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All sources NASA NTRS DOE OSTI

DOE OSTI2021

Self-Security for Grid-Interactive Smart Inverters Using Steady-State Reference Model

Smart inverters exchange information with other devices through a shared communication link, making the inverters more prone to receive harmful commands from external parties. This erroneous data can be received due to an anomaly in the system, such as a device fault, unintentional utility operator action, or a cyber-attack. In this paper, a device-level self-security strategy is implemented using reference models for a grid-interactive inverter to examine the incoming power setpoints, detect the anomalies, and protect the system accordingly. The PQ setpoints received from the utility supervisory controller are autonomously examined using the inverter’s normal and stable operating regions before engaging the setpoints to the inverter’s local controller. Grid parameters are estimated in real-time during the examination process. The efficacy of the self-security algorithm is tested using a three-phase 3-kVA SiC-MOSFET inverter and a 12-kW NHR 9410 regenerative grid emulator. The results verify that the proposed method can detect harmful PQ setpoints that can cause abnormal or unstable inverter operation.

Gursoy, Mehmetcan↗

DOE OSTI2021

Smart Inverter Twin Model for Anomaly Detection

Smart inverters connected to a communication network are vulnerable to various anomalies in the form of cyberattacks. In this paper, a self-security approach is implemented using the digital twin concept for smart inverters. The digital twin is formed using the inverter’s dynamic model. Then, the incoming setpoints are autonomously examined using the digital twin, and only the safe setpoints are engaged to the inverter’s local controller. This paper demonstrates the details of the self-security algorithm and how the inverter’s digital twin is formed. In particular, the stable and unstable operation region is experimentally verified by changing the power setpoints engaged to the local controller, using a laboratory setup including a three-phase 1.5-kVA SiC-MOSFET inverter and a 12-kW NHR 9410 regenerative power grid emulator. The results demonstrate that the digital twin model can potentially protect inverters from abnormal operation by examining the incoming commands (new setpoints) using the inverter’s digital twin before engaging the setpoints to the local controller.

Hossen, Tareq↗

DOE OSTI2020

Decoupled Active and Reactive Power Control without PLL Requirement for Differential Buck Converter

This paper presents a decoupled active and reactive power control for the differential buck converter. This control does not require phase locked loop (PLL) for synchronization. Also, it achieves active and reactive power control in a simple single control loop structure. The differential buck converter has the capability to compensate the double line frequency power ripple without relying on additional hardware. Particularly, the Common Mode (CM) operation is used for active double line frequency power ripple absorption. Whereas, the Differential Mode (DM) operation is used as an active and reactive power exchanging port between the converter and the grid at the point of common coupling (PCC). The motivation behind this paper proposal are: (i) to avoid PLL induced instabilities, especially, when connecting the differential buck converter with weak grid, and (ii) direct active and reactive power control for the differential buck in a single loop control. The theoretical analyses are verified with a 5 kW converter with only 50 μF decoupling capacitor connected to a weak grid.

Khan, Ahmad↗

DOE OSTI2020

Design of Auxiliary Circuit Elements for Achieving Zero Voltage Switching in a Wireless Power Transfer System

The auxiliary resonant commutated pole (ARCP) is being used to achieve zero voltage switching (ZVS) of power switches for improved efficiency and/or to reduce dv/dt at the switch node for better electromagnetic interference (EMI) performance and overall system reliability. This paper shows how an ARCP circuit can be used in a wireless power transfer system to achieve ZVS. Detailed analysis of ARCP circuit operation is presented to determine the requirements for achieving ZVS in the main switches of a wireless electric vehicle charging system. Based on this analysis, a design algorithm is developed to optimize the design of the ZVS assisting circuit components. The designed ARCP achieves soft switching of the MOSFETs in the primary inverter of an 85 kHz, 10 kW series-series compensated, stationary wireless power transfer system.

Saha, Tarak↗

DOE OSTI2021

Flux Switching Permanent Magnet Motor with Metal Amorphous Nanocomposite Soft Magnetic Material and Rare Earth Free Permanent Magnets

The power losses in high power-density motors due to high rotational speed and/or high pole counts may be reduced adopting metal amorphous nanocomposites (MANCs) featuring low power loss and a relatively high flux density (~1.3 T). We recently proposed a flux switching permanent magnet (FSPM) motor with a rating of 2.5 kW at 1400 Hz electrical speed by incorporating low loss (< 3 W/kg at 1 kHz) FeNi-based MANC material with projected iron loss of about 5 W. The motor design allows use of rare earth-free permanent magnets. For incorporation of MANC materials, an axial flux motor where the rotor and stator core are made from a wound ribbon core has been developed. We have performed a 3-d FEA to optimize the design and built and tested a prototype demonstrating that the low loss MANC material can be used for motor applications.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Digital Twin for Self-Security of Smart Inverters

Smart inverters connected to a communication network are susceptible to man-in-the-middle attacks. In this paper, a self-security approach is implemented using the digital twin concept for smart inverters. The digital twin is formed using the inverter’s normal operating region and the inverter’s dynamic model. Then, the incoming setpoints are autonomously examined using the digital twin, and only the safe setpoints are engaged to the inverter’s local controller. This paper demonstrates how the inverter’s normal operating region and dynamic model are formed. In particular, the normal operation region is experimentally verified by changing the P and Q setpoints engaged to the local controller, using a laboratory setup including a three-phase 3-kVA SiC-MOSFET inverter and a 12-kW NHR 9410 regenerative power grid emulator. The results demonstrate that the self-security technique can potentially protect inverters from man-in-the-middle attacks by examining the incoming commands (new setpoints) using the inverter’s digital twin before engaging the setpoints to the local controller.

Hossen, Tareq↗

DOE OSTI2021

Optimized AC/DC Dual Active Bridge Converter using Monolithic SiC Bidirectional FET (BiDFET) for Solar PV Applications

Grid interface power conversion systems for commercial, industrial and residential solar power generation are becoming ubiquitous due to the competitive cost of solar energy. The AC/DC dual active bridge (DAB) converter is an upcoming topology in industrial PV energy and energy storage applications, providing bidirectional power transfer and galvanic isolation. In this paper, the properties of a DAB-type converter are leveraged to propose a design optimization process. It can optimize the high-frequency RMS current, size of magnetic elements and zero-voltage-switching (ZVS) region of the converter. The resulting design is compared against that derived from a conventional approach. In addition, an algorithm to compute the harmonic currents at the DC and line frequency AC ports of the system is proposed, and the respective filter designs are presented. The optimized design of the AC/DC DAB converter is implemented using the newly developed, 1200 V, 46 mΩ, four quadrant, SiC-based monolithic bidirectional FETs (BiDFET). Experimental results from the 2.3 kW, 400V/277VRMS hardware prototype are finally presented to verify the design process.

Bidirectional isolated AC-DC conversion, solar ene↗

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

On Stability of PQ-Controlled Grid-Following and Droop-Control Grid-Forming Inverters

In this paper, the nonlinearity impacts of PQ-control schemes and LCL filter parameter variations on the stability of grid-interactive inverters are studied under weak grid conditions. This work demonstrates that the control nonlinearity and parameter variations can cause unexpected instability at low power levels. This instability issue in the nominal operating range may occur under specific control parameters due to the shift of the low-frequency eigenvalues of PQ-controlled inverters. A full-order small-signal model for PQ-controlled inverters is applied to analyze this instability issue. Furthermore, the impacts of the droop coefficients on the stability of the droop-controlled grid-forming inverter are also investigated using the closed-loop inverter model. The findings are experimentally verified using a small-scale two-level 208 V, 5 kVA inverter feeding a 12 kW NHR 9410 power grid emulator and a hardware setup of a microgrid fed by two 5 kVA 208V inverters.

Hossen, Tareq↗

DOE OSTI2022

A Decoupled Droop Control Strategy for Cascaded Multicell Inverter with Low-Frequency Modulation

Cascaded multicell inverter (CMI), featured by its merits of modularity and fault-tolerance, is suitable for medium-voltage applications without using bulky step-up transformers. However, little research has reported grid-forming control of the CMI for the application in the power grid with high penetrations of inverter-interfaced generation. To bridge this research gap, this paper proposes a novel droop control strategy for the CMI with a low-frequency modulation to offer inertia and reactive power support to the power grid. A decoupled Q/V droop control strategy is proposed to eliminate the coupling effect from the P/ω control loop caused by the phase-angle difference between the voltages of the CMI and the grid. The output of the Q/V control loop is set as the reference voltage for each cell of the CMI, which makes the CMI naturally a voltage source to provide a grid-forming capability. Finally, the proposed control strategy shows great active and reactive power regulation and sharing capability, which is validated by simulation on two 100 kW, 2.4 kV CMIs connected in parallel to a power grid.

14 SOLAR ENERGY↗

DOE OSTI2023

A High-Power Density Segmented Traction Drive Inverter

High power density is one of the requirements for traction drive inverters for meeting increasing demand for higher power and performance electrical vehicles (EV). This paper presents design and preliminary experimental results for a 100 kW high-power density inverter for EV traction drive applications. The inverter design was based on the segmented inverter topology that can significantly reduce the inverter DC filter capacitor and employs low-profile planar double-sided cooled SiC MOSFET-based power modules, compact mini-channel heat sinks with fin-profile optimized using genetic-algorithms, and high-ripple current capacitors. The design produced a compact inverter package with a total volume less than 1 litter, exceeding the power density goal of 100 kW/L. Experimental results are included to demonstrate the cooling and electrical performance.

Su, Gui-Jia↗

DOE OSTI2023

Isolated Single-stage Three-phase AC/DC Converter using Bidirectional Switches

The advent of the SiC Bidirectional FET (BiDFET), a monolithic 1.2 kV bidirectional switch, has rendered the single-stage three-phase AC/DC converter topology a promising approach for implementing AC/DC converters. This topology, which integrates a full-bridge converter with a single-phase to three-phase matrix converter via a high-frequency transformer, is particularly suitable for applications requiring galvanic isolation, buck-boost functionality, and bidirectional power flow. The single-stage design eliminates the need for bulky and unreliable electrolytic capacitors, and utilizes a single magnetic component for power transfer. In the matrix converter, bidirectional switches, which were traditionally implemented using combinations of multiple semiconductor devices such as MOSFETs, IGBTs, and diodes, can now be realized using the single-chip solution, BiDFET. This advancement leads to a lower switch count, compact converter implementation, with lower inductance commutation cells, thereby enhancing the overall efficiency and compactness of the system. The paper presents a unified model of the converter, considering all control parameters, including the duty cycles and phase shift of transformer voltages. Detailed expressions for power transfer, transformer currents, and currents at AC and DC ports are provided. Additionally, the paper outlines the conditions necessary for soft-switching of all switches and the commutation schemes required for the practical implementation of the matrix converter modulation scheme. A hardware prototype of a 10 kW, 480 VRMS, LL/ 800 V AC/DC system has been developed, and experimental results are presented to demonstrate its performance.

BiDFET↗

DOE OSTI2023

A Novel Honeycomb-DD Multi Coil Design for Wireless Power Transfer Systems

Wireless power transfer (WPT) technology has received significant attention recently as an alternative charging method for batteries in a wide range of power levels. In the literature, many types of coil structures have been well-studied. Honeycomb coil arrays, which have been used mostly for low-power applications, have not been well-studied for high-power-level applications. In this paper, a novel honeycomb-DD coil design is proposed for high-power wireless battery charging systems. The proposed coil design with step by step design process is given and Finite Element Analysis (FEA) was performed to observe the full performance characteristics of the system for a 100 kW system. In addition, the misalignment tolerance of the proposed system was observed by shifting the secondary side charging pad at different misalignment positions, and the electromagnetic compatibility to the standards was investigated. The core and strand losses were obtained. The results show that the honeycomb coil array provides high coupling coefficient and better misalignment tolerance, making it a potential coil topology for WPT applications.

Aydin, Emrullah↗

DOE OSTI2025

Heat Pipe Enhanced Thermal Management System for GaN Switches in an Integrated Modular Motor Drive for Aircraft Propulsion

This paper presents the process of sizing a heat pipe enhanced thermal management system (TMS) for GaN switches in an integrated modular motor drive (IMMD) powering a 250 kW aircraft propulsion electric motor. A test setup mimicking the TMS and GaN switches assembly is constructed. The condenser chamber of the TMS is modeled in ANSYS Fluent while the GaN switches assembly is modeled in ANSYS Thermal allowing us to verify heat spreader temperature under test conditions and estimate GaN temperatures under test and actual application operating conditions.

DIRECT ENERGY CONVERSION↗

DOE OSTI2025

A Cost-Effective Wave Energy Harvesting System with Maximum Power Point Tracking Capability

In this paper, we propose a low-cost bidirectional four-switch inverter that transfers three-phase energy between a permanent magnet synchronous generator (PMSG) driven by a wave energy collector and the power grid or a local ac load. To achieve high control performance, the machine-side inverter uses a high-gain observer for rotor position estimation and a Lyapunov-based approach for torque control. For the gridside inverter control, we estimate the filter capacitor voltage with a model reference adaptive system and control the dc-link voltage with a Lyapunov-based energy function. We also track the maximum power point from the sea waves with an integral control law that actively matches the generator impedance with that of the wave collection device. The proposed system supports both grid-following/forming modes. We validate our control design with simulation results on a 3-kW hardware setup.

wave energy, power systems integration, control de↗

DOE OSTI2025

Real-time Simulation Model of a Vanadium Redox Flow Battery Energy Storage System with Power Electronics Integration

This paper presents a real-time (RT) model of a 20 kW multi-stack vanadium redox flow battery (VRFB) system including power electronics converters in a single real-time framework. Implemented on a Typhoon HIL 604 device, this model is designed to simulate the operation of the flow battery with system-level controls. To provide a realistic overview of a VRFB system, the model incorporates a closed-loop control system for managing the speeds of two centrifugal pumps and an electro-thermal model of the battery stacks, enabling realtime temperature estimation. Furthermore, a two-stage power electronics topology and associated control solution are presented, operating with distinct strategies for interfacing the battery model with the main grid and a local load. Results from simulations demonstrate that the VRFB model is well suited for RT environment, and system can manage power during both charging and discharging cycles, while a SCADA monitor is used to display critical variables for safe, efficient, and reliable operation of the VRFB systems.

Rezende Da Costa Reis Kimpara, Renata [ORNL] (ORCI↗

DOE OSTI2025

A Simulation Framework to Support the Deployment of Vanadium Redox Flow Batteries

This work presents a simulation framework to support Vanadium Redox Flow Batteries deployment. First, an electrical equivalent model of a commercial three-stack, 20 kW VRFB is implemented to capture the battery dynamics. Next, a topology of a power electronics-based solution to integrate a VRFB is introduced, and the effectiveness of the control system is evaluated through battery charging and discharging operation under varying conditions. The results provide insights into power and voltage levels, demonstrating that the series-connected architecture can alleviate the voltage boost on the interface power electronics converter. Additionally, efficiency and temperature-critical factors for VRFB system deployment-are also analyzed.

Rezende Da Costa Reis Kimpara, Renata [ORNL] (ORCI↗

DOE OSTI2020

Self-Secure Inverters Against Malicious Setpoints

The next generation of grid-interactive inverters brings a communication feature that allows data sharing from utility supervisory controllers and smart devices that are connected to the same network. This feature enhances the control capabilities of grid-interactive inverters to provide services beyond active power injection. However, communication networks entail more vulnerable surfaces to malicious attacks that may result in modifying active and reactive power setpoints and causing weak-grid conditions or abnormal inverter operation. In this paper, steady-state and the dynamic behavior of the inverter for the incoming setpoints are analyzed to detect false data injection attacks and provide device-level security. The steady-state behavior of the inverter in the operating region is determined from the grid parameters such as the grid voltage and the grid impedance. These estimations are accomplished by the proposed self-security technique through a low-frequency signal injection-based approach combined with the recursive least square method. Moreover, a reduced fourth-order inverter model is used as the dynamic reference model, and grid parameters as well as the incoming setpoints are implemented to the reference model to verify whether the dynamic behavior of the inverter is inside the permissible region of operation. The validity and performance of the proposed method are verified experimentally through Allen-Bradley Powerflex 755 three-phase inverter and a 12 kW NHR 9410 regenerative power grid emulator. The results show that the self-secure smart-inverter is able to accept or reject the incoming commands and thus is protected from malicious cyber-physical attacks.

Hossen, Tareq↗