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FY2008 Annual Progress Report for the Advanced Power Electronics and Electric Machinery Program

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FY2008 Annual Progress Report for the Advanced Power Electronics and Electric Machinery Program annual progress report 2008V EHICLE TECHNOLOGIES PROGRAM ANNUAL PROGRESS REPORT FOR THE ADVANCED POWER ELECTRONICS AND ELECTRIC MACHINERY TECHNOLOGY AREA A Strong Energy Portfolio for a Strong America Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies. For more information contact: EERE Information Center 1-877-EERE-INF (1-877-337-3463) www.eere.energy.gov U.S. Department of Energy FreedomCAR and Vehicle Technologies, EE-2G 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121 FY 2008 Annual Progress Report for the Advanced Power Electronics and Electric Machinery Technology Area Submitted to: Energy Efficiency and Renewable Energy Vehicle Technologies Program Susan A. Rogers, Technology Development Manager January 2009 Power Electronics and Electric Machines FY 2008 Progress Report Contents Page Contents .......................................................................................................................................................iii Acronyms and Abbreviations ......................................................................................................................iv 1. Introduction..............................................................................................................................................1 2. Thermal Management Systems................................................................................................................5 2.1 Direct-Cooled Power Electronics Substrate.....................................................................................5 2.2 Characterization and Development of Advanced Heat Transfer Technologies.............................15 2.3 Research and Development of Air Cooling Technology for Power Electronics Thermal Control ...........................................................................................................................................27 2.4 Project Title: Thermal Stress & Reliability for Advanced Power Electronics & Electric Machines........................................................................................................................................40 2.5 Project Title: Power Electronics Thermal System Performance and Integration...........................53 2.6 Thermal interface materials for power electronics applications ....................................................65 3. Electric Machinery Research and Technology Development.................................................................78 3.1 Uncluttered Rotor PM Machine for a CVT Design .......................................................................78 3.2 Axially Excited Electro-Magnetic Synchronous Motor.................................................................86 3.3 Application of Concentrated Windings to Electric Motors without Surface-Mounted PMs .........96 3.4 Amorphous Core Material Evaluation .........................................................................................109 3.5 Development of Improved Powder for Bonded Permanent Magnets ..........................................116 4. Power Electronics Research and Technology Development ................................................................128 4.1 Wide Bandgap Materials..............................................................................................................128 4.2 An Active Filter Approach to the Reduction of the dc Link Filter ..............................................135 4.3 Advanced Converter Systems for High-Temperature Hybrid Electric Vehicle Environments ...............................................................................................................................142 4.4 Current Source Inverter................................................................................................................154 4.5 Using the Traction Drive Power Electronics System to Provide Plug-in Capability for Hybrid Electric Vehicles (HEVs) ................................................................................................166 4.6 High Dielectric Constant Capacitors for Power Electronic Systems...........................................176 4.7 Glass Ceramic Dielectrics for DC Bus Capacitors ......................................................................185 4.8 High Temperature Thin Film Polymer Dielectric Based Capacitors for HEV Power Electronic Systems.......................................................................................................................191 5. Systems Research and Technology Development ................................................................................198 5.1 Benchmarking of Competitive Technologies ..............................................................................198 iii Power Electronics and Electric Machines FY 2008 Progress Report Acronyms and Abbreviations 3D 3-dimensional AEEMS axially excited electromagnetic synchronous AlN aluminum nitride APEEM Advanced Power Electronics and Electric Machines APF active power filter BCD bipolar CMOS-DMOS BeO beryllium oxide CMOS complementary metal–oxide semiconductor CPLD complex programmable logic device CSI current source inverter CVT continuously variable transmission DBC direct-bonded copper DMOS double-diffused metal-oxide semiconductor DOE Department of Energy DSP digital signal processing ECVT electronically-controlled continuously variable transmission EETT Electrical and Electronics Technical Team ESR equivalent series resistance EV electric vehicle FEA finite element analysis FreedomCAR derived from “Freedom” and “Cooperative Automotive Research” FSCW fractional-slot concentrated windings FUDS Federal Urban Driving Schedule HEV hybrid electric vehicle IC integrated circuit ICE internal combustion engine IGBT insulated gate bipolar transistor INV/CONV inverter/converter IPM interior permanent magnet JFET junction field effect transistor MG motor/generator MOSFET metal-oxide semiconductor field-effect transistor NMOS negative-channel metal-oxide semiconductor iv Power Electronics and Electric Machines FY 2008 Progress Report OEM original equipment manufacturer ORNL Oak Ridge National Laboratory PCB printed circuit board PCU power converter unit PHEV plug-in hybrid electric vehicle PM permanent magnet PMOS positive-channel metal-oxide semiconductor PWM pulse-width modification SiC silicon carbide SOI silicon-on-insulator SR set/reset TC temperature coefficient THD total harmonic distortion VSATT Vehicle Systems Analysis Technical Team VSI voltage source inverter VTP Vehicle Technologies Program WBG wide-bandgap WEG water–ethylene glycol ZSIN zero-sequence impedance networks Power Electronics and Electric Machines FY 2008 Progress Report 1. Introduction The objective of the Advanced Power Electronics and Electric Machines (APEEM) activity is to develop technologies compatible with the high-volume manufacturing of motors, inverters, and DC/DC converters that will enable the automotive industry to achieve the goal by 2020 of an electric propulsion system with a 15-year life capable of delivering at least 55 kW for 18 seconds and 30 kW continuous at a system cost of $8/kW peak. In order to make the electric propulsion system practical and affordable, the cost must be reduced by about 80%, the specific power must be increased by about 50%, the power density increased by about 55%, and the efficiency increased by about 10%. Researchers supporting the Advanced Power Electronics and Electric Machines R&D activity continued to make significant progress in meeting these challenges during FY 2008. In FY08 the APEEM motor activity concentrated on reducing cost via reductions in manufacturing costs, improvements in motor efficiency, elimination of the need for permanent magnets, and integrating the motor and generator functionality into a single machine. The amorphous core assessment concluded that the high cost of the amorphous material and its unavailability in forms needed for electric motor cores does not allow it to meet the cost targets. Even though significant decreases in core losses are experienced the low saturation flux limits the ability of the material to meet the performance requirements. Analysis of the concentrated windings approach indicated that in addition to anticipated manufacturing cost benefits the motor design offered reduced torque ripple and higher efficiency because of reduced copper losses. However, the motor had difficulty meeting the power requirements of the US06 driving cycle without modification of the gear set. The uncluttered CVT design was modeled and the machine delivered a 30% increase in torque with a weight increase (compared to the baseline motor) of only 15%. In addition, the efficacy of the 3­ dimensional torque path was confirmed. Design development of the axially excited motor concept indicated that with the unique rotor configuration developed by ORNL a feasible design emerged that yielded a specific power of 1 kW/kg with a power density of 5 kW/L. This confirmed that it may be possible to achieve PM like performance from a PM-less motor. The power electronics activity concentrated on topology activities that incorporated multiple functionality into a single unit and reduced the need for bulk capacitance, PE options for
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