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This presentation provides an overview of de-risking the field deployment of controller and power hardware technologies.
The share of renewable and distributed energy resources (DERs), like wind turbines, solar photovoltaics and grid-connected batteries, interconnected to the electric grid is rapidly increasing due to reduced costs, rising efficiency, and regulatory requirements aimed at incentivizing a lower-carbon electricity system. These distributed energy resources differ from traditional generation in many ways including the use of many smaller devices connected primarily (but not exclusively) to the distribution network, rather than few larger devices connected to the transmission network. DERs being installed today often include modern communication hardware like cellular modems and WiFi connectivity and, in addition, the inverters used to connect these resources to the grid are gaining increasingly complex capabilities, like providing voltage and frequency support or supporting microgrids. To perform these new functions safely, communications to the device and more complex controls are required. The distributed nature of DER devices combined with their network connectivity and complex controls interfaces present a larger potential attack surface for adversaries looking to create instability in power systems. To address this area of concern, the steps of a cyberattack on DERs have been studied, including the security of industrial protocols, the misuse of the DER interface, and the physical impacts. These different steps have not previously been tied together in practice and not specifically studied for grid-connected storage devices. In this work, we focus on grid-connected batteries. We explore the potential impacts of a cyberattack on a battery to power system stability, to the battery hardware, and on economics for various stakeholders. We then use real hardware to demonstrate end-to-end attack paths exist when security features are disabled or misconfigured. Our experimental focus is on control interface security and protocol security, with the initial assumption that an adversary has gained access to the network to which the device is connected. We provide real examples of the effectiveness of certain defenses. This work can be used to help utilities and other grid-connected battery owners and operators evaluate the severity of different threats and the effectiveness of defense strategies so they can effectively deploy and protect grid-connected storage devices.
Combining battery energy storage with distributed wind energy systems can increase production, ability to meet local electricity demands, interconnection capacity, and potential sales of surplus energy back to the grid, while reducing demand charges and the overall levelized cost of energy (LCOE). Energy storage options for distributed wind energy systems can vary widely in terms of power level and energy storage capacity, and their potential benefits depend on factors including wind resource, turbine design, connection requirements, use patterns, utility rates, and regulations. Windurance received a 2022 Competitiveness Improvement Project (CIP) funding award to add battery energy storage capabilities to the company's bidirectional DC converter. The energy storage component will complete a comprehensive portfolio of power conversion and control electronics that can be seamlessly integrated with distributed wind systems. The company received earlier CIP awards to fund prototype design and construction of wind turbine pitch actuators, inverters, and controllers.
The utility grid is constantly evolving with new generation sources and diverse loads from backup generators, backup batteries, rooftop photovoltaics (PV), and flexible charging loads. Each of these technologies presents consumers with an opportunity to work with their local utility to promote grid stability, reliability, and affordability. Through a wide range of programs, utilities are incentivizing the use of these resources to benefit the grid. However, especially for devices with inverters that supply power back to the grid, it is important that these assets comply with local grid codes to ensure human safety, power quality, and grid reliability. One of the most promising of these new technologies is the bidirectional electric vehicle (EV) coupled with bidirectional electric vehicle supply equipment (EVSE). This report introduces the technologies that enable bidirectional charging and how these systems operate. It then outlines the necessary interconnection codes and industry standards that govern the operations of grid-tied inverters, including those in bidirectional charging. A key challenge is then outlined from the complex landscape of communication protocols and proprietary systems designed to coordinate these grid assets. Finally, a single gateway solution is proposed to harmonize communications between all assets across an entire site for a cohesive response to grid codes and utility programs that is flexible enough to support a range of market options.
Battery energy storage systems (BESS) are increasingly important to meet the needs of grid resilience and reliability. BESS provide critical grid services, maintaining stability of the grid with increased variable conditions. However, there are significant geopolitical and security concerns regarding their operation in critical infrastructure, due to lack of a domestic supply chain and prevalence of foreign entity of concern (FEOC) components in BESS and associated inverter-based resources. The supply chain challenge is dually exacerbated by a lack of alternative suppliers who can meet the economic targets for energy delivery and a potentially adversarial supply chain. Solutions are needed to secure components, addressing mixed layers of risk and engineering controls. This paper presents a specific application of Cyber-Informed Engineering (CIE) principles for BESS and recommends an alternative strategy to blocking the supply chain, ensuring that grid modernization targets can be met despite lack of a validated or secure supply chain. This study focuses on the United State (U.S.) use case, but the process can be applied globally to address supply chain security challenges. CIE practices represent the next step in functional assurance and risk mitigation, ensuring optimal resource allocation and enhancing security measures to safeguard the future of energy in the U.S. and beyond.
In this paper, an automated controller for an integrated, reconfigurable dc-dc converter for plugin electric vehicles (EVs) is presented. The integrated converter combines both an interleaved boost converter and dual active bridge (DAB) converter, sharing magnetics and switching devices. The converter switches between operating modes using the existing battery management system (BMS) contactors. The integrated converter operates in isolated DAB mode during battery charging operation. During traction operation, the integrated converter is operated in interleaved boost mode for heavy load and DAB mode during light load, high voltage operation. An online transition algorithm is used to transition from interleaved boost mode to DAB mode with minimal bus distortion. The automated controller selects the operating mode and inverter bus voltage at different torque-speed conditions to get maximum overall traction drive efficiency. An experimental prototype of the integrated converter demonstrates the automated controller functionality.
The Power and Energy Storage Systems Toolbox (PSTess) is a MATLAB-based computing package for dynamic simulation and analysis of utility-scale battery storage systems. This codebase is a fork of the Power Systems Toolbox Version 3.0, developed at Rensselaer Polytechnic Institute (RPI) and Cherry Tree Scientific Software. While PSTess shares a common lineage with PST, it is a substantially different application. As the name implies, the main distinguishing characteristic of PSTess is its ability to model inverter-based energy storage systems (ESS). The model that enables this is called ess.m, and it serves the dual role of representing ESS operational constraints and the generator/converter interface. With PSTess, the generator/converter interface is modeled as a controllable current source with the ability to modulate both active and reactive current. The model ess.m permits four-quadrant modulation, which allows it to represent a wide variety of inverter-based resources beyond energy storage when paired with an appropriate supplemental control model. Examples include utility-scale photovoltaic (PV) power plants, type 4 wind plants, and static synchronous compensators (STATCOM). This capability is especially useful for modeling hybrid plants that combine energy storage with renewable resources. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525. SAND2021-8322 O
Significant investment is driving the essential modernization and digitization of U.S. energy infrastructure, but the United States faces a key challenge in this grid transformation: our renewable and clean energy supply chains have limited capacity to source necessary digital assets through U.S. or allied sources. Batteries and their associated power electronic interfaces are key components to delivering clean and more resilient energy delivery, providing much-needed fast ramping, emergency discharge, generation, and operations support to the electric grid. These services have grown to be invaluable over the past 10 years and will soon be an irreplaceable component of energy delivery. While there have been significant strides to move supply chains for raw and critical materials to U.S. and allied nations, the control and power electronic industry has lagged, in part because of lower cost margins. For example, the United States now has growing capacity to manufacture solar photovoltaic (PV) panels, but 90% of the inverters—which are essential to the conversion of DC to AC for grid connection and controls—are made in or source parts from the People’s Republic of China (PRC). While a global supply chain is beneficial for many economic and supply diversification reasons, presence of foreign entities of concern (FEOC) in a dominant role in this supply chain brings additional concerns for national security of infrastructure. The BESS relationship and new clean energy have features that warrant discussions and additional focus on impact for technology security, given their critical role. This review considers the impact and solutions for complex business and policy landscapes in clean energy supply chain, and the benefit trade-offs, focusing on the Battery Energy Storage System case study, and its complex organizational relationships across both the US, Allied countries and Foreign Entities of Concern. While many examples in this paper are presented on PRC focused manufacture, this could apply to any potentially adversarial relationship
The results of evaluation of power semiconductor devices for electric hybrid vehicle ac drive applications are summarized. Three types of power devices are evaluated in the effort: high power bipolar or Darlington transistors, power MOSFETs, and asymmetric silicon control rectifiers (ASCR). The Bipolar transistors, including discrete device and Darlington devices, range from 100 A to 400 A and from 400 V to 900 V. These devices are currently used as key switching elements inverters for ac motor drive applications. Power MOSFETs, on the other hand, are much smaller in current rating. For the 400 V device, the current rating is limited to 25 A. For the main drive of an electric vehicle, device paralleling is normally needed to achieve practical power level. For other electric vehicle (EV) related applications such as battery charger circuit, however, MOSFET is advantageous to other devices because of drive circuit simplicity and high frequency capability. Asymmetrical SCR is basically a SCR device and needs commutation circuit for turn off. However, the device poses several advantages, i.e., low conduction drop and low cost.
Doubly-fed induction generators (DFIGs) are prone to subsynchronous resonance (SSR) with series-compensated transmission lines and experiencing SSR-generated harmonics of wide-ranging magnitudes. This paper presents a large-signal impedance-based approach for the prediction of the magnitude of SSR-generated harmonics in DFIGs. Note that the large-signal impedance of a network shows variation in its impedance response with the magnitude of perturbation at its terminals. It is discovered in this paper that the impedance of a series-compen- sated transmission line starts changing with the magnitude of SSR because of the metal-oxide varistor-based protection of series capacitors in the line. The changing line impedance halts the growth of the SSR beyond a certain point, where the DFIG forms a limit-cycle mode and emits harmonics at the SSR frequency. The discovered role of the protection of series capacitors in SSR not only enables the prediction of SSR-generated harmonics but also can be used for the timely detection of an SSR event to avoid system disruption and sudden loss of bulk generation. The large- signal impedance-based prediction of SSR-generated harmonics in DFIG-based wind and hydro generators is demonstrated using numerical simulations of a 2.5-MVA, 690-V DFIG supplying to a series-compensated transmission line.
The transition to electric road transport technologies requires electric traction drive systems to offer improved performances and capabilities, such as fuel efficiency (in terms of MPGe, i.e., miles per gallon of gasoline-equivalent), extended range, and fast-charging options. The enhanced electrification and transformed mobility are translating to a demand for higher power and more efficient electric traction drive systems that lead to better fuel economy for a given battery charge. To accelerate the mass-market adoption of electrified transportation, the U.S. Department of Energy (DOE), in collaboration with the automotive industry, has announced the technical targets for light-duty electric vehicles (EVs) for 2025. This article discusses the electric drive technology trends for passenger electric and hybrid EVs with commercially available solutions in terms of materials, electric machine and inverter designs, maximum speed, component cooling, power density, and performance. Additionally, the emerging materials and technologies for power electronics and electric motors are presented, identifying the challenges and opportunities for even more aggressive designs to meet the need for next-generation EVs. Some innovative drive and motor designs with the potential to meet the DOE 2025 targets are also discussed.
Advanced electric propulsion system concepts with flywheels for electric vehicles are evaluated and it is predicted that advanced systems can provide considerable performance improvement over existing electric propulsion systems with little or no cost penalty. Using components specifically designed for an integrated electric propulsion system avoids the compromises that frequently lead to a loss of efficiency and to inefficient utilization of space and weight. A propulsion system using a flywheel power energy storage device can provide excellent acceleration under adverse conditions of battery degradation due either to very low temperatures or high degrees of discharge. Both electrical and mechanical means of transfer of energy to and from the flywheel appear attractive; however, development work is required to establish the safe limits of speed and energy storage for advanced flywheel designs and to achieve the optimum efficiency of energy transfer. Brushless traction motor designs using either electronic commutation schemes or dc-to-ac inverters appear to provide a practical approach to a mass producible motor, with excellent efficiency and light weight. No comparisons were made with advanced system concepts which do not incorporate a flywheel.
Solar photovoltaic (PV) and battery energy storage system (BESS) technologies are two immediately available options for meeting U.S. electricity demands, which are increasing due to expansion of loads from end uses including data centers, buildings, vehicles, and factories. Globally, PV and BESS supply chains are dominated by products manufactured in China and elsewhere by Chinese companies. However, U.S. PV and BESS manufacturing have recently grown, with some capacity in each step of the PV supply chain, albeit not enough to currently meet demand with domestic manufacturing alone. This study analyzes U.S. PV supply chains and costs in 2024, for the crystalline silicon and cadmium telluride module supply chains. The full report additionally addresses the PV balance of system, inverter and BESS supply chains. The study concludes with an analysis of technology installation trends, government support for domestic manufacturing, manufacturing jobs, and the domestic content of PV systems installed in the United States in 2024.
Alkaline Zn anodes are fundamental to commercial Zn-MnO 2 batteries as well as emerging rechargeable designs. In these electrodes, Zn particles are both the active material and source of electronic conduction. However, there are known cases in which electronic connectivity between Zn particles or the current collecting pin is lost even though the battery continues to function. Here we use X-ray computed tomography (CT) of AA batteries to demonstrate several examples of Zn particle-to-particle connectivity breakdown, which is observed even in cases at relatively high discharge rate. This indicates maintenance of the electronic network through the less-conductive ZnO discharge product. We introduce a new equation for electronic conductivity maintained through bridges of ZnO formed between percolating Zn particles. This necessitates discarding the Bruggeman correlation and instead redefining effective electronic conductivity using percolation theory. We demonstrate that such a model for conduction enables prediction of an inverted reaction zone, which is an experimentally observed case in which significant Zn dissolution and ZnO formation occurs heavily near the current collecting pin. Current computational Zn-MnO 2 models never predict an inverted reaction zone, and thus the updated conductivity enables models to accurately explain a wider range of experimental conditions.
In an isolated grid, wind turbines are typically deployed to provide energy to maximize energy production, reduce diesel-fuel consumption, reduce carbon emissions, and reduce costs for energy and fuel transportation. However, in addition to solely providing energy to the power system, wind turbines contain rotating masses and inverter-based controls that can enable various reliability and resilience services through advance controls. As part of the Microgrids, Infrastructure Resilience, and Advanced Controls Launchpad (MIRACL) this paper demonstrates, through desktop simulations, advanced wind turbine controls that can be employed to support higher contributions of wind in isolated grids, and to demonstrate ways that wind can play a role in supporting stability of an isolated grid. This isolated grid used in these desktop simulations is comprised of a wind turbine (600 kW), solar PV (430 kW), battery energy storage system (1 MW/1MWh), a simulated diesel generator (2 MW) and various types of loads (critical, dynamic). We developed a model of the subsystems in MATLAB/Simulink and validated them with available data from real-world components on NREL's Flatirons Campus. These validated models are then configured for various case studies. We compare the output of the desktop simulation with a baseline case with the diesel generator. Active and reactive power control of the wind turbine can help improve frequency and voltage responses in the isolated grid, respectively. By utilizing a small integrated battery energy storage system in the DC-link of the wind turbine, we also demonstrate that wind turbines can help blackstart a critical load comparable to its rated power and support other renewables (e.g. solar PV) come online and pick up an additional load. This report illustrates some of these reliability and resilience services a wind turbine can provide in an isolated grid.
Through the ARIES platform, this proposed project aims to bridge a gap and utilize the power hardware-in-the-loop (PHIL) and controller hardware-in-the-loop (CHIL) experiments and create open-source interconnection and interoperability information that can aid in faster and cheaper installation and operation of grid forming fuel cell inverters.
Medium-voltage DC (MVDC) grids are attractive for electric aircraft and ship power systems, battery energy storage system (BESS), fast charging electric vehicle (EV), etc. Such EV or BESS applications need isolated bidirectional MVDC to LVDC or LVAC converters. However, the existing Si-based solutions cannot fulfill the requirements of a high-efficiency and robust converter for MVDC grids. This paper presents a 5 kV SiC-based universal modular solid-state transformer (SST). This universal current-source SST can interface either a LVAC or LVDC grid with a MVDC grid in single-stage power conversion, while the conventional dual active bridge (DAB) converter needs an additional inverter. The proposed SST module using 3.3 kV SiC MOSFETs and diodes is bidirectional and can serve as a building block in series or parallel for higher-voltage higher-power systems. The topology of each module is based on the soft-switching solid-state transformer (S4T) with reduced conduction loss, which features reduced EMI through controlled dv/dt, and high efficiency with full-range ZVS for main devices and ZCS for auxiliary devices. Operation principle of the modular S4T (M-S4T), capacitor voltage balancing control between the cascaded modules, design of components including a medium-voltage (MV) medium-frequency transformer (MFT) to realize a 50 kVA 5 kV DC to 600 V DC or 480 V AC M-S4T are presented. Importantly, the MV MFT prototype achieves very low leakage inductance (0.13%) and 15 kV insulation with coaxial cables and nanocrystalline cores. Here, the proposed universal modular SST is compared against the DAB solution and verified with DC-DC and DC-AC simulation and 4 kV experimental results. Significantly, the MV experimental results of a modular DC transformer with each module at MVDC are rarely covered in the literature and reported for the first time.
Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. Upscaling the charging power to 200 kW (High Power DWPT) reduces the percentage of electrified roadway required, and the solution becomes cost-effective. To smooth the power at the battery and grid, a secondary regulation stage must be added. The DWPT system therefore relies on power electronics to interface with the coils and regulate the power flow. Designing this high power system using wide bandgap devices makes ensuring high efficiency, small size, and reliable operation very challenging, and significant engineering effort is required to build such complicated systems for large-scale installation and deployment. Here, this paper describes a modular design approach for the power electronics to achieve the 200 kW wireless power transfer. As described, the SiC power electronics building block is designed, simulated, and characterized. The approach is validated in the DWPT system to build the inverter, the rectifier, and the DC/DC converter, which demonstrated high performance and reliable operation with 188 kW power.