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At least 523 records · Page 29

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DOE OSTI2024

High-Penetration Microgrids Providing Grid Stability Using Frequency Watt Control

The U.S. grid is rapidly transitioning towards utilizing inverter-based renewable energy resources such as solar, wind, and batteries, reducing the carbon emission footprint. Inverter-based microgrid control architectures remain a critical focus to address power system stability issues in future high penetration markets lacking spinning generation assets. Idaho National Laboratory (INL) is researching an active layered inverter based frequency-Watt control scheme that provides distribution level stability in high-penetration markets where grid inertia is lacking. Hardware in the loop case study was implemented using INL’s Microgrid Testbed to combat scalable frequency deviations ranging from 60 Hz down to 50 Hz initialized by a hydropower model implementing step loads using a 540-kW grid emulator. Our research findings demonstrate the importance of distribution level, inverter-based active frequency-Watt controls utilizing a battery energy storage system (BESS) to provide adequate frequency support at the point of common coupling without major power infrastructure upgrades.

14 SOLAR ENERGY↗

DOE OSTI2022

On Projection of Safe Operation for Grid-Following Inverters - Grid Parameter Estimation

This work investigates the projection of safe operation for grid-following inverters using a reference model. This work applies recursive-least square and model reference adaptive estimation techniques to estimate the unknown grid parameters. The estimated grid parameters are used in a dynamic reference model to project the safe operation of the inverter. This work also demonstrates that the controller nonlinearity and parameter variations can cause unsafe operations, such as unexpected instability at low power levels, namely hidden mode of instability. This instability issue in the nominal operating range may occur for given control parameters in a weak-grid condition. The dynamic reference model for PQ-controlled inverters is applied to analyze this instability issue using the estimated grid parameters. Both adaptive identification techniques can estimate the unknown parameters accurately, and the dynamic reference model can safeguard inverters from an unsafe operation, i.e., hidden instability, by examining the incoming new power setpoints before engaging them to the local controller. 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.

Hossen, Tareq↗

DOE OSTI2021

Power Converter Topologies for Electrolyzer Applications to Enable Electric Grid Services

Hydrogen electrolyzers, with their operational flexibility, can be configured as smart dynamic loads which can provide grid services and facilitate the integration of more renewable energy sources into the electrical grid. However, to enable this ability, the electrolyzer system should be able to control both active and reactive power in coordination with the low-level controller of the electrolyzer via the power electronics system interface between the utility grid and electrolyzer. This paper discusses power converter topologies and the control scheme of this power electronics interface for electrolyzer applications to enable electricity grid services. For the sake of unity, in this paper, we consider the power converter system interfacing the utility grid at the line-to-line root mean square (RMS) value of 480 VAC-60 Hz and supplying to the 3500 A-750 kW PEM electrolyzer stack.

electrolyzer↗

DOE OSTI2025

Novel Approach to PV Inverter Modeling and Simulation Leveraging Experiments, Learning Based Modeling and Co-Simulation

Photovoltaic (PV) inverter manufacturers use custom, proprietary control approaches and topologies in their inverter design. The proprietary nature of these approaches makes it challenging to share electromagnetic transients (EMT) domain models for system studies. This research work presents an approach to develop EMT models from experimental data. We use novel approach in experimental design, high fidelity data collection, use of learning-based modeling, and co-simulation to reduce the time taken to develop an EMT model for an inverter under test (IUT). We used a 20 kW off-the-shelf grid following PV inverter and subjected the inverter to controlled tests. The tests include voltage and frequency step changes, as well as solar irradiance variations. The recorded high frequency data were used to train a neural network model representing the dynamic behavior of the IUT. The model was subsequently imported into an EMT tool using co-simulation techniques, and thus completing the modeling effort.

black box inverter modeling↗

DOE OSTI2023

Aviation Mission Profile Performance Evaluation in a High Specific Power Surface Permanent Magnet Machine with Additively Manufactured Coils and Integrated Heat Pipes

The purpose of this paper is to accurately evaluate the performance and overall efficiency of an electrical machine driving a propeller (as a part of a hybrid or electric propulsion system) during the flight mission profile using electromagnetic-thermal simulations. The study focuses on a 250 kW, 5000 rpm, 1.25 kHz, 36/30 slot/pole surface permanent magnet (SPM) machine with additively manufactured (AM) hollow conductors and integrated heat pipes (HP). The machine drive parameters (frequency, and current) are tuned to maximize the efficiency for a given flight cycle, while providing the highest specific power (SP) during takeoff. Afterward using Multiphysics simulations, the transient thermal behavior of the machine is studied and temperature profile for different parts of the machine is extracted. Finally, steady-state temperatures during cruising are estimated and overall efficiency is re-evaluated.

additive manufacturing↗

DOE OSTI2020

Thermal Analysis of Wireless Power Transfer Coils for Dynamic Wireless Electric Vehicle Charging

In this paper, safe operating conditions of a wireless power transfer coil were identified and road infrastructure for a dynamic wireless electric vehicle charging system was studied. Magneto-thermal simulations were used to map the power loss directly into the computed fluid dynamics solver. This method allowed the authors to analyze the heating pattern of the enclosed wireless power transfer coil in the road structure, as well as for the vehicle coil. Thermal heating patterns for three types of rectangular coil structures were analyzed. Heating patterns were analyzed for 200 kW coils and different magnetic field densities in the magnetic core.

Wojda, Rafal↗

DOE OSTI2021

Power-to-Gas Systems for Active Load Management at EV Charging Sites with High DER Penetration

Intermittent renewable systems and increasing electric vehicle (EV) penetrations increase load intermittency—and will require expensive distribution system infrastructure upgrades. Power-to-gas (P2G) systems are highly controllable loads that can be modulated to regulate the net load behind the meter. In this work, we present an active load management approach using P2G systems to regulate the net load for an EV charging station with high penetrations of renewable generation. The system also validates the feasibility of the proposed approach using a 750-kW electrolyzer operated with the distribution system in a real-time power-hardware-in-the-loop test. Finally, we evaluate the impact of the size of the P2G system on its ability to regulate the net load.

ADVANCED PROPULSION SYSTEMS,POWER TRANSMISSION AND↗

DOE OSTI2022

Modeling of RMS Current in CSI Filter Capacitor and Minimum Conduction Loss Operation of CSI-Fed PMSM Drives for Traction Applications

This paper presents a new minimum conduction loss (MCL) torque control algorithm for current source inverter- (CSI-) fed permanent-magnet synchronous machine drives that improves the overall machine drive efficiency by minimizing the combined conduction losses in the inverter and machine at each operating point. First, analytical models of conduction losses in CSI-fed motor drives are presented, and a closed-form expression for optimal d-axis stator current to achieve MCL operation is derived. An expression for the rms current in both wye- and delta-connected CSI output capacitors is derived. A detailed simulation model that emulates the operation of a 100 kW SiC CSI-fed integrated machine drive (IMD) has been developed based on experimental results and finite element analysis. This simulation model is used to evaluate the proposed MCL control algorithm applied to a CSI-fed IMD system for a battery-electric vehicle traction drive, and the predicted total drive system loss with MCL control is compared to predicted losses with maximum-torque-per-ampere (MTPA) and minimum dc-link current (MDCC) control. Results show that MCL control can achieve loss reductions compared to the other two control algorithms over a wide range of operating conditions, with significant loss reductions >20% in the medium-speed regime.

42 ENGINEERING↗

DOE OSTI2023

Design Considerations of DC/DC Regulator for High-Power Dynamic Wireless Charging Systems

Due to fast fluctuating input voltage, dynamic wireless charging requires a post-regulator stage for battery charging control and management. This regulator stage has a high requirement on efficiency, size as well as control performance to ensure tight regulation and fast trainset. This paper addresses the control challenges by modeling the system and designing the compensator with input voltage feedforward control. In addition, high resolution PWM is implemented to improve transient performance and current balancing among the phases. Experimental results prove the effectiveness of the proposed schemes and validates 180 kW closed-loop 4-phase operation at 99% efficiency.

Xue, Lincoln↗

DOE OSTI2023

Bidirectional Three-phase Current Source Converter based Buck-boost AC/DC System using Bidirectional Switches

The 1.2 kV 4H-SiC BiDirectional Field Effect Transistor (BiDFET) is the first monolithic SiC bidirectional switch, which offers a lower voltage drop and semiconductor devices count alternative to the reverse-voltage-blocking (RB) switch used in the current-source converters (CSC). The bidirectional switch based CSC also allows DC-link current reversal for bidirectional power flow and provides multiple system-level benefits in a buck-boost AC/DC system consisting of buck-type DC/DC converter and CSC. This paper discusses the selection of buck converter duty cycle and CSC modulation index for the system’s buck-boost operation with a wide variation in DC voltage. CSC modulation schemes categorized based on the number of hard-turn-on transitions per switching cycle are also analyzed along with the three-step and four-step commutation schemes that are essential for the CSC commutation cells. Finally, the different schemes are evaluated and compared through the experimental results of a 10 kW, 480 VRMS, LL/ (400 − 800) V AC/DC system.

Bidirectional switches, four-quadrant switches, cu↗

DOE OSTI2024

Thermal Integration of a High Power Polyphase Inductive Coil Assembly

As inductive wireless power transfer reaches higher power levels; thermal management becomes essential. To address these concerns, past works have demonstrated the benefit of encapsulating coil assemblies with thermally conductive materials and integrating backside liquid cooling into coil assemblies. This work adds to these developments by considering the thermal analysis and construction of a liquid-cooled high power polyphase wireless power transfer ground assembly intended for long duration operation at high power levels, aiming towards hundreds of kW or even 1 MW.

Foote, Andrew↗

DOE OSTI2024

Crack Propagation Modeling of a High-Speed Outer Rotor Motor

This study aims to investigate the propagation of initial cracks in electric motors and their rate of spread through the rotor structure under various operating conditions. Traction motors are subjected to high centrifugal load owing to their speed and rapid acceleration and deceleration. In the manufacturing process, some initial imperfections or cracks in the rotor components are likely to occur. Under the influence of loading, these cracks will grow, and factors such as loading frequency, material strength, and location of material voids will affect this threshold speed. In the current study, a fracture mechanics–based approach has been used to investigate the crack growth rate for a 100 kW outer rotor motor with a rated speed of 6,000 rpm and a peak speed of 20,000 rpm for an integrated drive application.

Barua, Himel↗

DOE OSTI2025

A New Design Consideration for Bidirectional Resonant Converters

This paper introduces innovative design considerations for a bidirectional resonant converter, optimized for Electric Vehicle (EV) charging and vehicle-togrid (V2G) applications. By eliminating the need for complex voltage or current gain functions, the proposed design greatly simplifies the development process, making it more accessible for manufacturers and system integrators. This approach not only reduces engineering time and resource investment but also accelerates time-to-market, giving stakeholders a competitive edge in rapidly expanding EV infrastructure markets. In addition, the streamlined design ensures soft switching at maximum output power, leading to higher efficiency and improved durability, which translates to lower operating costs and a longer service life for EV charging equipment. These benefits provide a clear pathway to more cost-effective, scalable, and sustainable EV charging and V2G solutions, enhancing value for stakeholders by facilitating smoother integration into the grid and supporting energy resilience. To validate the benefits, a 60 kW bidirectional charger with a flexible input range of 700−900VDC and an output range of 400−1250VDC was developed, underscoring the design's adaptability and potential for large-scale implementation.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗

DOE OSTI2025

A Novel Three-Phase Isolated LLC and Non-Isolated LCL-T Resonant Converter for Fuel Cell Applications

In this paper, a novel three-phase isolated LLC and non-isolated LCL−T resonant converter topologies are introduced for fuel cell applications. In order to improve the fuel cell DC/DC converter efficiency, the current amplitude should be reduced in the power stage components. Cascaded connections of fuel cell blocks through a controllable system enable using higher voltage amplitude and bring the current amplitude lower at the target power. In this way, power losses in the passive components can be reduced, and maximum energy transfer can be established, improving the DC/DC converter efficiency from the fuel cell to the load. The introduced new converter also achieves soft switching (ZVS), minimizing the switching losses in all input and output load conditions. The presented three-phase isolated LLC and non-isolated LCL−T resonant converter systems, fed by three fuel cell modules with an output range of 190380 V, deliver 580−730 V at 450 kW maximum output power. The results reveal that the proposed systems have the advantage of reducing the size, volume, and weight and increasing the overall DC/DC converter system efficiency compared to the single-phase systems.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗

DOE OSTI2026

A System Level Comparative Study of SecondarySide Rectifiers for UAV Wireless Power Transfer in High-Altitude Airborne Energy Platforms

Wireless power transfer (WPT) systems for unmanned aerial vehicles (UAVs) must satisfy stringent design requirements to ensure reliable operation under constraints related to efficiency, thermal performance, altitude, weight, and reliability, particularly in airborne and high-altitude environments. Thermal management becomes increasingly challenging at higher altitudes due to reduced air density, while reliability is strongly affected by the number and complexity of active components. The weight and compactness of secondary-side rectifiers directly impact UAV flight endurance and system integration, influencing energy consumption and payload allocation. These factors collectively define the practical feasibility of UAV WPT systems and guide rectifier topology selection. This paper presents a comparative and experimentally validated evaluation framework for secondary-side rectifiers under UAV-specific constraints. Three representative rectifier architectures are analyzed using component-based assessment of weight, thermal behavior, and reliability, together with experimental efficiency measurements obtained from a 1 kW WPT prototype. The results show that the single-switch active rectifier achieves the highest peak efficiency of approximately 93.2% and an overall efficiency of 91%, while also offering advantages in weight and reliability. The findings demonstrate how constraint-oriented analysis, combined with experimental validation, enables informed selection of secondary-side rectifiers for UAV wireless power transfer applications, including emerging airborne and high-altitude platforms.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗

DOE OSTI2026

Design and Performance Assessment of Intermediary Coils for Misalignment Tolerance Improvement in Wireless Power Transfer Systems

This paper investigates the use of intermediate coils positioned between the primary and secondary coils in Wireless Power Transfer (WPT) systems for electric vehicle (EV) charging, with the objective of improving power transfer efficiency and robustness under misalignment conditions. An optimized 1 kW power system that operates at 85 kHz is developed and the misalignment performance was analyzed and compared with and without intermediate coils. A preliminary increase in efficiency of 2.3% at a misalignment of 52% of the coil radius is shown to be possible for a passive intermediate coil. An experimental prototype is built for design verification.

Sivka, Gozde [ORNL]↗

DOE OSTI2026

A Unified Design Theory for Multi-Port Polyphase Transformers Enabling Scalable Power-Multiplexed EV Fleet Charging Systems

This paper presents a unified analytical design theory for multi-port polyphase transformers, targeting scalable and isolated high-power Electric Vehicle (EV) fleet charging systems with power multiplexing capability. As fleet electrification accelerates, conventional one-to-one charger architectures face significant challenges in infrastructure cost, peak power demand, and low utilization of installed power electronics. Power-multiplexed charging architectures, which dynamically distribute power from a shared pool of converter modules across multiple vehicles, have emerged as a promising solution. However, such architectures require scalable, isolated multi-port power interfaces capable of routing energy among multiple inputs and outputs, whose design remains complex and dependent on iterative modeling. To address this gap, the proposed theory provides closed-form expressions for self-inductance, leakage inductance, and mutual coupling terms for arbitrary multi-phase, multi-port transformer structures. The formulation enables direct synthesis of isolated multi-input and multi-output resonant converter systems without reliance on geometry-specific finite-element analysis or extensive parameter extraction. This capability is particularly critical for power-multiplexed systems, where modular converter structures must interface with multiple vehicles while maintaining galvanic isolation and flexible power allocation. The effectiveness of the proposed framework is demonstrated through the design of a 360 kW multi-phase system operating over a 700–900 VDC input and 400–1250 VDC output range. PLECS simulation results confirm accurate prediction of system behavior and validate the applicability of the approach to multi-port, power-multiplexed charging scenarios. The proposed method significantly reduces design complexity while enabling scalable, cost-effective, and fully utilized EV fleet charging infrastructure.

Asa, Erdem [ORNL] (ORCID:0000000190884812)↗

DOE OSTI2021

A High-Efficiency Isolated PFC AC-DC Topology with Reduced Number of Semiconductor Devices

A new three-level isolated ac-dc power factor correction (PFC) topology with a minimum number of semiconductor devices is the focus of this paper. This topology provides a high input power factor (PF), soft-switching, and higher efficiency than existing isolated ac-dc converters. Furthermore, the proposed circuit has lower voltage rating requirements for the secondary side devices, which leads to a lower total cost and minimizes total converter losses. This article presents a theoretical analysis describing the complete characterization of this new topology, and experimental results on a 1-kW prototype showing high PF and efficiency throughout the operating range.

42 ENGINEERING↗