Engineering Papers⌕ Search

Engineering topics

Gao, Zihan

Publications and source records attributed to Gao, Zihan.

15 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

SiC Based Modular Transformer-less MW-Scale Power Conditioning System and Control for Flexible CHP System

This project aims at developing a SiC-based, modular, transformer-less (60-Hz-transformers-free), MW-scale, four-wire DC/AC power conditioning system (PCS) converter, and a corresponding control system for flexible-CHP (F-CHP) systems. With the help of an F-CHP controller and power electronics converters, different CHP sources, renewable sources, and batteries can be assembled to the DC grid, which is then connected to the medium voltage (MV) AC grid through the PCS converter. To meet grid support and performance requirements, the F-CHP controller design and PCS converter design follow IEEE 1547 and IEEE 2030.7 standards. Five main tasks, including PCS converter design, F-CHP controller development, PCS converter prototype building and testing, F-CHP controller testing, and PCS paralleling, have been carried out. In this project, the F-CHP controller testing has been completed in simulation, HIL and HTB, and the PCS converter prototypes have been successfully built and tested.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Design and Demonstration of an 850 V dc to 13.8 kV ac 100 kW Three-phase Four-wire Power Conditioning System Converter Using 10 kV SiC MOSFETs

In this paper, an 850 V dc to 13.8 kV ac 100 kW modular multilevel three-phase four-wire dc/ac converter based on 10 kV SiC MOSFETs is designed and demonstrated. The design considerations of key components, including the dc-link, device cooling, gate driver, isolated gate driver power supply (GDPS), medium voltage (MV) ac filter inductor, MV and medium frequency transformer, and the mechanical design are discussed. Two converters are designed, and two prototypes are developed, to study the converter paralleling operation and scalability. Both converters are fully tested up to their voltage and power ratings. However, the two converters are not identical. Based on the design and test results of the first converter, the MV power stage, transformer design, GDPS, as well as the low voltage power stage in the second converter are improved for smaller size and/or higher efficiency. Compared to the version 1 converter, the version 2 converter achieves 49% volume reduction and 2 percentage point efficiency improvement, with a peak efficiency of 98.4% at the rated power.

Li, Haiguo↗
DOE OSTI2023

Medium-Voltage Isolated Auxiliary Power Supply Design for High Insulation Capability, Ultra-Low Coupling Capacitance, and Small Size

To fully utilize the benefits of medium-voltage (MV) silicon carbide (SiC)-based converter and achieve high power density, the isolated auxiliary power supply (IAPS) needs to be as small as possible. However, the high insulation and low coupling capacitance requirements, considering the high voltage and high dv / dt , are constraints of size reduction. This article proposes an MV IAPS design for high insulation capability, ultra-low coupling capacitance, and small size. The topology selection, efficiency, load regulation, coupling capacitance, and size reduction considerations are discussed. A 2.5 W MV IAPS is designed and built for a 10 kV SiC mosfet -based 13.8 kV/100 kW three-phase converter, achieving a partial discharge (PD) inception voltage of higher than 15 kV rms, ultra-low coupling capacitance of 1.03 pF, and smaller size than that of the commercial products as well as the state-of-art research prototypes. Experimental results of PD test, 10 kV SiC mosfet -based half-bridge test, and 13.8 kV/100 kVA three-phase converter full rating test are conducted for design validation.

42 ENGINEERING↗
DOE OSTI2022

A Flux Balancing Strategy for 10-kV SiC-Based Dual-Active-Bridge Converter

The transformer flux unbalance in dual-active-bridge (DAB) converters is a critical issue due to the electrical parameter and modulation mismatch, and load or control transients. Compared to low voltage DAB converters, the unbalance problem in medium voltage DAB converters may cause more severe problem, and become more difficult to deal with, because of the high operating voltage and insulation requirement. In this paper, a flux balancing strategy for a medium voltage (MV) DAB converter is proposed, including the transformer design with ferrite gap, current harmonic-based unbalance detection, as well as the flux balancing control scheme. With the proposed ferrite gap, nonlinear magnetizing current and its modeling are induced. Then, by analyzing the current harmonics, the flux unbalance level can be detected, and hence controlled. Test results have verified the proposed method in a MV DAB converter.

Gao, Zihan↗
DOE OSTI2022

A PWM Strategy for Cascaded H-bridges to Reduce the Loss Caused by Parasitic Capacitances of Medium Voltage Dual Active Bridge Transformers

In this paper, to reduce the power loss caused by the parasitic capacitances of medium voltage medium frequency transformers in a two-stage dc/ac converter, including a dual active bridge (DAB)-based dc/dc stage and a cascaded H-bridge (CHB)-based dc/ac stage, a PWM strategy is proposed for the dc/ac stage. For each H-bridge, by shifting the high switching frequency to one half-bridge and having the other half-bridge switching at the fundamental frequency of the ac voltage, equivalent frequencies of transformer terminal-to-ground voltages are reduced. As a result, the frequencies of charging and discharging current to the parasitic capacitance are reduced, and therefore the loss caused by the parasitic capacitances is reduced. Compared to the conventional phase-shift PWM, the proposed PWM strategy can reduce the parasitic capacitance loss by about 75%. Experimental test results of one phase in the 13.8 kV/ 100 kW converter prototype are provided to validate the approach.

Li, Haiguo↗
DOE OSTI2022

Improved Double Pulse Test for Accurate Dynamic Characterization of Medium Voltage SiC Devices

This article presents an improved double pulse test (DPT) for accurate dynamic characterization of the medium voltage (MV) silicon carbide device. The difference between low voltage (LV) and MV DPT setup grounding is first introduced, which results in different measurement considerations. Then, parasitic capacitances in the DPT and their impact on the DPT are discussed considering different grounding points and device connections. Approaches are proposed to minimize the impact of parasitic capacitances on DPT results. In addition, the impact of switching V-I timing alignment on the testing results is discussed, compared to that in the LV DPT; a V-I alignment approach is introduced for the MV DPT. A 10 kV/20 A SiC mosfet -based DPT is taken as an example of the improved DPT, and test results show that it can minimize the impact from parasitic and improve the accuracy of the device switching loss estimation.

42 ENGINEERING↗
DOE OSTI2022

A Medium Voltage Testbed for the Performance and Function Tests of a 13.8 kV Power Conditioning System Converter

Medium voltage SiC devices facilitate the development of medium voltage grid-connected power electronics converters. However, it is difficult to test these converters directly on the real medium voltage grid, especially considering abnormal grid conditions, such as grid voltage and frequency variation, and different converter operation modes, such as grid-connected mode and islanded mode. This paper introduces the design and implementation of a medium voltage testbed, which supports tests of medium voltage converters in both grid-connected and islanded mode tests. In the grid-connected mode, the testbed can provide up to 13.8 kV grid voltage, can support the four-quadrant operation, and can emulate different grid conditions, such as voltage and frequency variation. In the islanded mode, the converter under test works as a voltage source and the testbed emulates a three-phase balanced or unbalanced load. Experiment test results are provided to validate the design and capability of the testbed.

Li, Haiguo↗
DOE OSTI2022

An Inrush Current Limiting Method for Grid-Connected Converters Considering Grid Voltage Disturbances

To support the electric power grid, some grid-connected converters are required to ride through abnormal grid conditions, including voltage disturbances. However, at the moment, when a grid voltage disturbance happens, a large inrush current could be induced due to the large difference between the grid and converter output pulsewidth modulation (PWM) voltages. This inrush current could be more severe in the faster switching SiC-based multilevel converter, which only needs a small filter inductance to meet its normal operation requirements, such as harmonics and peak ripple currents. In this article, a PWM mask method is used to limit the inrush current. With this method, the inrush current can be effectively limited to a preset value and can help the converter ride through grid voltage disturbances. Furthermore, the method is validated through experiments conducted on a single-phase SiC-based five-level converter considering low voltage, high voltage, and phase angle disturbances.

42 ENGINEERING↗
DOE OSTI2021

Medium Voltage Converter Inductor Insulation Design Considering Grid Requirements

Medium voltage (MV) SiC devices facilitate direct (without 50-/60-Hz transformer) connection of the power electronics converter to the MV grid using simple topology. Compared to the insulation design of MV inductors that have been widely used in the power system, the insulation design of the MV converter filter inductors has new challenges. Particularly, the grid impact on insulation requirements on converter filter inductors is rarely discussed. This article introduces the insulation design of a grid-side filter inductor for a 13.8-kV power conditioning system converter. The grid insulation requirements, including the short-duration power frequency overvoltage and the lightning impulse voltage, are considered in the design. To meet the requirements, the layer-to-layer insulation, winding-to-core/ground insulation, the air gap discharge between the winding and the core, the local electric field, as well as the interturn transient voltage distribution are considered. Furthermore, the designed inductors are validated by the 46 kV (>1 min) dc hi-pot test, 12-kV ac partial discharge test, one-hour single-phase converter full rating test, as well as three-phase converter full rating test.

42 ENGINEERING↗
DOE OSTI2021

Development of a Power Electronics-based Testbed for a Flexible Combined Heat and Power System

A flexible combined heat and power (F-CHP) concept, enabled by a power electronics-based power conditioning system (PCS), has been recently proposed as a cost-effective way for supporting the grid with high penetration of renewable energy sources. To verify the design, control, and performance of the overall system, a laboratory-scale testbed is essential. This paper focuses on the development of a power electronics-based testbed for such a F-CHP system. The developed testbed can test the control, grid-connected mode operation, islanded mode operation, and mode transitions, including planned/unplanned islanding and reconnection, of the F-CHP system. In the grid-connected mode, both the steady state and transients of the ac grid can be emulated, and various grid support functions can be tested with the help of the developed PCS converter. In the islanded mode, the external ac loads can also be supported by the F-CHP system. Also, the central controller, which is implemented in a NI CompactRIO, can be tested. Experimental test results for the grid-connected mode, islanded mode, and mode transitions are provided to validate the testbed design.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Medium Voltage Converter Inductor Insulation Design Considering Grid Insulation Requirements

Medium voltage SiC devices facilitate direct (without 50/60 Hz transformer) connection of the power electronics converter to the medium voltage grid using simple topology. Compared to the insulation design of medium voltage inductors that have been widely used in the power system, the insulation design of directly connected medium voltage converter filter inductors has more challenges. Although some works has been done discussing that, the grid insulation requirements on converter filter inductors are rarely discussed. This paper introduces the insulation design of a grid-side filter inductor for a 13.8 kV power conditioning system converter. The grid insulation requirements, including the short-duration power frequency overvoltage and the lightning impulse voltage, are considered in the design. To meet the requirements, the layer-to-layer insulation, winding-to-core/ground insulation, the air gap discharge between the winding and the core, as well as the local electrical field have been taken into consideration. Experimental tests are provided to validate the design.

Li, Haiguo↗
DOE OSTI2021

An Inrush Current Limit Method for SiC-based Multi-level Grid-connected Converter During Low-Voltage Ride-Through

Low-voltage ride-through is one of the grid requirements for grid-connected converters, and during the transient of grid voltage change, a large inrush current could be induced due to the control delay of the converter. This inrush current is more severe in SiC-based multi-level converters due to the small filter inductance, which is selected based on harmonics consideration. In this paper, a PWM mask method is used to limit the inrush current of a cascaded H-bridge-based grid-connected converter during the transient of grid voltage change. Simulation and experiment results are provided to validate this method.

Li, Haiguo↗
DOE OSTI2021

A Transformer Flux Balancing Scheme Based on Magnetizing Current Harmonic in Dual-Active-Bridge Converters

The Dual-Active-Bridge (DAB) converter transformer flux unbalance, or dc bias, could be a critical issue due to the mismatches of converter circuit parameters and control transients. In this paper, a steady-state flux balancing scheme, based on the second-order harmonic of magnetizing current has been proposed. The relationship between steady-state flux/magnetizing current unbalance and its harmonic contents has been analyzed, with which a new current sensing method and control strategy are introduced. The proposed magnetizing current sensing method can be implemented for both unity and complicated fractional turns ratios, without high sensitivity to dc offset from the analog circuitry. The proposed scheme has been validated with experimental results on 850-V/850-V DAB converters within a system, as well as in an 850-V/6700-V medium voltage DAB unit.

Gao, Zihan↗