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FY2001 Progress Report for the Vehicle Power Electronics And VEHICLE POWER ELECTRONICS AND ELECTRIC MACHINES 2001 ANNUAL PROGRESS REPORT U.S. Department of Energy Energy Efficiency and Renewable Energy Office of Transportation Technologies ACKNOWLEDGEMENT We would like to express our sincere appreciation to National Renewable Energy Laboratory and Energetics, Inc., for their artistic and technical contributions in preparing and publishing this report. In addition, we would like to thank all our program participants for their contributions to the programs and all the authors who prepared the project abstracts that comprise this report. U.S. Department of Energy Office of Advanced Automotive Technologies 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121 FY 2001 Progress Report for the Vehicle Power Electronics and Electric Machines Program Energy Efficiency and Renewable Energy Office of Transportation Technologies Office of Advanced Automotive Technologies Energy Management Team David Hamilton Program Manager December 2001 Contents 1. INTRODUCTION ...........................................................................................................................1 2. AUTOMOTIVE INTEGRATED POWER MODULES (AIPM)...............................................................5 · Silicon Power Corporation (SPCO)/Rockwell...........................................................................5 · Satcon.................................................................................................................................. 17 · Semikron ............................................................................................................................. 22 · AIPM Validation Testing and Contract Support ...................................................................... 26 3. AUTOMOTIVE ELECTRIC MOTOR DRIVE (AEMD).....................................................................28 · Delco Remy ......................................................................................................................... 28 · Delphi.................................................................................................................................. 34 · AEMD Validation Testing and Contract Support .................................................................... 40 4. CAPACITORS .............................................................................................................................42 · High Dielectric Constant Capacitor Technologies for Power Electronic Systems ...................... 42 · Dc Bus Capacitors for PNGV Power Electronics .................................................................... 47 · Mechanical Reliability of Electronic Ceramics and Electronic Ceramic Devices....................... 54 5. MAGNETIC MATERIALS .............................................................................................................58 · Development of Improved Powder for Bonded Permanent Magnets......................................... 58 · Low-Cost, High Energy-Product Permanent Magnets ............................................................. 62 6. THERMAL MANAGEMENT..........................................................................................................67 · CARAT – Use of Micro-PCM Fluids as Enhanced Liquid Coolants in Automotive Electric and Hybrid Electric Vehicles ....................................................................................................... 67 · Carbon Foam for Electronics Cooling .................................................................................... 74 · SBIR - Improved Rotor Cooling for PM Machines.................................................................. 81 7. SUPPORTING RESEARCH............................................................................................................85 · Fiber-optic Microsensors for Automotive Power Electronics ................................................... 85 · Silicon-Carbide Modeling Tool for Transportation Applications .............................................. 87 · Field Weakening and Magnet Retention for PM Machines ...................................................... 93 · Inverter/Converter Topologies and Packaging R&D.............................................................. 100 · Electric Machinery R&D..................................................................................................... 113 · Real-Time Platform for the Evaluation of Electric Machinery Control Algorithms .................. 125 · HEV Motor Inverter Modeling ............................................................................................ 136 · Exploration of Advanced Propulsion Concepts and Control................................................... 145 · HEV Switched Reluctance Machines ................................................................................... 150 · SBIR – Integrated Electric Traction System.......................................................................... 155 · 8. ACRONYMS ............................................................................................................................. 159 i ii 1. INTRODUCTION Power Electronics and Electric Machines Program On behalf of the Department of Energy's Office of Advanced Automotive Technologies (OAAT), I am pleased to introduce the Fiscal Year (FY) 2001 Annual Progress Report for the Power Electronics and Electric Machines Program. Together with DOE laboratories and in partnership with private industry and universities, OAAT engages in high-risk research and development that provides enabling technology for fuel-efficient and environmentally friendly light- and heavy-duty vehicles. Through many of its technology research programs, the DOE Office of Advanced Automotive Technologies (OAAT) has supported the government/industry Partnership for a New Generation of Vehicles (PNGV) since its inception. The PNGV leadership is now re-evaluating the partnership goals to identify changes that will maximize the potential national petroleum-savings benefit of the emerging PNGV technologies. When these PNGV goal changes have been defined, the OAAT will adjust the focus of its technology research programs accordingly. The goal of the Power Electronics and Electric Machines Program is to develop power electronics and electric machinery technologies that enable dramatic decreases in vehicle system costs by increasing component integration, while maintaining system flexibility, high reliability, ruggedness, low volume, and low weight. National laboratories and universities are conducting high-risk, enabling technology R&D focused on overcoming the critical technical barriers that impede the development of advanced power electronics and electric machines. The lead laboratory in the Power Electronics and Electric Machines Program is Oak Ridge National Laboratory (ORNL). This program requires the close coordination of research and diagnostic efforts at a number of national laboratories and universities, primarily Argonne National Laboratory (ANL), Lawrence Livermore National Laboratory (LLNL), Sandia National Laboratory (SNL), Pennsylvania State University (PSU), Ames Laboratory, University of Tenessee (UT), and North Carolina State University (NCS). The Power Electronics and Electric Machines Program is also partnering with automotive suppliers and other federal government agencies to develop technologies that will be compatible with automotive-scale manufacturing and other attributes conducive to wide- scale deployment in allied applications to ensure lowest possible cost. This approach ensures that the resulting technologies reside with companies that not only have the capability to supply derived products, but also have a return-on-investment incentive to do so. Within OAAT, the Power Electronics and Electric Machines Program works in cooperation with the Automotive Propulsion Materials, Advanced Combustion and Emissions Control, and the Fuel Cells for Transportation research and development programs. Projects within the Power Electronics and Electric Machines Program address integrated power controls, integrated chassis system controls, and navigational and 1 communication systems that are needed to enable the success of these other OAAT/DOE programs. Addressing Technical Challenges Significant progress has been made in the development of more efficient electric machinery such as permanent magnet AC traction motors and high-power electronic controls. These technologies demonstrate the feasibility of designing and delivering hybrid and electric vehicles that can achieve the performance levels of current light-duty automobiles. However, major barriers must still be overcome in power electronics and electric machines development. High system cost remains critical, as do thermal management and the high degree of reliability and ruggedness demanded for automotive applications, while under the intense thermal stress of the power devices and the harsh environmental conditions. Volume and weight considerations and other integration issues remain important, due mainly to signal radiation considerations. Materials, processing, and fabrication technologies for both power electronics and electric machinery are currently too expensive for automotive applications. Existing power electronics and electric machinery are bulky, heavy and difficult to package in automotive applications. The challenge of simultaneously achieving low cost and high performance is exacerbated by the need to effectively package and cool the components. The components
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