N141-073 TITLE: Multi-Stage, Multi-Phase, High Efficiency, Intelligent, Electrical Energy Conversion Unit for Navy and USMC

TECHNOLOGY AREAS: Ground/Sea Vehicles, Sensors, Electronics

OBJECTIVE: Develop an electrical energy conversion unit for sea vehicles and expeditionary systems that has a volumetric power density of 500 kW/m^3, a frequency of 50-100 kHz, 97% efficiency with a minimum efficiency of 94%, and is 2-man portable.

DESCRIPTION: The Navy and USMC are embarking on an aggressive power and energy program for applications in surface and underwater vehicles as well as expeditionary systems. Limited by either shipboard space and weight or portability, the Navy and USMC require innovative technology solutions to increase electrical energy conversion efficiency and density in order to reduce volume, weight, and cost.

As of 2011, demonstrated state-of-the-art converter technology was capable of 210-230 kW/m^3, though this excludes the thermal management unit. The frequency range was 10-20 kHz with roughly 94% efficiency. For this program, the objective is to develop an electrical energy conversion unit for sea vehicles and expeditionary systems that has a volumetric power density of 500 kW/m^3 including cooling, a frequency up to 50-100 kHz, maximum 97% efficiency with a minimum efficiency of 94%, and is 2-man portable.

PHASE I: Perform a feasibility study and develop physics-based models in order to produce a converter design capable of meeting the following:

For this program, the objective is to develop an electrical energy conversion unit for sea vehicles and expeditionary systems that has a volumetric power density of 500 kW/m^3 including cooling, a frequency up to 50-100 kHz, maximum 97% efficiency with a minimum efficiency of 94% efficiency, and is 2-man portable.

Additional Requirements:
1. Ability to convert AC-DC, DC-AC, DC-DC, AC-AC
2. An adjustable speed drive capability for different electric machine configurations/topologies
3. Multi-stage power electronic system with thermal management included, and without external power source
4. Control of the electric machine forward and reverse without using external resistive loads
5. Real-time non-invasive prognostic/diagnostic capability of each phase of the electric machine and power electronics

PHASE II: Develop a prototype based on Phase I work for demonstration and validation. The prototype should be delivered at the end of Phase II. The design should be at TRL 3 or 4 at the end of this phase.

PHASE III: Integrate the Phase II developed converter into the P&E-FY14-01 FNC program for transition to the ESO acquisition program.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: The desired electrical power converter has direct applications in power conversion, machine drive, and transportation traction, making it broadly applicable to the commercial world.

REFERENCES:
1. D.G. Holmes and T.A. Lipo, Pulse Width Modulation for Power Converters: Principles and Practice, Number ISBN:0-471-20814-0. Wilsey.

2. Shin, H. B., J. G. Park, S. K. Chung, H. W. Lee and T. A. Lipo, "Generalized Steady-state Analysis of Multiphase Interleaved Boost Converter with Coupled Inductors," IEE Proc.-Electr. Power Appl., Vol. 152, No. 3, May 2005.

3. Gupta, R.K.; Mohapatra, K.K.; Somani, A.; Mohan, N.; "Direct-Matrix-Converter-Based Drive for a Three-Phase Open-End-Winding AC Machine With Advanced Features," Industrial Electronics, IEEE Transactions on , vol. 57, no. 12, pp.4032-4042, Dec. 2010.

4. Tenca, P., A.A. Rockhill, T.A. Lipo. "Low Voltage Ride-Through Capability for Wind Turbines based on Current Source Inverter Topologies." Seventh IEEE International Conference on Power Electronics and Drive Systems (IEEE PEDS 2007) November 27-30, 2007, Bangkok, Thailand.

5. Mohapatra, K.K., Gupta, R., Thuta, S., Somani, A., Umarikar, A., Basu, K., Mohan, N. "New research on AC-AC converters without intermediate storage and their applications in power-electronic transformers and AC drives" (2009) IEEJ Transactions on Electrical and Electronic Engineering, 4 (5), pp. 591-601.

6. S.D. Sudhoff and O. Wasynczuk, "Analysis and Average-Value Modeling of Line-Commutated Converter � Synchronous Machine Systems," IEEE Transactions on Energy Conversion, Vol. 8, No. 1, March 1993, pp. 92-99.

7. S.D. Sudhoff and K.A. Corzine, H.J. Hegner, D.E. Delisle, "Transient and Dynamic Average-Value Modeling of Synchronous Machine Fed Load-Commutated Converters," IEEE Transactions on Energy Conversion, Vol. 11, No. 3, September 1996, pp. 508-514.

8. Ning, Puqi; Boroyevich, Dushan; Wang, Fred; Jiang, Dong; Burgos, Rolando P.; Zhang, Di; Lai, Rixin; Karimi, Kamiar; Immanuel, Vikram; Solodovnik, Eugene, "Development of a 10 kW High Temperature, High Power Density, Three-Phase AC-DC-AC SiC Converter" CPES Conference 2012, Blacksburg, VA (April 1-3, 2012).

9. F. Schafmeister and J. Kolar, "Analytical calculation of the conduction and switching losses of the conventional matrix converter and the sparse matrix converter," Proc. of IEEE Applied Power Electronics Conference, vol. 2, pp. 875-881, 2005.

10. L. Abraham and M. Reddig, "Determination of switching losses in IGBTs by loss-summation method," Proc. of IEEE Industry Applications Society Annual Meeting, vol. 2, pp. 1061-1068, 1995.

KEYWORDS: Electrical Converter; Efficiency; Energy Security; Enhanced Performance; Thermal Performance; Power Electronics

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