The mass-market adoption of electrification in the transportation sector mandates stringent and aggressive requirements in terms of cost, power rating, efficiency, power density, and specific density of power electronics. Modular packaging of power electronics is advantageous and thus ubiquitously used by the automotive industry. A trend of shrinking die sizes and increased integration is evident and will inevitably continue. The thermal management system has become ever more significant as it is one of the main obstacles to higher power densities. The cooling system must be cost-effective, simple, efficient, reliable, and compatible with system requirements. Pin fins are a reliable and effective means of augmenting heat transfer. They rely on inducing turbulence, increasing the effective wetted surface, and accelerating fluid velocity. Unavoidably the pin fin array also produces an undesirable pressure drop that is commensurate to the pumping power required for the system. In this thesis, a tool is developed for the geometry optimization of pin fin arrays to dissipate the heat at a rate large enough to ensure junction temperatures do not exceed the maximum value possible at a minimal pressure drop. It is hoped that this tool would contribute to the multi-physics optimization and integration of power electronics for electrified vehicles. This optimization is confined to equalaterally spaced short pin fins, aspect ratios less than three. The tool employs empirical correlations since flow is too complex to solve analytically and numerical solutions or CFD-simulations are too time and computationally extensive. The tool development is done in a comprehensive manner. Starting from the first principles of a two-level voltage source inverter's operation. Next, the inevitable power losses from the operation are explained and a method for their calculations is presented. Correlations in the literature related to both pressure drop and heat transfer are reviewed afterward. Then the methodology of the construction of the tool is explicated in detail. Employing a commercial power module to benchmark results; three scenarios with different flow rates and inlet temperatures are optimized for. Simulations in ANSYS Fluent are run to verify the accuracy of correlations used in the tool. Comparing the optimized geometry of pin fins to the original benchmarking geometry it is evident that employing this tool on a per-application basis provides superior performance. / Thesis / Master of Applied Science (MASc)

Many distributed energy resource (DER) systems are remotely located and are often interfaced at low or medium voltage levels through power electronics converters such as voltage-sourced converters (VSC). Therefore, a weak-grid situation is encountered where the voltage and frequency at the point of DER coupling can experience fluctuations. A power converter designed to operate in normal and strong grid conditions may not perform satisfactorily during such weak and distorted grid conditions. Hence, considering the full dynamics of the system during weak-grid conditions in the design of converter control is indispensable to ensure the stability of the DER and the grid. For instance, the phase-locked loop (PLL) has been identified as a critical component of the VSC controller that can compromise the DER performance during weak-grid conditions. This dissertation investigates and enhances the performances of inverters connected to weak and polluted grids. It primarily presents a novel approach of enhancing the inverter current controller by including the PLL state variables among the entire system state and use them to optimally generate the control input for the VSC. This mitigates the loop interactions between the PLL and other control loops resulting in a mitigation of the oscillations that could cause system instabilities. The procedure is accomplished using the recently developed linear model of the enhanced PLL (EPLL) for single-phase applications and using a model of the three-phase PLL developed in this dissertation. Extensive simulation and experimental results are presented to evaluate and validate the proposed control approaches. Full practical models of all system components are considered for simulation studies. The experimental tests are done on a practical inverter connected to the utility grid. Significant improvement of the inverter performance in weak-grid conditions is confirmed. This dissertation offers a systematic way of integrating and designing the PLL and controller in a VSC to achieve a robust performance in weak-grid conditions.

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This dissertation is devoted to a unified and comprehensive study of zero-current-transition (ZCT) soft-switching techniques for high-power three-phase PWM inverter applications. Major efforts in this study are as follows: 1) Conception of one new ZCT scheme and one new ZCT topology; 2) Systematic comparison of a family of ZCT inverters; 3) Design, implementation and experimental evaluation of two 55-kW prototype inverters for electric vehicle (EV) motor drives that are developed based on the proposed ZCT concepts; and 4) Investigation of the ZCT concepts in megawatts high-frequency power conversions. The proposed ZCT techniques are also applicable to three-phase power-factor-correction (PFC) rectifiers. In order to minimize switching losses, this work first proposes a new control scheme for an existing three-phase ZCT inverter circuit that uses six auxiliary switches. The proposed scheme, called the six-switch ZV/ZCT, enables all main switches, diodes and auxiliary switches to be turned off under zero-current conditions, and in the meantime provides an opportunity to achieve zero-voltage turn-on for the main switches. Meanwhile, it requires no modification to normal PWM algorithms. Compared with existing ZCT schemes, the diode reverse-recovery current is reduced significantly, the switching turn-on loss is reduced by 50%, the resonant capacitor voltage stress is reduced by 30%, and the current and thermal stresses in the auxiliary switches are evenly distributed. However, a big drawback of the six-switch ZV/ZCT topology, as well as of other types of soft-switching topologies using six auxiliary switches, is the high cost and large space associated with the auxiliary switches. To overcome this drawback, this work further proposes a new three-phase ZCT inverter topology that uses only three auxiliary switches-- the three-switch ZCT. The significance of the proposed three-switch ZCT topology is that, among three-phase soft-switching inverters developed so far, this is the only one that uses fewer than six auxiliary switches and still has the following three features: 1) soft commutation for all main switches, diodes and auxiliary switches in all operation modes; 2) no modification to normal PWM algorithms; and 3) in practical implementations, no need for extra resonant current sensing, saturable cores, or snubbers to protect the auxiliary switches. The proposed six-switch ZV/ZCT and three-switch ZCT inverters, together with existing ZCT inverters, constitute a family of three-phase ZCT inverters. To explore the fundamental properties of these inverters, a systematic comparative study is conducted. A simplified equivalent circuit is developed to unify common traits of ZCT commutations. With the visual aid of state planes, the evolution of the family of ZCT inverters is examined, and their differences and connections are identified. Behaviors of individual inverters, including switching conditions, circulating energy, and device/component stresses, are compared. Based on the proposed six-switch ZV/ZCT and three-switch ZCT techniques, two 55-kW prototype inverters for EV traction motor drives have been built and tested to the full-power level with a closed-loop controlled induction motor dynamometer. The desired ZCT soft-switching features are realized together with motor drive functions. A research effort is carried out to develop a systematic and practical design methodology for the ZCT inverters, and an experimental evaluation of the ZCT techniques in the EV motor drive application is conducted. The design approach integrates system optimization with characterizations of the main IGBT device under the ZCT conditions, selection, testing and characterization of the auxiliary devices, design and selection of the resonant inductors and capacitors, inverter loss modeling and numerical analysis, system-level operation aspects, and layout and parasitic considerations. Different design aspects between these two ZCT inverters are compared and elaborated. The complexity of the 55-kW prototype implementations is compared as well. Efficiencies are measured and compared under a group of torque/speed points for typical EV drive cycles. Megawatts high-frequency power conversion is another potential application of the ZCT techniques. The integrated gate commutated thyristor (IGCT) device is tested and characterized under the proposed six-switch ZV/ZCT condition, and the test shows promising results in reducing switching losses and stresses. Improvements in the IGCT switching frequency and simplification of the cooling requirements under ZCT operations are discussed. In addition, a generalized ZCT cell concept is developed based on the proposed three-switch ZCT topology. This concept leads to the discovery of a family of simplified multilevel soft-switching inverters that reduce the number of auxiliary switches by half, and still maintain desirable features. / Ph. D.

Microinverter has become a new trend for photovoltaic (PV) grid-tie systems due to its advantages which include greater energy harvest, simplified system installation, enhanced safety, and flexible expansion. Since an individual microinverter system is typically attached to the back of a PV module, it is desirable that it has a long lifespan that can match PV modules, which routinely warrant 25 years of operation. In order to increase the life expectancy and improve the long-term reliability, electrolytic capacitors must be avoided in microinverters because they have been identified as an unreliable component. One solution to avoid electrolytic capacitors in microinverters is using a two-stage architecture, where the high voltage direct current (DC) bus can work as a double line ripple buffer. For two-stage electrolyte-free microinverters, a high boost ratio dc-dc converter is required to increase the low PV module voltage to a high DC bus voltage required to run the inverter at the second stage. New high boost ratio dc-dc converter topologies using the hybrid transformer concept are presented in this dissertation. The proposed converters have improved magnetic and device utilization. Combine these features with the converter's reduced switching losses which results in a low cost, simple structure system with high efficiency. Using the California Energy Commission (CEC) efficiency standards a 250 W prototype was tested achieving an overall system efficiency of 97.3%. The power inversion stage of electrolyte-free microinverters requires a high efficiency grid-tie inverter. A transformerless inverter topology with low electro-magnetic interference (EMI) and leakage current is presented. It has the ability to use modern superjunction MOSFETs in conjunction with zero-reverse-recovery silicon carbide (SiC) diodes to achieve ultrahigh efficiency. The performance of the topology was experimentally verified with a tested CEC efficiency of 98.6%. Due to the relatively low energy density of film capacitors compared to electrolytic counterparts, less capacitance is used on the DC bus in order to lower the cost and reduce the volume of electrolyte-free microinverters. The reduced capacitance leads to high double line ripple voltage oscillation on DC bus. If the double line oscillation propagates back into the PV module, the maximum power point tracking (MPPT) performance would be compromised. A control method which prevents the double line oscillation from going to the PV modules, thus improving the MPPT performance was proposed. Finally, a control technique using a single microcontroller with low sampling frequency was presented to effectively eliminate electrolyte capacitors in two-stage microinverters without any added penalties. The effectiveness of this control technique was validated both by simulation and experimental results. / Ph. D.

Three-phase rectifiers/inverters are widely used in grid-tied applications. Take the electric vehicle (EV) charging systems as an example. Within a certain space designated for the chargers, quick charging yet high efficiency are demanded. According to the current industry practice, with a power rating between 10 and 30 kW, the power density are limited by silicon (Si) power semiconductor devices, which make the systems operate at only up to around 30 kHz. The emerging wide bandgap (WBG) power semiconductor devices are considered as game changing devices to exceed the limits brought by their Si counterparts. Much higher switching frequency, higher power density and higher system efficiency are expected to be achieved with WBG power semiconductor devices. Among different types of WBG power semiconductor devices, Silicon Carbide Metal-Oxide-Semiconductor Field-Effect Transistors (SiC MOSFETs) are more popular in current research conducted for tens of kW power converter applications. However, the commonly adopted hard switching operation in this application still leads to significant switching loss at high frequency operation even for SiC-based systems. With the unique feature that the turn-off energy is almost negligible compared with the turn-on energy, critical conduction mode (CRM) based zero voltage soft switching turn-on operation is preferred for the SiC MOSFETs to eliminate the turn-on loss with small penalty on the conduction loss and on the turn-off loss. With this soft switching operation, switching frequency of SiC-based systems is able to be pushed to more than ten times higher than Si-based systems, and therefore higher power density yet even higher system efficiency can be achieved. The CRM-based soft switching is applied to three-phase rectifiers/inverters under the unity power factor operating condition first. Decoupled CRM-based control is enabled, and the inherent drawback of wide switching frequency variation range at CRM-based operation is overcome by the proposed novel modulation technique. It is the first time that CRM-based soft switching modulation is demonstrated in the most conventional three-phase H-bridge ac–dc converter, and more than three-time size reduction compared with current industry practice yet 99.0% peak efficiency are achieved at above 300 kHz switching frequency operation. Then this proposed soft switching modulation technique is extended to non-unity power factor operating conditions especially for grid-tied inverter system applications. With several improvements on the modulation, a generalized CRM-based soft switching modulation technique is proposed, which is applicable to both the unity and non-unity power factor conditions. With the power factor down to 0.8 lagging or leading according to commercial products, above 98.0% peak efficiency is achieved with the generalized soft switching modulation technique at above 300 kHz switching frequency operation. Furthermore from the aspect of electromagnetic interference (EMI), compared with the traditional Si-based design, CRM operation brings higher differential-mode (DM) EMI noise, and higher dv/dt with SiC MOSFETs brings higher common-mode (CM) EMI noise. What's more, hundreds of kHz switching frequency operation makes the main components of the system EMI spectrum located within the frequency range related to the EMI standard (150 kHz – 30 MHz). Therefore, several methods are adopted for the reduction of EMI noise. The total inductor current ripple is reduced with multi-channel interleaving control in order to reduce DM EMI noise. The balance technique is applied in order to reduce CM EMI noise. With PCB winding coupled inductors, the well-controlled parasitic parameters make the balance technique able to be effective for a uniform reduction of CM EMI noise from 150 kHz to above 20 MHz. In addition, PCB winding based magnetic designs are beneficial to achieving manufacture automation and reducing the labor cost. / Doctor of Philosophy / Power electronics and power conversion are crucial to many applications related to electricity, such as consumer electronics, domestic and commercial appliances, automobiles, data centers, utilities and infrastructure. In today's market, quality and reliability are usually considered as a given; high efficiency (low loss), high power density (small size and weight) and low cost are the main focuses in the design of power electronics products. In the past several decades, significant achievements in power electronics have been witnessed thanks to the silicon (Si) semiconductor technology, especially the Si power semiconductor devices. Nowadays, the development of Si power semiconductor devices is already close to the theoretical limits of the material itself. Therefore, in order to meet the increasing demands from customers in different applications, wide bandgap (WBG) based power semiconductor devices, namely Gallium Nitride (GaN) and Silicon Carbide (SiC), are becoming attractive because of its great potential compared with their Si counterparts. In literature, great contributions have already been made to understanding the WBG based power semiconductor devices. It is exciting and encouraging that some of the GaN-based power electronics products featuring high efficiency, high power density and low cost have been commercialized in consumer electronics applications. However, when pursuing these objectives, previous literature has not shown any applications of high frequency soft switching technology into the high power ac–dc conversion (usually three-phase ac–dc) in a simple way as the low power ac–dc conversion (usually single-phase ac–dc) in consumer electronics products. The key to achieving high efficiency, high power density and low cost is the high frequency soft switching operation. For single-phase ac–dc systems, the research on the realization of soft switching by control strategies instead of additional physical complexity has been intensively conducted, and this technology has also been adopted in the current industry practice. Therefore, the major achievement of this work is the development of a generalized soft switching control strategy for three-phase ac–dc systems, without adding any physical complexity, which is applicable to the simplest and most conventional three-phase ac-dc circuit topology. The proposed soft switching control strategy features bidirectional (rectifiers/inverters) power conversion, active/reactive power transfer, grid-tied/stand-alone modes, and scalability to multi-channel interleaved operation. Furthermore, with high frequency, the integration of magnetic components with embedded windings in the printed circuit board (PCB) becomes feasible, which is also beneficial to achieving electromagnetic compatibility (EMC) and manufacture automation. Based on the proposed control strategy and design methodology, a SiC-based 25-kW three-phase high frequency soft switching rectifier/inverter is developed for various applications such as electric vehicle (EV) charging stations, uninterruptible power supplies (UPS) and renewable energy based utilities.

The design of a high-frequency transformer at levels above 1 kVA is limited by the winding and core materials which are available. This res~arch presents methods for the design and modeling of a 10 kVA transformer operating at a frequency of 20 kHz using readily available materials. A special winding technique is employed to increase both energy density and transformation efficiency by reducing leakage inductance and eddy current losses in the windings. The procedures for calculating the equivalent circuit parameters applicable to this design are outlined, and the calculated values compared with the measured quantities. A thermal analysis of the design is also explored using the equivalent circuit model as a basis for the calculation. Some of the calculations are specific to this particular design, whereas others are quite generic, however the overall concepts employed in the design and analysis of this device have widespread application within the area of high-frequency, high-power transformer design. / Master of Science

Due to the increase in the integration of renewable energy to the grid, there is a critical need for varying the existing methods and techniques for grid operation. With increased renewable energy, mainly wind and photovoltaics, there is a reduction in inertia as the percentage of inverter-based resources is increasing. This can bring about an issue with the maintenance and operation of the grid with respect to frequency and voltage. Thus, the ability of inverters to regulate the voltage and frequency becomes significant. Under normal operation of the system, the ability of the inverters to support the grid frequency and voltage while following the grid is sufficient. However, the operation of the inverters during a resiliency mode, under which there is an extended outage of the utility system, will require the inverter functionality to go beyond support and actually maintain the voltage and frequency as done by synchronous machines, acting as the grid-forming inverter. This project focuses on the operation of grid forming sources based on the virtual synchronous generator to regulate the voltage and frequency in the absence of the grid voltage through decentralized control of the inverters in the distribution feeder. With the most recent interconnection standard for the distributed generation, IEEE-1547 2018, the inverter-based generation can be used for this purpose. The simulations are performed in the Simulink environment and the case studies are done on the IEEE 13 node test-feeder. / Master of Science / With the increase in the renewable energy sources in the present grid, the established methods for the operation of the grid needs to be updated due to the changes that the large amount of renewable energy sources bring to the system. Due to the While the conventional resources in the power system was mainly synchronous generators that had an inherent characteristic for frequency support and regulation due to the inertia this characteristic can be lacking in many of the renewable energy sources that are usually inverter-based. At present, the commonly adapted function for the inverters is to follow the grid which is suitable in case of normal operation of the power system. However, during emergency scenarios when the utility is disconnected and a part of the system has to operate independently the inverters need to be able to regulate both the voltage and frequency on their own. In this project the inverter-based control, termed as the virtual synchronous generator, has been studied such that it mimics the well-established controls for the conventional generators so that the inverter-based renewable resource appears similar to the conventional generator from the point of view of the grid in terms of the electrical quantities. The utilization of this type of control for operation of a part of the feeder with each inverter-based resource controlling its output in a decentralized manner is studied. The controls try to mimic the established controls for conventional synchronous machine and use it for maintain operation of the system with inverters.

Small-signal stability is of great concern for distributed power systems with a large number of regulated power converters. These converters are constant-power loads (CPLs) exhibit a negative incremental input resistance within the output voltage regulation bandwidth. In the case of dc systems, design requirements for impedances that guarantee stability have been previously developed and are used in the design and specification of these systems. In terms of three-phase ac systems, a mathematical framework based on the generalized Nyquist stability criterion (GNC), reference frame theory, and multivariable control is set forth for stability assessment. However, this approach relies on the actual measurement of these impedances, which up to now has severely hindered its applicability. Addressing this shortcoming, this research investigates the small-signal stability of three-phase ac systems using measured d-q frame impedances. Prior to this research, negative incremental resistance is only found in CPLs as a results of output voltage regulation. In this research, negative incremental resistance is discovered in grid-tied inverters as a consequence of grid synchronization and current injection, where the bandwidth of the phase-locked loop determines the frequency range of the negative incremental resistance behavior, and the power rating of inverter determines the magnitude of the resistance. Prior to this research, grid synchronization stability issue and sub-synchronous oscillations between grid-tied inverter and its nearby rectifier under weak grid condition are reported and analyzed using characteristic equation of the system. This research proposes a more design oriented analysis approach based on the negative incremental resistance concept of grid-tied inverters. Grid synchronization stability issues are well explained under the framework of GNC. Although stability and its margin of ac system can be addressed using source and load impedances in d-q frame, method to specify the shape of load impedances to assure system stability is not reported. This research finds out that under unity power factor condition, three-phase ac system is decoupled. It can be simplified to two dc systems. Load impedances can be then specified to guarantee system stability and less conservative design. / Ph. D.

One of the greatest technological challenges of the world today is reducing the size and weight of the existing products to make them portable. Specifically, in electric vehicles such as electric cars, UAVs and aero planes, the size of battery chargers and inverters needs to be reduced so as to make space for more parts in these vehicles. Electromagnetic Interference (EMI) filters take up a more than 80 % of these power converters, the size of these filters can be reduced by pushing the switching frequency higher. High frequency operation (> 300 kHz) leads to a size in reduction of EMI filters though it also leads to an increase in switching losses thus compromising on efficiency. Thus, soft switching becomes necessary to reduce the losses, adding more electrical components to the converter to achieve soft switching is a common method. However, it increases the physical complexity of the system. Hence, advanced control methods are adopted for today's power converters that enable soft switching for devices specifically ZVS turn-on as the turn-off losses of next generation WBG devices are negligible. Thus, the goal of this research is to discover novel switching algorithms for soft turn-on. The state-of the-art control methods namely CRM and TCM achieve soft turn-on by enabling bi-directional current such that the anti-parallel body diode starts conducting before the device is turned on. CRM and TCM result in variable switching frequency which leads to asynchronous operation in multi-phase and multi-converter systems. Hence, TCM is modified in this dissertation to achieve constant switching frequency, as the goal of this research is to be able to achieve ZVS turn-on for a three-phase converter. Further, Triangular Current Mode (TCM) to achieve soft switching and phase synchronization for three-phase two-level converters is proposed. It is shown how soft switching and sinusoidal currents can be achieved by operating the phases in a combination of discontinuous conduction mode (DCM), TCM and clamped mode. The proposed scheme can achieve soft switching ZVS turn-on for all the three phases. The algorithm is tested and validated on a GaN converter, 99% efficiency is achieved at 0.7 kW with a density of 110 W/in3. The discussion of TCM in current literature is limited to unity power factor assumption, however this limits the algorithm's adoption in real world applications. It is shown how proposed TCM algorithm can be extended to accommodate phase shift with all the three phases operating in a combination of DCM+TCM+Clamped modes of operation. The algorithm is tested and validated on a GaN converter, 99% efficiency is achieved at 0.7 kVA with a density of 110 W/in3. TCM operation results in 33 % higher rms current which leads to higher conduction losses, as WBG devices have lower on-resistance, these devices are the ideal candidates for TCM operation, hence to accurately obtain the device parameters, a detailed device characterization is performed. Further, proposed TCM+DCM+Clamped control algorithm is extended to three-level topologies, the control is modified to extract the advantage of reduced Common Mode Voltage (CMV) switching states of the three-level topology, the switching frequency can thus be pushed to 3 times higher as compared to state-of-the-art SVPWM control while maintaining close to 99 % efficiency. Two switching schemes are presented and both of them have a very small switching frequency variation (6%) as compared to state-of-the-art methods with >200% switching frequency variation. / Doctor of Philosophy / Power supplies are at the heart of today's advanced technological systems like aero planes, UAVs, electrical cars, uninterruptible power supplies (UPS), smart grids etc. These performance driven systems have high requirements for the power conversion stage in terms of efficiency, density and reliability. With the growing demand of reduction in size for electromechanical and electronic systems, it is highly desirable to reduce the size of the power supplies and power converters while maintaining high efficiency. High density is achieved by pushing the switching frequency higher to reduce the size of the magnetics. High switching frequency leads to higher losses if conventional hard switching methods are used, this drives the need for soft switching methods without adding to the physical complexity of the system. This dissertation proposes novel soft switching techniques to improve the performance and density of AC/DC and DC/AC converters at high switching frequency without increasing the component count. The concept and the features of this new proposed control scheme, along with the comparison of its benefits as compared to conventional control methodologies, have been presented in detail in different chapters of this dissertation.