposed to MV converters. For the modular multilevel converter, a systematical power cell design and assessment methodology (DAM) to tackle the unprecedented challenge synergy is essential and, yet, absent. Thereby, this article aims to develop a DAM based on a high-current 10-kV SiC MOSFET half-bridge module. An overall introduction of the power cell and a hierarchical DAM workflow is first presented, followed by the comprehensive component-level DAM with details on design challenges, solutions, assessment instruments, procedures, and test results. Subsequently, the DAM is expanded to the power cell level by exploring its safe operating area associated with switching frequency, power-processing capability, and temperature limit in various operation modes, which, in turn, validates the component designs and determines if they need iterations. Following the methodology, the power cell design is finalized, capable of continuous operation under 6 kV, 84-A rms, and 10 kHz, exhibiting 99.3% efficiency and transient immunity up to 100 V/ns.

Power Cell Design and Assessment Methodology Based on a High-Current 10-kV SiC MOSFET Half-Bridge Module

Simultaneously imposed challenges of high-voltage insulation, high <tex xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">$\mathrm{d}v/\mathrm{d}t$</tex> , high-switching frequency, fast protection, and thermal management associated with the adoption of 10 kV SiC MOSFET, often pose nearly insurmountable barriers to potential users, undoubtedly hindering their penetration in medium-voltage (MV) power conversion. Key novel technologies such as enhanced gate-driver, auxiliary power supply network, PCB planar dc-bus, and high-density inductor are presented, enabling the SiC-based designs in modular MV converters, overcoming aforementioned challenges. However, purely substituting SiC design instead of Si-based ones in modular MV converters, would expectedly yield only limited gains. Therefore, to further elevate SiC-based designs, novel high-bandwidth control strategies such as switching-cycle control (SCC) and integrated capacitor-blocked transistor (ICBT), as well as high-performance/high-bandwidth communication network are developed. All these technologies combined, overcome barriers posed by state-of-the-art Si designs and unlock system level benefits such as very high power density, high-efficiency, fast dynamic response, unrestricted line frequency operation, and improved power quality, all demonstrated throughout this paper. 

/pdf/design-of-a-10-kv-sic-mosfet-based-high-density-high-26zb3990.pdf

Design of a 10 kV SiC MOSFET-based high-density, high-efficiency, modular medium-voltage power converter

Silicon-carbide (SiC) devices are receiving popularity for high-power converter systems in aircraft due to many advantages over silicon counterparts. However, the electromagnetic interference (EMI) problems are more serious with the SiC devices operating at higher switching speeds and higher switching frequencies. The common-mode (CM) EMI filter design of the high-power SiC converter is especially challenging for high-altitude applications due to the harsher requirements of insulation and heat dissipation. The optimization of the parameters and physical design of a CM EMI filter in a 100-kW SiC inverter/rectifier system operating at 50 000 ft is conducted in this article to obtain the highest power density. The effect of the switching frequency on the EMI filter volume and the total power density of the converter system is analyzed. The lower breakdown voltage of air and the higher thermal resistance of natural convection make the conventional design of the CM choke infeasible at high altitudes. A printed circuit board (PCB)-based planar CM choke is designed with the consideration of partial discharge (PD) and heat dissipation at the altitude of 50 000 ft. The structure of the CM choke is optimized with embedded electric-field shielding plates, which controls the electric-field intensity in the air below 300 V/mm. The PCB windings improve the efficiency of heat dissipation at high altitudes and reduce the profile of the CM choke. A Pareto optimization is conducted to minimize the size of the choke and the volume of the final design is only 155 cm3. The experimental results show that the CM noise is reduced effectively with the CM EMI filter. PD is not observed even at the altitude of 50 000 ft and the thermal performance is excellent with a current of 190 A. With the optimization and the dedicated design of the CM EMI filter, the power density of the converter system is up to 33.3 kW/L. 

Planar Common-Mode EMI Filter Design and Optimization for High-Altitude 100-kW SiC Inverter/Rectifier System

A Solid-state transformer (SST) can directly convert medium voltage to low voltage (e.g. 400 V) with minimized power-conversion stages. The transformer in the DC-DC module not only provides medium voltage insulation but also significantly affects the power density of the module. In this paper, an innovative compact transformer structure is proposed to handle medium voltage insulation using an insulation coordination with epoxy, bobbin, shielding layer and stress-control layer. A brand-new bobbin design and related fabrication process ensures a partial-discharge-free insulation. Besides traditional core loss and winding loss, high-frequency related core loss and shielding loss is modeled in detail for an accurate loss evaluation. A simple and comprehensive multi-parameter, multi-objective optimization process is proposed to achieve the size and loss trade-off. The transformer prototype passes the related insulation tests, following the standard IEEE Std. C57.12.01. Finally, the design is demonstrated on a 15 kW, 200 kHz CLLC converter with 98.9% peak efficiency and 3.8 kW/L power density. 

High-Frequency Transformer Design with Medium-Voltage Insulation for Resonant Converter in Solid-State Transformer

This paper presents the design and optimization of a single-turn magnetic-core inductor for a 6kV, 40Hz power electronics building block (PEBB) using 10kV SiC MOSFET modules The inductor design begins with a comprehensive comparison between air-core, single-turn and multi-turn magnetic core structures, and the single-turn magnetic core structure is concluded to be the most suitable solution for the given specifications The design process is then followed by an optimization of geometric dimensions and magnetics by a trade-off among power loss, volume, and parasitic capacitance To achieve high compactness by minimizing the electric field stress in the air, a grounded shielding layer is applied to surround the winding, and the high-electric-field space is filled with void-free solid insulators Major issues resulting from the shielded winding structure include extra loss on the shield, concentrated electric field at fringes, and induced grounding current These problems have been addressed by shield conductivity selection, a proposed field-grading termination, and a well-designed damping circuit, respectively Finally, the fabrication process of a prototype and the experimental performance are demonstrated

A High-Density Single-Turn Inductor for a 6 kV SiC-based Power Electronics Building Block

This paper details the design and implementation of a power hardware-in-the-loop (PHIL) electric machine emulator for the purpose of induction motor drive testing. The biggest advantage of PHIL over traditional motor drive testbenches is its flexibility to serve as a test bench for a variety of electric machines without any hardware changes, thereby reducing the testbench hardware overhead. The topology and the capabilities of EGSTON Power Electronics’ CSU PHIL platform to emulate the electrical machines are presented. Additionally, the practical implementation of the PHIL testbench is discussed, including the interface inductor and the measurement setup. The tradeoffs between current-source and voltage-source based emulation of electric machines are presented. This work considers current-source based emulation because the current emulation fidelity is independent of the interface inductor value which makes this approach very flexible. Finally, the emulation results are presented and compared experimentally with a physical machine.

Design and Evaluation of a Power Hardware-in-the-Loop Machine Emulator

As the aerospace industry moves towards the More Electric Aircraft (MEA), there is a growing need to model the increasingly complex electrical systems Real-time modeling and simulation allows standalone simulations to be completed much faster than traditional simulation methods, and allows for Power Hardware-in-the-Loop (P-HIL) emulation and testing The P-HIL testbench demonstrated in this paper can be run back-to-back where both the source and the load are emulated systems with real power transferred between them This paper demonstrates the development and execution of machine and power converter emulation on the EGSTON Power Electronics' COMPISO System Unit CSU200-1GAMP6 P-HIL platform The advantages and capabilities of P-HIL for the MEA are presented in this paper

A Power Hardware-in-the-Loop Testbench for Aerospace Applications

As aerospace industries are progressing towards the More Electric Aircraft (MEA) concept, the need for complex electrical system testing is urgently increasing. Power Hardware-in-the-Loop (PHIL) allows for a variety of electrical system tests without changing hardware, thereby reducing the development time and cost, enabling concurrent development and fault modes testing. In this paper, the development of a PHIL emulator testbench using EGSTON Power Electronics COMPISO System Unit CSU200-1GAMP6 and external motor drive inverter is explained and challenges in the implementation are evaluated. An 18-pulse autotransformer rectifier unit (ATRU), a three-phase active front end (AFE), and an induction machine were emulated and evaluated. Furthermore, the induction machine was emulated under several operation scenarios and compared to tests with the same motor drive and an actual induction machine, showing excellent steady-state and transient emulation capabilities.

Development and Evaluation of a Power Hardware-in-the-Loop (PHIL) Emulator Testbench for Aerospace Applications

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