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At least 289 records · Page 16

A case study of high-temperature polyetherimide film capacitor fabrication

Capacitors, as the basic building block of power electronics and electrical systems, are the major constraint of the increasingly integrated power systems that require new capable polymer dielectric films operating at higher temperatures >125 °C. Despite tremendous research efforts on the lab scale, there remains a considerable barrier and knowledge basis for converting polymeric films to functioning capacitors desired in actual applications. Here, the authors tackled the polyetherimide (PEI) film scale up issues and developed various engineering processes for film de-wrinkling, optimal metallization, static elimination, and capacitor fabrication improvement. The authors discovered various fabrication challenges such as the electrostatic charge, metallization scheme, winding tension, and end electrode disconnects. To fabricate a high yield of PEI capacitor bobbins, it is necessary to utilize static eliminators (radioactive ionizers), moderately thick aluminum metallization (15–30 Ω/sq), and winding tension (60–100 g). It is also effective to evaluate capacitance, dielectric loss, equivalent series resistance, and thermal cycling stability of capacitors. This work sheds some light on converting PEI films and other polymeric films to capacitors on a scale up fabrication effort. The practical learning from film handling to capacitor fabrication in this work provided the necessary knowledge for manufacturing high-temperature polar film capacitors.

36 MATERIALS SCIENCE↗

Power Electronics as an Enabler of the Current and Future Grid: Control Instead of Copper

Power electronics are becoming more pervasive in the power system. Solar, wind and battery energy storage systems regularly connect to the grid using power electronic interfaces. Loads are also increasingly power electronic-based. These changes, coupled with the change in the power system's operating characteristics as more and more renewable energy is integrated into the power system, offer a challenge to power electronic and power system engineers alike - how do we design and operate the power system moving forward?

direct connect↗

Preprocessing for Unintended Conducted Emissions Classification with ResNet

Characterization of Unintended Conducted Emissions (UCE) from electronic devices is important when diagnosing electromagnetic interference, performing nonintrusive load monitoring (NILM) of power systems, and monitoring electronic device health, among other applications. Prior work has demonstrated that UCE analysis can serve as a diagnostic tool for energy efficiency investigations and detailed load analysis. While explaining the feature selection of deep networks with certainty is often not fully comprehensive, or in other applications, quite lacking, additional tools/methods for further corroboration and confirmation can help further the understanding of the researcher. This is true especially in the subject application of the study in this paper. Often the focus of such efforts is the selected features themselves, and there is not as much understanding gained about the noise in the collected data. If selected feature and noise characteristics are known, it can be used to further shape the design of the deep network or associated preprocessing. This is additionally difficult when the available data are limited, as in the case which the authors investigated in this study. Here, the authors present a novel work (which is a proposed complementary portion of the overall solution to the deep network classification explainability problem for this application) by applying a systematic progression of preprocessing and a deep neural network (ResNet architecture) to classify UCE data obtained via current transformers. By using a methodical application of preprocessing techniques prior to a deep classifier, hypotheses can be produced concerning what features the deep network deems important relative to what it perceives as noise. For instance, it is hypothesized in this particular study as a result of execution of the proposed method and periodic inspection of the classifier output that the UCE spectral features are relatively close to each other or to the interferers, as systematically reducing the beta parameter of the Kaiser window produced progressively better classification performance, but only to a point, as going below the Beta of eight produced decreased classifier performance, as well as the hypothesis that further spectral feature resolution was not as important to the classifier as rejection of the leakage from a spectrally distant interference. This can be very important in unpredictable low-FNR applications, where knowing the difference between features and noise is difficult. As a side-benefit, much was learned regarding the best preprocessing to use with the selected deep network for the UCE collected from these low power consumer devices obtained via current transformers. Baseline rectangular windowed FFT preprocessing provided a 62% classification increase versus using raw samples. After performing a more optimal preprocessing, more than 90% classification accuracy was achieved across 18 low-power consumer devices for scenarios in which the in-band features-to-noise ratio (FNR) was very poor.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

An accurate online calibration system based on combined clamp-shape coil for high voltage electronic current transformers

Electronic transformers are widely used in power systems because of their wide bandwidth and good transient performance. However, as an emerging technology, the failure rate of electronic transformers is higher than that of traditional transformers. As a result, the calibration period needs to be shortened. Traditional calibration methods require the power of transmission line be cut off, which results in complicated operation and power off loss. This paper proposes an online calibration system which can calibrate electronic current transformers without power off. In this work, the high accuracy standard current transformer and online operation method are the key techniques. Based on the clamp-shape iron-core coil and clamp-shape air-core coil, a combined clamp-shape coil is designed as the standard current transformer. By analyzing the output characteristics of the two coils, the combined clamp-shape coil can achieve verification of the accuracy. So the accuracy of the online calibration system can be guaranteed. Moreover, by employing the earth potential working method and using two insulating rods to connect the combined clamp-shape coil to the high voltage bus, the operation becomes simple and safe. Tests in China National Center for High Voltage Measurement and field experiments show that the proposed system has a high accuracy of up to 0.05 class.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Sizing Power Components of an Electrically Driven Tail Cone Thruster and a Range Extender

The aeronautics industry has been challenged on many fronts to increase efficiency, reduce emissions, and decrease dependency on carbon-based fuels. The NASA Aeronautics Research Mission Directorate has identified a suite of investments to meet long term research demands beyond the purview of commercial investment. Electrification of aviation propulsion through turboelectric or hybrid electric propulsion is one of many exciting research areas which has the potential to revolutionize the aviation industry. This paper will provide an overview of the turboelectric and hybrid electric technologies being developed under NASAs Advanced Air Transportation Technology (AATT) Project, and how these technologies can impact vehicle design. An overview will be presented of vehicle system studies and the electric drive system assumptions for successful turboelectric and hybrid electric propulsion in single aisle size commercial aircraft. Key performance parameters for electric drive system technologies will be reviewed, and the technical investment made in materials, electric machines, power electronics, and integrated power systems will be discussed. Finally, power components for a single aisle turboelectric aircraft with an electrically driven tail cone thruster and a hybrid electric nine passenger aircraft with a range extender will be parametrically sized.

turbogenerator↗

Thermal Management System of an Outer-Rotor-Motor-Based Traction Drive With Integrated Power Electronics in its Central Cavity

Increasing power densities of electric vehicle traction drive systems necessitates combining the electric motor and the power electronics into one unit. A compact, integrated traction drive unit with fewer components also drives production costs down, enabling wider adoption of electric vehicles. However, the integration of power electronics in the electric machine is associated with challenges of designing an effective thermal management solution for the combined traction drive system. This paper focuses on the thermal management approach selected for Oak Ridge National Laboratory’s outer-rotor-motor-based integrated traction drive and evaluates its potential performance. The outer-rotor-motor configuration provided an opportunity for integration of the six-phase inverter in the available space in the central cavity of the internal stator. A cylindrical inverter enclosure with integrated coolant (water-ethylene glycol) channels in its walls was designed to enable heat removal from the power electronics. Numerical thermal-fluid modeling and initial channel/fin optimization results for the cylindrical heat sink are presented here. As permanent magnets are integrated in a high-speed (20 000 RPM) outer rotor, forced air convection provides cooling for the magnets. The magnets were segmented axially to mitigate the eddy current losses. Heat generated in the stator windings and laminations is removed by water-ethylene glycol coolant circulating in interpolar T-shape ceramic heat exchangers inserted between windings. General design concepts and numerical thermal-fluid simulations illustrating the electric motor thermal management solution are also presented.

Kekelia, Bidzina↗

Processing and Characterization of Sol-Gel Cerium Oxide Microspheres

Of interest to space exploration and power generation, Radioisotope Thermoelectric Generators (RTGs) can provide long-term power to remote electronic systems without the need for refueling or replacement. Plutonium-238 (Pu-238) remains one of the more promising materials for thermoelectric power generation due to its high power density, long half-life, and low gamma emissions. Traditional methods for processing Pu-238 include ball milling irregular precipitated powders before pressing and sintering into a dense pellet. The resulting submicron particulates of Pu-238 quickly accumulate and contaminate glove boxes. An alternative and dust-free method for Pu-238 processing is internal gelation via sol-gel techniques. Sol-gel methodology creates monodisperse and uniform microspheres that can be packed and pressed into a pellet. For this study cerium oxide microspheres were produced as a surrogate to Pu-238. The similar electronic orbitals between cerium and plutonium make cerium an ideal choice for non-radioactive work. Before the microspheres can be sintered and pressed they must be washed to remove the processing oil and any unreacted substituents. An investigation was performed on the washing step to find an appropriate wash solution that reduced waste and flammable risk. Cerium oxide microspheres were processed, washed, and characterized to determine the effectiveness of the new wash solution.

36 MATERIALS SCIENCE↗

High power test of a wideband diplexer with short-slotted metal half mirrors for electron cyclotron current drive system

The wideband high power diplexer has been developed for combining and fast switching of high power millimeter waves generated by a dual frequency gyrotron. The actual diplexer was tested at the frequency band of 170 GHz in low power. After adjusting a resonant frequency of diplexer for the gyrotron frequency, the evacuated wideband diplexer with short-slotted metal half mirrors was tested at an incident power of about 150 kW, a pulse duration of 30 ms and a frequency band of 170.2–170.3 GHz. Any discharge damage was not observed in the diplexer.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Electric propulsion in 1965.

Electric propulsion in 1965, discussing electron bombardment and contact ionization thrustors, nuclear and solar-electric power systems, etc

ELECTRON BOMBARDMENT↗

Electron motion of an annular beam in a low-magnetic-field drift tube

Foil-less diodes and annular electron beams are widely adopted in high power microwave systems, and the electron beam is usually constrained by a guiding magnetic field to pass through the downstream drift tube and beam-wave interaction region. The electron beam, however, will present obvious radial motion when a low magnetic field is adopted, which will prominently influence the beam transmission and beam-wave interaction. This paper focuses on the radial motion of the electron beam in a low-magnetic-field drift tube. A spatial period is demonstrated with methods of theoretical analysis, single-particle calculations, particle-in-cell simulations, and experiments. The results obtained with different methods show good coherency, indicating that the real spatial period of the electron beam can be predicted by a simple formula which is based on single-particle motion regardless of space-charge effect.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

SP-100 Dynamic Power and Lithium-Propellant MPD Nuclear Electric Propulsion Technology Requirements

The objective of this study was to evaluate the requirements (including system integration, design, test requirements, and schedule) for the propulsion and power conversion systems of a nuclear electric propulsion (NEP) vehicle using an SP-100 reactor with a dynamic power conversion system, Li-propellant magnetoplasmadynamic (MPD) thrusters, Li-propellant storage and feed systems, and the power conditioning electronics required to convert the power output from the power system to the form (voltage, current) needed by the thrusters. Potassium-Rankine power conversion systems have the potential for the greatest mission benefit in terms of minimum mass and volume (as compared to Brayton or Stirling power conversion systems), but they require the most development.

Murray, Kathy H.↗

Dielectric Fluids for the Direct Forced Convection Cooling of Power Electronics

The future of electrification of vehicles and other systems will require the creation of high-power density power electronics with low junction-to-fluid thermal resistance cooling solutions. One way to create this solution is to move high-heat-flux liquid cooling (single- or two-phase) as close to the power electronics components as possible. One novel approach involves submersion in dielectric fluids as the cooling solution. We first provide the range of fluid properties and develop a figure of merit (FOM) to aid in dielectric fluid selection. Next, we perform computational fluid dynamics/heat transfer (CFD/HT) modeling using single-phase cooling (submerged jet impingement on an enhanced surface) to validate the dielectric fluid FOM. Results of the study show that the developed FOM is a good representation of the performance of the fluids when compared to the results of the CFD/HT analysis. Both FOM and the CFD/HT analysis show that based on pure thermohydraulic considerations, several commercially available fluids present higher performance, on the order of 5% of water. Finally, the FOM can be used to quickly assess the thermohydraulic performance of a dielectric fluid, as well as the secondary application-specific properties such as boiling point, saturation pressure, flash point, and global warming potential, thereby allowing for fluid candidates to be readily compared.

computational fluid dynamics↗

Boosting Thermal Management & Reliability of Vehicle Power Electronics

Electric vehicles rely heavily on power electronics—including inverters, converters, and chargers—to control the flow of electricity between the battery, the motor, and other powertrain components. NREL is helping boost the performance of power electronics components and systems, while driving down size, weight, and cost. In electric vehicles, these components need to operate at higher temperatures, voltages, switching frequencies, and power conversion efficiencies. That’s where NREL’s thermal management and reliability research comes in.

33 ADVANCED PROPULSION SYSTEMS↗

Characterization and novel application of power over fiber for electronics in a harsh environment

Power-over-Fiber (PoF) technology has been used extensively in settings where high voltages require isolation from ground. In a novel application of PoF, power is provided to photon detector modules located on a surface at ∼ 300 kV with respect to ground in the planned DUNE experiment. In cryogenic environments, PoF offers a reliable means of power transmission, leveraging optical fibers to transfer optical power. PoF technology excels in maintaining low noise levels when delivering power to sensitive electronic systems operating in extreme temperatures and high voltage environments. This paper presents the R&D effort of PoF in extreme conditions and underscores its capacity to revolutionize power delivery and management in critical applications, offering a dependable solution with low noise, optimal efficiency (∼ 51%), and superior isolation.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗