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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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DOE OSTI2016

Avoiding Divergent Oscillation of Cascode GaN Device under High Current Turn-off Condition

Cascode structure is widely used for high voltage normally-on GaN devices. However, the capacitance mismatch between the high voltage GaN device and the low voltage normally- off Si MOSFET may induce several undesired features, such as Si MOSFET reaches avalanche during turn-off, and high voltage GaN device loses ZVS turn-on condition internally during soft-switching turn-on process in every switching cycle. This paper presents another issue associated with the capacitance mismatch in the cascode GaN devices. Divergent oscillation could occur at high current turn-off condition, and eventually destroy the device. The intrinsic reason of this phenomenon is analyzed in detail in this paper. A simple solution is proposed by adding an additional capacitor whose position is critical and should be optimized. Experimental results validate the theoretical analysis, and show that the proposed method improves device performance significantly under high current turn-off condition.

Du, Weijing↗

DOE OSTI2017

Multi-phase Coupled and Integrated Inductors for Critical Conduction Mode Totem-Pole PFC Converter

Coupled inductor has been widely used in voltage regulator (VR) applications for many years because it can help reducing current ripple and improving transient performance. In this paper, the coupled inductor concept is applied to interleaved totem-pole critical conduction mode (CRM) PFC converter for 6.6kW on board battery charger. The difference between negative coupling and positive coupling will be discussed. The benefit of positive coupling for battery charger will be presented, such as reducing switching frequency range and reducing input differential mode (DM) noise. In addition, balance technique is applied to help minimize common mode (CM) noise. Last but not least, the inductor will be integrated into PCB winding with a little sacrifice on loss. With the inductor integration, the converter can avoid labor intensive production and achieve fully automated manufacture. The analysis is verified by both simulation and experiment.

Yang, Yuchen↗

DOE OSTI2017

A Novel PCB Winding Transformer with Controllable Leakage Integration for a 6.6kW 500kHz High Efficiency High Density Bi-Directional On-Board Charger

Printed Circuit Board (PCB) transformer has been widely used in low power applications. Compared with conventional litz-wire transformer, the manufacture process is greatly simplified and the parasitic is much easier to control. However, in high power applications like on-board charger for electric vehicle, no one has ever done it due to the limitation of high winding loss and high multi-layer PCB cost. The emerging wideband- gap devices provide the opportunity to adopt PCB transformer in high power applications. In addition, the low inductance requirement brought by high frequency also makes it possible to realize magnetic integration in PCB transformer. In this paper, by using a two stage variable DC-link voltage structure, a novel 6-layer only PCB winding transformer structure is proposed for the second stage of the 6.6kW on-board charger, of which leakage inductance is controllable without sacrificing winding loss. A 6.6kW 500kHz prototype with almost 98% efficiency and 130W/in3 power density is built to verify the feasibility of the proposed PCB winding transformer.

42 ENGINEERING↗

DOE OSTI2017

Bi-Directional On-Board Charger Architecture and Control for Achieving Ultra-High Efficiency with Wide Battery Voltage Range

One challenge of on board charger application is bi-directional operation. Due to the absence of reverse recovery charge and small junction capacitance, it is much easier to do bi-directional operation using wide band gap devices. Another challenge is the very wide battery voltage range. It is very difficult to optimize converter over the whole battery voltage range and efficiency drops either the battery voltage is too high or too low. In this paper, a novel two stage structure is proposed utilizing both SiC and GaN devices. Bi-directional power flow as well as zero voltage switching is achieved with the proposed structure. In addition, a variable DC-link voltage operation is adopted to deal with the wide battery voltage range so that the CLLC resonant converter can always work at its optimized point. Design considerations of the two stage on-board charger are introduced, including system structure evaluation, resonant converter design and control strategy. A 6.6kW on board charger prototype with 500kHz (300kH for AC/DC stage) switching frequency is demonstrated with 43W/in3 power density and above 96% efficiency over the whole battery voltage range.

Li, Bin↗

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

The Impact of the Lightning Surge on SiC-based Medium-voltage Three-phase Four-wire Grid-connected Converters

The surge voltage induced by lightning will generate an inrush current in a grid-connected converter. It may not be large in Si-based converters because of the large grid side inductive filter. However, for SiC-based multi-level converters, the inrush current could be very large due to the small filter inductance, which is selected based on the current harmonic consideration. Most previous work focuses on system-level lightning protection while the converter-level impact, especially the internal components of the converter, is rarely discussed. This paper presents the analysis of the impact of the lightning surge on a 10 kV SiC MOSFET-based 13.8 kV three-phase four-wire grid-connected converter. The IEEE arrester model and the combined wave generator model in IEC 61000-4-5 standard are used to evaluate the inrush current, DC-link overvoltage, and component-to-ground potential of the converter. Analysis and simulation results have been provided to demonstrate the impact of lightning on the grid-connected converter. It is found that large inrush current occurs due to the small filter inductance, and the neutral-to-ground impedance impacts both the inrush current and the neutral point-to-ground potential.

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↗

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 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

Hybrid Analysis of Fusion Data for Online Understanding of Complex Science on Extreme Scale Computers

The current practice for fusion scientists running first principle simulations on high performance computing plat-forms is to either run their simulations and output their data for post-hoc analysis, or to place in situ analytics into their code. In this paper we examine a complex workflow using XGC fusions simulation run on the Oak Ridge Leadership Computing Facility's supercomputer Summit, which also involve three anal-yses as part of the results necessary for scientific discovery. We discuss the challenges faced when implementing these algorithms and present an original hybrid staging technique to help enable the physicists to make discoveries during the execution of the simulation. By creating this infrastructure, we can examine complicated physics results, which may not have been possible without the infrastructure. For example, our work enables the online visualization of turbulent homoclinic tangle around the magnetic X-point, breaking the last confinement surface. This visualization could help fusion scientists to better understand and improve the turbulence spread of plasma exhaust heat, which is crucial toward realizing plasmas beyond the currently accessible physics regimes of present-day tokamak reactors. The physics of turbulent homoclinic tangle will be reported in a future physics publication, by utilizing the original online analysis/visualization framework presented in this paper.

Suchyta, Eric↗

DOE OSTI2025

A Versatile Simulated Data Transport Layer for in Situ Workflows Performance Evaluation

In situ processing does not only allow scientific applications to face the explosion in data volume and velocity but also to address the time constraints of many simulation-analysis workflows by providing scientists with early insights about their applications at runtime. Multiple frameworks implement the concept of a data transport layer (DTL) to enable such in situ workflows. These tools are very versatile, directly or indirectly access the data generated on the same node, another node of the same compute cluster, or a completely distinct node, and allow data publishers and subscribers to run on the same computing resources or not. This versatility puts on researchers the onus of taking key decisions related to resource allocation and how to transport data to ensure the most efficient execution of their in situ workflows. However, domain scientists and workflow practitioners lack the appropriate tools to assess the respective performance of particular design and deployment options. In this paper we introduce a versatile simulated DTL designed to provide researchers with insights on the respective performance of different execution scenarios of in situ workflows. This open-source, standalone library builds on the SimGrid toolkit and can be linked to any SimGrid-based simulator. It facilitates the evaluation of the performance behavior, at scale, of different data transport configurations and the study of the effects of resource allocation strategies. We demonstrate the scalability, versatility, and accuracy of this simulated DTL by reproducing the execution of two synthetic benchmarks and of a real-world in situ workflow composed of an MPI application and a parallel data analysis. Results of simulations run on a single core show that the proposed library can simulate the interactions of tens of thousands of simulated processes deployed on two interconnected commodity clusters in a few seconds, and the execution by a thousand simulated processes of an in situ workflow in less than three minutes.

Suter, Fred [ORNL] (ORCID:0000000319021955)↗

DOE OSTI2023

Driving Next-Generation Workflows from the Data Plane

We observe the emergence of a new generation of scientific workflows that process data produced at a sustained rate by scientific instruments and large scale numerical simulations. This data is consumed by multiple analysis, visualization, or Machine Learning components not only to enable inference and justify the scientific program, but also to monitor and steer the evolution of these experiments. In such workflows, moving intermediate data efficiently is key to performance, more than efficiently scheduling computational tasks. However, most traditional workflow management systems focus on optimizing task scheduling and then deal with data management, assuming a “move little, compute for long” model, which makes them unfit to the efficient management of this new generation of workflows. Therefore, we advocate for a new way to manage scientific workflows. We propose to consider an efficiently and independently managed data plane that can store and stream data. Workflows compute components, in the application plane can then interact with the data plane, abstracted from complexities of data management. Then, the role of a workflow management system would become that of a control plane that allows users to connect services together to execute the workflow and manages connections between the application and data planes. In this position paper, we characterize several next-generation workflow motifs and describe how their interaction with the data plane is a challenge to traditional workflow management systems. Then, we express a set of requirements that a workflow management system should meet to efficiently manage next-generation workflows at different scales. Based on these requirements, we expose our vision of driving next-generation workflows from the data plane and list remaining open challenges.

Suter, Fred↗

DOE OSTI2024

Workflow Provenance in the Computing Continuum for Responsible, Trustworthy, and Energy-Efficient AI

As Artificial Intelligence (AI) becomes more pervasive in our society, it is crucial to develop, deploy, and assess Responsible and Trustworthy AI (RTAI) models, i.e., those that consider not only accuracy but also other aspects, such as explainability, fairness, and energy efficiency. Workflow provenance data have historically enabled critical capabilities towards RTAI. Provenance data derivation paths contribute to responsible workflows through transparency in tracking artifacts and resource consumption. Provenance data are well-known for their trustworthiness helping explainability, reproducibility, and accountability. However, there are complex challenges to achieve RTAI, which are further complicated by the heterogeneous infrastructure in the computing continuum (Edge-Cloud-HPC) used to develop and deploy models. As a result, a significant research and development gap remains between workflow provenance data management and RTAI. In this paper, we present a vision of the pivotal role of workflow provenance in supporting RTAI and discuss related challenges. We present a schematic view between RTAI and provenance, and highlight open research directions.

Santos Souza, Renan↗

DOE OSTI2024

Towards Resilient Near Real-Time Analysis Workflows in Fusion Energy Science

Nuclear fusion holds the promise of an endless source of energy. Several research experiments across the world and joint modeling and simulation efforts between the nuclear physics and high performance computing communities are actively preparing the operation of the International Thermonuclear Experimental Reactor (ITER). Both experimental reactors and their simulated counterparts generate data that must be analyzed quickly and in a resilient way to support decision making for the configuration of subsequent runs or prevent a catastrophic failure. However, the cost if the traditional techniques used to improve the resilience of analysis workflows, i.e., replicating datasets and computational tasks, becomes prohibitive with explosion of the volume of data produced by modern instruments and simulations. Therefore, we advocate in this paper for an alternate approach based on data reduction and data streaming. The rationale is that by allowing for a reasonable, controlled, and guaranteed loss of accuracy it becomes possible to transfer smaller amounts of data, shorten the execution time of analysis workflows, and lower the cost of replication to increase resilience. We develop our research and development roadmap towards resilient near real-time analysis workflows in fusion energy science and present early results showing that data streaming and data reduction is a promising way to speed up the execution and improve the resilience of analysis workflows.

Suter, Fred↗

DOE OSTI2016

Design of CRM AC/DC Converter for Very High-Frequency High-Density WBG-Based 6.6kW Bidirectional On-Board Battery Charger

The wide-band-gap (WBG) devices based 6.6 kW bidirectional on-board charger (OBC) system for plug-in electric vehicles (PEVs) is recently developed. With the proposed novel variable DC-link voltage system architecture, high frequency soft switching operation, and integrated magnetics, the OBC system becomes more compact and more efficient compared to a Sibased counterpart. The design considerations of the AC/DC stage are introduced in this paper including the evaluation of 1.2 kV SiC MOSFETs; the zero-voltage-switching (ZVS) extension function for the line-cycle ZVS operation; and the novel universal control strategy for both the rectifier mode and the inverter mode. The prototype of the AC/DC stage is built which achieves 98.5% efficiency at higher than 300 kHz switching frequency. Finally, the complete 6.6 kW OBC system using both SiC and GaN devices is demonstrated with 37 W/in3 power density and above 96% efficiency.

Liu, Zhengyang↗

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 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↗