This dissertation introduces a hierarchical optimization framework for power converter-based energy management systems, with a primary focus on weight minimization. Emphasizing modularity and scalability, the research systematically tackles the challenges in optimizing these systems, addressing complex design variables, couplings, and the integration of heterogeneous models. The study begins with a comparative evaluation of various metaheuristic optimization methods applied to power inductors and converters, including genetic algorithm, particle swarm optimization, and simulated annealing. This is complemented by a global sensitivity analysis using the Morris method to understand the impact of different design variables on the design objectives and constraints in power electronics. Additionally, a thorough evaluation of different modeling methods for key components is conducted, leading to the validation of selected analytical models at the component level through extensive experiments. Further, the research progresses to studies at the converter level, focusing on a weight-optimized design for the thermal management systems for silicon carbide (SiC) MOSFET-based modular converters and the development of a hierarchical digital control system. This stage includes a thorough assessment of the accuracy of small-signal models for modular converters. At this point, the research methodically examines various design constraints, notably thermal considerations and transient responses. This examination is critical in understanding and addressing the specific challenges associated with converter-level design and the implications on system performance. The dissertation then presents a systematic approach where design variables and constraints are intricately managed across different hierarchies. This strategy facilitates the decoupling of subsystem designs within the same hierarchy, simplifying future enhancements to the optimization process. For example, component databases can be expanded effortlessly, and diverse topologies for converters and subsystems can be incorporated without the need to reconfigure the optimization framework. Another notable aspect of this research is the exploration of the scalability of the optimization architecture, demonstrated through design examples. This scalability is pivotal to the framework's effectiveness, enabling it to adapt and evolve alongside technological advancements and changing design requirements. Furthermore, this dissertation delves into the data transmission architecture within the hierarchical optimization framework. This architecture is not only critical for identifying optimal performance measures, but also for conveying detailed design information across all hierarchy levels, from individual components to entire systems. The interrelation between design specifications, constraints, and performance measures is illustrated through practical design examples, showcasing the framework's comprehensive approach. In summary, this dissertation contributes a novel, modular, and scalable hierarchical optimization architecture for the design of power converter-based energy management systems. It offers a comprehensive approach to managing complex design variables and constraints, paving the way for more efficient, adaptable, and cost-effective power system designs. / Doctor of Philosophy / This dissertation introduces an innovative approach to designing energy control systems, inspired by the creativity and adaptability of a Lego game. Central to this concept is a layered design methodology. The journey begins with power components, the fundamental 'Lego bricks'. Each piece is meticulously optimized for compactness, forming the robust foundation of the system. Like connecting individual Lego bricks into a module, these power components come together to form standardized power converters. These converters offer flexibility and scalability, similar to how numerous structures can be built from the same set of Lego pieces. The final layer involves assembling these power converters in order to construct comprehensive energy control systems. This mirrors the process of using Lego subassemblies to build larger, more intricate structures. At this system-level design, the standardized converters are integrated to optimize overall system performance. Key to this dissertation's methodology is an emphasis on modularity and scalability. It enables the creation of diverse energy control systems of varying sizes and functionalities from these fundamental units. The research delves into the intricacies of design variables and constraints, ensuring that each 'Lego piece' contributes optimally to the bigger picture. This includes exploring the scalability of the architecture, allowing it to evolve with technological advancements and design requirements, as well as examining data transmission within the system to ensure efficient data communication across all levels. In essence, this dissertation is about recognizing the potential in the smallest components and understanding their role in the grand scheme of the system. It is akin to playing a masterful game of Lego, where building something greater from small, well-designed parts leads to more efficient, adaptable, and cost-effective energy control system designs. This approach is particularly relevant for applications in transportation systems and renewable energy in remote locations, showcasing the universal applicability of this 'Lego game' to energy management.

Over the past ten years, there has been increased use of electronic power processing in alternative, sustainable, and distributed energy sources, as well as energy storage systems, transportation systems, and the power grid. Three-phase voltage source converters (VSCs) have become the converter of choice in many ac medium- and high-power applications due to their many advantages, such as high efficiency and fast response. For transportation applications, high power density is the key design target, since increasing power density can reduce fuel consumption and increase the total system efficiency. While power electronics devices have greatly improved the efficiency, overall performance and power density of power converters, using power electronic devices also introduces EMI issues to the system, which means filters are inevitable in those systems, and they make up a significant portion of the total system size and cost. Thus, designing for high power density for both power converters and passive components, especially filters, becomes the key issue for three-phase converters. This dissertation explores two different approaches to reducing the EMI filter size. One approach focuses on the EMI filters itself, including using advanced EMI filter structures to improve filter performance and modifying the EMI filter design method to avoid overdesign. The second approach focuses on reducing the EMI noise generated from the converter using a three-level and/or interleaving topology and changing the modulation and control methods to reduce the noise source and reduce the weight and size of the filters. This dissertation is divided into five chapters. Chapter 1 describes the motivations and objectives of this research. After an examination of the surveyed results from the literature, the challenges in this research area are addressed. Chapter 2 studies system-level EMI modeling and EMI filter design methods for voltage source converters. Filter-design-oriented EMI modeling methods are proposed to predict the EMI noise analytically. Based on these models, filter design procedures are improved to avoid overdesign using in-circuit attenuation (ICA) of the filters. The noise propagation path impedance is taken into consideration as part of a detailed discussion of the interaction between EMI filters, and the key design constraints of inductor implementation are presented. Based on the modeling, design and implementation methods, the impact of the switching frequency on EMI filter weight design is also examined. A two-level dc-fed motor drive system is used as an example, but the modeling and design methods can also be applied to other power converter systems. Chapter 3 presents the impact of the interleaving technique on reducing the system passive weight. Taking into consideration the system propagation path impedance, small-angle interleaving is studied, and an analytical calculation method is proposed to minimize the inductor value for interleaved systems. The design and integration of interphase inductors are also analyzed, and the analysis and design methods are verified on a 2 kW interleaved two-level (2L) motor drive system. Chapter 4 studies noise reduction techniques in multi-level converters. Nearest three space vector (NTSV) modulation, common-mode reduction (CMR) modulation, and common-mode elimination (CME) modulation are studied and compared in terms of EMI performance, neutral point voltage balancing, and semiconductor losses. In order to reduce the impact of dead time on CME modulation, the two solutions of improving CME modulation and compensating dead time are proposed. To verify the validity of the proposed methods for high-power applications, a 100 kW dc-fed motor drive system with EMI filters for both the AC and DC sides is designed, implemented and tested. This topology gains benefits from both interleaving and multilevel topologies, which can reduce the noise and filter size significantly. The trade-offs of system passive component design are discussed, and a detailed implementation method and real system full-power test results are presented to verify the validity of this study in higher-power converter systems. Finally, Chapter 5 summarizes the contributions of this dissertation and discusses some potential improvements for future work. / Ph. D.