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DOE OSTI2024

EVs@Scale Lab Consortium High-Power Charging Pillar Deep-Dive Technical Meeting

Managed under the the U.S. Department of Energy (DOE)-funded EVs@Scale Consortium, the High-Power Electric Vehicle Charging Hub Integration Platform (eCHIP) project aims to create an experimental platform for integration and control approaches in a direct current (DC), distribution-based high-power charging (HPC) system. The eCHIP project addresses the crucial need to design and validate efficient, low-cost, reliable, and interoperable solutions for a DC-coupled charging hub ("DC hub" for short). This report explains the design, development, and implementation process of an experimental platform for the DC hub. DC distribution holds significant potential for enhancing the operation of an HPC station architecture. However, there are challenges in establishing a DC hub, including interoperability, commoditization, distributed energy resource integration, stability, DC protection, and a lack of common system-level controllers. To address these challenges, a testing setup is required that accommodates commercial off-the-shelf (COTS) products, as well as novel, in-house designed solutions, to evaluate different use cases at rated power and voltage levels. The developed proof-of-concept charging platform and open-source SEMS allow the development and testing of various controllers and chargers from different vendors. The DC hub platform integrated EVs, an ESS, a PV system, and building load to demonstrate the flexibility of the platform. The open-source SEMS controlled the devices within the hub using a rule-based implementation, realizing available standards.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Time-resolved electron energy distribution functions at the substrate during a HiPIMS discharge with cathode voltage reversal

Abstract The time-dependent plasma properties of a high-power impulse magnetron sputtering plasma are investigated which include a positive ‘kick’ pulse on the sputtering target 2 μ s after the main negative pulse, this reversing the voltage on the cathode. At a substrate 15 cm distant from the magnetron, the time-dependent electron energy distribution function (EEDF), plasma potential, potential commute time and plasma diffusion properties are measured using a single Langmuir probe. Results show that the positive pulse on the target expels plasma and raises the plasma potential across the chamber on the order of 1 to 2 μ s, which is the time scale of the electron diffusion. The EEDF at the substrate fits a Druyvesteyn distribution during the main negative pulse rising slightly in average energy over time. The distribution is still Druyvesteyn and at the very start of the positive pulse, but then loses the higher energy electrons and drops in average electron energy as the positive pulse progresses. A Boltzmann equation solver, BOLSIG+, was used to predict the EEDF at the substrate during the positive pulse and it agrees best with the measurements assuming a value of 0.2 Td for the E / N (electric field/gas number density).

Physics↗

NASA NTRS1998

SiC Technology

Silicon carbide (SiC)-based semiconductor electronic devices and circuits are presently being developed for use in high-temperature, high-power, and/or high-radiation conditions under which conventional semiconductors cannot adequately perform. Silicon carbide's ability to function under such extreme conditions is expected to enable significant improvements to a far-ranging variety of applications and systems. These range from greatly improved high-voltage switching [1- 4] for energy savings in public electric power distribution and electric motor drives to more powerful microwave electronics for radar and communications [5-7] to sensors and controls for cleaner-burning more fuel-efficient jet aircraft and automobile engines. In the particular area of power devices, theoretical appraisals have indicated that SiC power MOSFET's and diode rectifiers would operate over higher voltage and temperature ranges, have superior switching characteristics, and yet have die sizes nearly 20 times smaller than correspondingly rated silicon-based devices [8]. However, these tremendous theoretical advantages have yet to be realized in experimental SiC devices, primarily due to the fact that SiC's relatively immature crystal growth and device fabrication technologies are not yet sufficiently developed to the degree required for reliable incorporation into most electronic systems [9]. This chapter briefly surveys the SiC semiconductor electronics technology. In particular, the differences (both good and bad) between SiC electronics technology and well-known silicon VLSI technology are highlighted. Projected performance benefits of SiC electronics are highlighted for several large-scale applications. Key crystal growth and device-fabrication issues that presently limit the performance and capability of high temperature and/or high power SiC electronics are identified.

Neudeck, Philip G.↗

DOE OSTI2023

Kinetic simulations of ignited mode cesium vapor thermionic converters

Cesium vapor thermionic converters are an attractive method of converting high-temperature heat directly to electricity, but theoretical descriptions of the systems have been difficult due to the multi-step ionization of Cs through inelastic electron–neutral collisions. This work presents particle-in-cell simulations of these converters, using a direct simulation Monte Carlo collision model to track 52 excited states of Cs. Here, these simulations show the dominant role of multi-step ionization, which also varies significantly based on both the applied voltage bias and pressure. The electron energy distribution functions are shown to be highly non-Maxwellian in the cases analyzed here. A comparison with previous approaches is presented, and large differences are found in ionization rates due especially to the fact that previous approaches have assumed Maxwellian electron distributions. Finally, an open question regarding the nature of the plasma sheaths in the obstructed regime is discussed. The one-dimensional simulations did not produce stable obstructed regime operation and thereby do not support the double-sheath hypothesis.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Voltage Estimation in Low-Voltage Distribution Grids with Distributed Energy Resources

Present distribution grids generally have limited sensing capabilities and are therefore characterized by low observability. Improved observability is a prerequisite for increasing the hosting capacity of distributed energy resources such as solar photovoltaics (PV) in distribution grids. In this context, this paper presents learning-aided low-voltage estimation using untapped but readily available and widely distributed sensors from cable television (CATV) networks. The cable broadband sensors offer timely local voltage magnitude sensing with 5-minute resolution and can provide an order of magnitude more data on the time-varying state of a secondary distribution system than currently deployed utility sensors. The proposed solution incorporates voltage readings from neighboring CATV sensors, taking into account spatio-temporal aspects of the observations, and estimates single-phase voltage magnitudes at all non-monitored low-voltage buses using random forests. The effectiveness of the proposed approach was demonstrated using a multi-phase 1572-bus feeder from the SMART-DS data set for two case studies passive distribution feeder (without PV) and active distribution feeder (with PV). The analysis was conducted on simulated data, and the results show voltage estimates with a high degree of accuracy, even at extremely low percentages of observable nodes.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2017

High Voltage Hybrid Electric Propulsion - Multilayered Functional Insulation System (MFIS) NASA-GRC

High power transmission cables pose a key challenge in future Hybrid Electric Propulsion Aircraft. The challenge arises in developing safe transmission lines that can withstand the unique environment found in aircraft while providing megawatts of power. High voltage AC, variable frequency cables do not currently exist and present particular electrical insulation challenges since electrical arcing and high heating are more prevalent at higher voltages and frequencies. Identifying and developing materials that maintain their dielectric properties at high voltage and frequencies is crucial.

Power distribution↗

NASA NTRS1976

Characteristics of corona impulses from insulated wires subjected to high ac voltages

Corona discharges arise due to ionization of air or gas subject to high electric fields. The free electrons and ions contained in these discharges interact with molecules of insulating materials, resulting in chemical changes and destroying the electrical insulating properties. The paper describes some results of measurements aimed at determining corona pulse waveforms, their repetition rate, and amplitude distribution during various randomly-sampled identical time periods of a 60-Hz high-voltage wave. Described are properties of positive and negative corona impulses generated from typical conductors at various test high voltages. A possible method for calculating the energies, densities, and electromagnetic interferences by making use of these results is suggested.

Doreswamy, C. V.↗

NASA NTRS1979

Effects of 1-MeV gamma radiation on a multi-anode microchannel array detector tube

A multianode microchannel array (MAMA) detector tube without a photocathode was exposed to a total dose of 1,000,000 rads of 1-MeV gamma radiation from a Co-60 source. The high-voltage characteristic of the microchannel array plate, average dark count, gain, and resolution of pulse height distribution characteristics showed no degradation after this total dose. In fact, the degassing of the microchannels induced by the high radiation flux had the effect of cleaning up the array plate and improving its characteristics.

Timothy, J. G.↗

NASA NTRS1988

Power conditioning for large dc motors for space flight applications

The design and performance of a prototype power-conditioning system for use with large brushless dc motors on NASA space missions are discussed in detail and illustrated with extensive diagrams, drawings, and graphs. The 5-kW 8-phase parallel module evaluated here would be suitable for use in the Space Shuttle Orbiter cargo bay. A current-balancing magnetic assembly with low distributed inductance permits high-speed current switching from a low-voltage bus as well as current balancing between parallel MOSFETs.

Veatch, Martin S.↗

NASA NTRS2006

Modular High-Energy Systems for Solar Power Satellites

Modular High-Energy Systems are Stepping Stones to provide capabilities for energy-rich infrastructure located in space to support a variety of exploration scenarios as well as provide a supplemental source of energy during peak demands to ground grid systems. Abundant renewable energy at lunar or other locations could support propellant production and storage in refueling scenarios that enable affordable exploration. Renewable energy platforms in geosynchronous Earth orbits can collect and transmit power to satellites, or to Earth-surface locations. Energy-rich space technologies also enable the use of electric-powered propulsion systems that could efficiently deliver cargo and exploration facilities to remote locations. A first step to an energy-rich space infrastructure is a 100-kWe class solar-powered platform in Earth orbit. The platform would utilize advanced technologies in solar power collection and generation, power management and distribution, thermal management, electric propulsion, wireless avionics, autonomous in space rendezvous and docking, servicing, and robotic assembly. It would also provide an energy-rich free-flying platform to demonstrate in space a portfolio of technology flight experiments. This paper summary a preliminary design concept for a 100-kWe solar-powered satellite system to demonstrate in-flight a variety of advanced technologies, each as a separate payload. These technologies include, but are not limited to state-of-the-art solar concentrators, highly efficient multi-junction solar cells, integrated thermal management on the arrays, and innovative deployable structure design and packaging to enable the 100-kW satellite feasible to launch on one existing launch vehicle. Higher voltage arrays and power distribution systems (PDS) reduce or eliminate the need for massive power converters, and could enable direct-drive of high-voltage solar electric thrusters.

Howell, Joe T.↗

NASA NTRS2005

Modular, Reconfigurable, High-Energy Systems Stepping Stones

Modular, Reconfigurable, High-Energy Systems are Stepping Stones to provide capabilities for energy-rich infrastructure strategically located in space to support a variety of exploration scenarios. Abundant renewable energy at lunar or L1 locations could support propellant production and storage in refueling scenarios that enable affordable exploration. Renewable energy platforms in geosynchronous Earth orbits can collect and transmit power to satellites, or to Earth-surface locations. Energy-rich space technologies also enable the use of electric-powered propulsion systems that could efficiently deliver cargo and exploration facilities to remote locations. A first step to an energy-rich space infrastructure is a 100-kWe class solar-powered platform in Earth orbit. The platform would utilize advanced technologies in solar power collection and generation, power management and distribution, thermal management, and electric propulsion. It would also provide a power-rich free-flying platform to demonstrate in space a portfolio of technology flight experiments. This paper presents a preliminary design concept for a 100-kWe solar-powered satellite with the capability to flight-demonstrate a variety of payload experiments and to utilize electric propulsion. State-of-the-art solar concentrators, highly efficient multi-junction solar cells, integrated thermal management on the arrays, and innovative deployable structure design and packaging make the 100-kW satellite feasible for launch on one existing launch vehicle. Higher voltage arrays and power management and distribution (PMAD) systems reduce or eliminate the need for massive power converters, and could enable direct- drive of high-voltage solar electric thrusters.

Howell, Joe T.↗

DOE OSTI2021

The Role of Metal Substitution in Tuning Anion Redox in Sodium Metal Layered Oxides Revealed by X‐Ray Spectroscopy and Theory

Abstract We investigate high‐valent oxygen redox in the positive Na‐ion electrode P2‐Na 0.67− x [Fe 0.5 Mn 0.5 ]O 2 (NMF) where Fe is partially substituted with Cu (P2‐Na 0.67− x [Mn 0.66 Fe 0.20 Cu 0.14 ]O 2 , NMFC) or Ni (P2‐Na 0.67− x [Mn 0.65 Fe 0.20 Ni 0.15 ]O 2 , NMFN). From combined analysis of resonant inelastic X‐ray scattering and X‐ray near‐edge structure with electrochemical voltage hysteresis and X‐ray pair distribution function profiles, we correlate structural disorder with high‐valent oxygen redox and its improvement by Ni or Cu substitution. Density of states calculations elaborate considerable anionic redox in NMF and NMFC without the widely accepted requirement of an A‐O‐A′ local configuration in the pristine materials (where A=Na and A′=Li, Mg, vacancy, etc.). We also show that the Jahn–Teller nature of Fe 4+ and the stabilization mechanism of anionic redox could determine the extent of structural disorder in the materials. These findings shed light on the design principles in TM and anion redox for positive electrodes to improve the performance of Na‐ion batteries.

Abate, Iwnetim↗

DOE OSTI2022

Performance Evaluation of Peer-to-Peer Distributed Microgrids Coordination for Voltage Regulation

This paper presents the performance evaluation of a peer-to-peer microgrids coordination algorithm for sub-transmission systems. As distributed energy resources (DERs) in distribution system start to show negative impact to the bulk power system, a paradigm shift is needed for transmission planning and operation. Because distribution substations are located far from the sub-transmission system, and it is hard to use traditional centralized control for real-time control and coordination. Thus, distributed control is a natural choice because it requires less communication and central computation. In this paper, each distribution substation is treated as a microgrid, and the peer-to-peer distributed microgrids control is formulated as a real-time optimal power flow problem to reduce the negative impact in sub-transmission systems. A distributed primal-dual optimization algorithm is adopted to solve the problem. Validation of the peer-to-peer algorithm is performed through the simulation of a real-world sub-transmission system composing of many distribution systems with high renewable penetration. Simulation results show that the peer-to-peer algorithm can achieve satisfactory performance (e.g., voltage regulation) in sub-transmission system by coordinating and controlling DERs in distribution systems.

distributed control↗

DOE OSTI2022

Performance Evaluation of Peer-to-Peer Distributed Microgrids Coordination for Voltage Regulation: Preprint

distributed control↗

NASA NTRS1984

Parametric analysis of hollow conductor parallel and coaxial transmission lines for high frequency space power distribution

A parametric analysis was performed of transmission cables for transmitting electrical power at high voltage (up to 1000 V) and high frequency (10 to 30 kHz) for high power (100 kW or more) space missions. Large diameter (5 to 30 mm) hollow conductors were considered in closely spaced coaxial configurations and in parallel lines. Formulas were derived to calculate inductance and resistance for these conductors. Curves of cable conductance, mass, inductance, capacitance, resistance, power loss, and temperature were plotted for various conductor diameters, conductor thickness, and alternating current frequencies. An example 5 mm diameter coaxial cable with 0.5 mm conductor thickness was calculated to transmit 100 kW at 1000 Vac, 50 m with a power loss of 1900 W, an inductance of 1.45 micron and a capacitance of 0.07 micron-F. The computer programs written for this analysis are listed in the appendix.

Jeffries, K. S.↗

NASA NTRS2017

Proposal and Development of a High Voltage Variable Frequency Alternating Current Power System for Hybrid Electric Aircraft

The development of ultra-efficient commercial vehicles and the transition to low-carbon emission propulsion are seen as strategic thrust paths within NASA Aeronautics. A critical enabler to these paths comes in the form of hybrid electric propulsion systems. For megawatt-class systems, the best power system topology for these hybrid electric propulsion systems is debatable. Current proposals within NASA and the Aero community suggest using a combination of alternating current (AC) and direct current (DC) for power generation, transmission, and distribution. This paper proposes an alternative to the current thought model through the use of a primarily high voltage AC power system, supported by the Convergent Aeronautics Solutions (CAS) Project. This system relies heavily on the use of doubly-fed induction machines (DFIMs), which provide high power densities, minimal power conversion, and variable speed operation. The paper presents background on the activity along with the system architecture, development status, and preliminary results.

Sadey, David J.↗

DOE OSTI2022

Grid-Connected Modular Soft-Switching Solid State Transformers (M-S4T)

The objective of this project is to develop and verify the concept of a flexible and modular soft-switching solid-state transformer (M-S4T) for direct grid-connected applications. The ability to directly connect power electronics converters to the medium voltage grid (4 kV – 13 kV), and to potentially replace the passive and bulky, but ubiquitous 60 hertz service transformer in the 25 kVA to 100 kVA range, with a more flexible and controllable device, has been regarded as the ‘holy grail’ in grid control. However, this has proven to be extremely difficult. This project has developed the solutions to several key challenges of the direct grid-connected power electronics and realized a 7.2 kV M-S4T prototype. First, a protection method to protect the M-S4T from the high voltages (110 kV for the 13 kV system) that occur on the grid due to transients and lightning strikes have been developed and experimentally verified. Second, the realization and the operation of the M-S4T based on high-voltage SiC devices (>3.3 kV) and a medium-frequency medium-voltage low-leakage transformer in a single-stage solid-state transformer with zero-voltage switching, low dv/dt, and low electromagnetic interference has been successfully demonstrated up to 7.5 kV peak. Third, an oil-cooling system and stable communication and distributed control system for converter module voltage sharing have been developed and experimentally verified. The developed M-S4T has realized a modular universal high-performance power conversion system. This conversion system is scalable to different voltage and power levels and adaptable to four-quadrant bidirectional operation. Moreover, the use of passive cooling techniques meets the equipment life requirements, and the lightning protection scheme fulfills the basic insulation level specifications for direct grid connection. Such power conversion system opens up near-term opportunities, including energy storage, solar PV, or electric vehicle charging with significant cost and footprint savings. In the longer term, the possibility of replacing the utility distribution transformer with an M-S4T will be transformative for future distribution grids with a compact footprint and full controllability to enable high renewable energy and storage penetration. In addition to the main project, this report expands on the Plus-Up projected including as part of the main award. This project developed and demonstrated the technology for autonomous collaborative inverters that can be connected in an ad hoc manner to the grid. The aim of the project was to: (1) evaluate the existing techniques for grid-connected inverters and find their limitations; (2) develop detailed requirements for grid-connected inverters in the modern grid with millions of active nodes; (3) design a unified control strategy that brings more autonomy and intelligence to grid-connected inverters, and addresses parts of the issues with the existing techniques. The proposed technique, called UniCon, enables inverters to 1) connect/disconnect to/from the grid in an ad hoc manner; (2) work based on local sensing. Slow communication could be used for a more optimized behavior; (3) work automatically in both grid-forming/grid-following mode; (4) handle large disturbances, e.g., big load step and fault, in an oscillation-free manner; (5) work collaboratively with other inverters in steady-state and during transients. UniCon can be implemented in the middle-level control; hence it is agnostic to the vendor and to the implementation of the inner voltage/current and protection loops. Furthermore, a new synchronization scheme, based on deep learning, was developed that can extract the grid voltage phase and amplitude in a stable manner. The method is cheap to implement can improve the dynamic performance of the grid-connected inverters during fast transients, e.g., fault. The proposed control scheme was validated by (1) MATLAB/Simulink; (2) hardware-in-the-loop results, and; (3) experimental results using three inverters that form a microgrid in a down-scaled feeder. Lastly, both the M-S4T and UniCon have achieved promising tangible paths to markets. In the case of the M-S4T, the underlying technology — the Soft Switching Solid State Transformer (S4T) developed at the Georgia Tech Center for Distributed Energy (GT-CDE) has been licensed by GridBlock from the Georgia Tech Research Corporation, and GridBlock has been working with manufacturing partner Jabil (one of the largest US-based contract manufacturers) and system integrator Power Secure (largest deployer of microgrids in the US with 4.7 GW under management), to meet the strong initial demand. Similarly, GridBlock has an exclusive license to the UniCon technology, developed under this award by GT-CDE. The UniCon provides an intermediate control layer that enables the implementation of the higher-level ‘transactive’ control commands for the system. The architecture of the system - slow communications with the cloud for system optimization and setpoints, and the use of locally measured quantities for real-time control, provide a very robust and secure way of implementing a real-time must-run grid that is also secure and stable. This is a brand-new functionality that is critical for the future grid and key to GridBlock’s business model.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS1990

Automation in the Space Station module power management and distribution Breadboard

The Space Station Module Power Management and Distribution (SSM/PMAD) Breadboard, located at NASA's Marshall Space Flight Center (MSFC) in Huntsville, Alabama, models the power distribution within a Space Station Freedom Habitation or Laboratory module. Originally designed for 20 kHz ac power, the system is now being converted to high voltage dc power with power levels on a par with those expected for a space station module. In addition to the power distribution hardware, the system includes computer control through a hierarchy of processes. The lowest level process consists of fast, simple (from a computing standpoint) switchgear, capable of quickly safing the system. The next level consists of local load center processors called Lowest Level Processors (LLP's). These LLP's execute load scheduling, perform redundant switching, and shed loads which use more than scheduled power. The level above the LLP's contains a Communication and Algorithmic Controller (CAC) which coordinates communications with the highest level. Finally, at this highest level, three cooperating Artificial Intelligence (AI) systems manage load prioritization, load scheduling, load shedding, and fault recovery and management. The system provides an excellent venue for developing and examining advanced automation techniques. The current system and the plans for its future are examined.

Walls, Bryan↗