skip to main content

Title: A 25kW Silicon Carbide 3kV/540V Series-Resonant Converter for Electric Aircraft Systems
In this work, a 25 kW all silicon carbide (SiC) series-resonant converter (SRC) design is proposed to enable a single stage dc to dc conversion from 3kV to 540V (±270V) for future electric aircraft applications. The proposed SRC consists of a 3-level neutral-point-clamped (NPC) converter using 3.3kV discrete SiC MOSFETs on the primary side, a H-bridge converter using 900V SiC MOSFET modules on the secondary side and a high frequency (HF) transformer. The detailed design methods for the SRC power stage and the HF transformer are presented. Especially, a tradeoff between the complexity for the cooling system and the need for power density is addressed in the transformer design, leading to a novel multi-layer winding layout. To validate the effectiveness of the proposed SRC design, a converter prototype has been developed and comprehensive experimental studies are performed.
; ; ;
Award ID(s):
Publication Date:
Journal Name:
2021 IEEE Applied Power Electronics Conference and Exposition (APEC)
Sponsoring Org:
National Science Foundation
More Like this
  1. A 300 V to 600 V 100 kW SiC MOSFET based one-cell switched tank converter (STC) is developed as a bidirectional dc-dc power transfer stage between the vehicle battery and the DC-link side of the vehicle dc-ac inverter. A continuous half-load 50 kW and short-period full-load 100 kW operation is targeted. Working principles of the proposed topology are analyzed. Design of the key components such as SiC MOSFET power modules, AC resonant capacitor and inductor is presented. A 100 kW prototype has been assembled and tested. An energy-efficient test platform is designed. The power density of the main power processing part is around 41.7 kW/L. The tested peak and full-load efficiencies are about 98.7% and 97.35%, respectively. The thermal performance has also been evaluated. Both the tested electrical and thermal results are consistent with the theoretical design.
  2. The CLLC converter is widely used in the power electronic applications as a DC transformer, which can provide galvanic isolation, bidirectional power flow and an adjustable output voltage with the use of proper controls. As the most critical component in the CLLC converter, the high frequency (HF) transformer should be optimized according to the design targets, such as efficiency and power density. Starting with the analysis of the CLLC operating characteristics, this paper proposes a formal approach to design the HF transformer of a 100kW CLLC converter for a grid-tied application. The optimization method for the HF transformer is presented and the effect of the resonant inductor is analyzed. The optimized transformer is simulated with the finite element analysis (FEA) and Matlab/Simulink.
  3. In this paper, a new topology for grid-connected solar PV inverter is proposed. The proposed topology employs an LLC resonant converter with high frequency isolation transformer in the DC-DC stage. The DC-DC converter stage is controlled to generate a rectified sine wave voltage and current at the line frequency. An unfolder inverter interfaces between this DC stage and the grid. Both phase-shift and frequency control methods are used to control the LLC resonant converter. The switching frequency is determined depending on the phase-shift angle to extend the zero-voltage switching (ZVS) region. The transformer leakage and magnetization inductances are also properly designed to provide ZVS for wide operation area. The LLC converter operates in the ZVS region except the narrow band around the zero-crossings of the inverter output current. Since the LLC resonant converter has a high frequency transformer, the line frequency transformer requirement is eliminated, and thus more compact and efficient design is obtained. The proposed topology is validated by the simulation and experimental results.
  4. This paper compares three different dc-dc topologies, i.e. boost converter, three-level flying capacitor multilevel converter (FCMC) and one-cell switching tank converter (STC) for a 100 kW electric vehicle power electronic system. This bidirectional dc-dc converter targets 300 V - 600 V voltage conversion. Total semiconductor loss index (TSLI) has been proposed to evaluate topologies and device technologies. The boost converter and one-cell STC have been fairly compared by utilizing this index. The simulation results of a 100 kW one-cell STC working at zero current switching (ZCS) mode have been provided. A 100 kW hardware prototype using 1200 V 600 A SiC power module has been built. The estimated efficiency is about 99.2% at 30 kW, 99.13% at half load, and 98.64% at full load. The power density of the main circuits is about 42 kW/L
  5. Chronic pain is a common disease and as a negative consequence can cause paralysis to an individual in the long run. Noninvasive brain stimulation is an effective method to reduce pain in the short term. However, for long-term treatment, neural data analysis along with the stimulation is highly desirable. In this work, a unique multilayer spiral coil with a total dimension of 500 μm×500 μm is designed in a 0.5 μm CMOS process to make it suitable for a fully implantable system. The electrical modeling of the coil is also analyzed and simulated using Keysight's Advanced Design System (ADS) software to compare the theoretical modeling results with the simulation results. The electromagnetic (EM) simulation to characterize the on-chip coil in-terms of scattering parameters (S-parameters), Q -factor, power transfer efficiency (PTE) is performed using the Ansys High-Frequency Structure Simulator (HFSS) software. The operating frequency of the WPT system is chosen to be within 402-405 MHz which is the Medical Implant Communication System (MICS) band. The simulated Q -factor of the proposed on-chip coil is approximately 15 at 402 MHz. The on-chip coil is integrated with an on-chip seven-stage rectifier and some commercial off-the-shelf (COTS) components such as a DC-DC converter andmore »a μ LED to design the complete optogenetic neuro-stimulation system. A minimum power transfer efficiency (PTE) of 0.4% is achieved through a 16 mm thick tissue media using the proposed WPT system. With that efficiency, the proposed system is able to provide constant power to light up a μ LED and proves to be a good candidate for neuromodulation applications.« less