1 Stephen J. Walsh, PhD, PE, Director EWD
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1Stephen J. Walsh, PhD, PE, Director EWD
2
Dean NC State University
College of Engineering
Dr. Louis Martin-Vega
Before We Begin – A Brief Announcement
Lunch: 12:00-1:00 (Sandwiches – Buffet at the back of the room)
• IMPORTANT: During lunch this room will be divided in two…
• Track-1 Foundry and Device Development – Suite A&B to my right
• Track-2 Power Module Development and Manufacturing & WBG
Commercialization Applications – Suite C&D to my left
• Choose your lunch seat accordingly, but feel free to move back and
forth when you desire
• Lunchtime Keynote Speaker: Capt. Lynn J. Peterson, Program
Officer, Office of Naval Research.
Agenda
4
• EWD Updates
• “Perfect Pitch”
– 90 second elevator pitches by the PowerAmerica
URS (Undergraduate Research Scholars)
• Graduate Student Presentations
5
Emily Cayton(Graduate Research Assistant)
[Friday Institute]
Dr. Gail Jones(Professor of Science Education)
Dr. Steve Walsh, PE(Director of EWD)
PowerAmerica/FREEDM
Education & Workforce Development Team
Dr. Pam Carpenter(Director Education)
[FREEDM Center]
Pamela Huff(Graduate Research Assistant)
[Friday Institute]
Dr. Mesut Baran(Professor of ECE, College of
Engineering Education Director) [FREEDM Center]
EWD Updates
6
BP2 FA2-4
Funding
Number of Students Training in Focus Areas 2, 3 and 4
Graduates Undergraduates Post-docs
> $4,000,000 32 41 9
EWD Event Attendees Comments
Graduate Student Summer Institute 18 8.69/10 Rating
Train-the-Trainer Summer Institutes 24 8.89/10 Rating
IPC Certified Interconnect Designer Course 12 11 Certified
URS Institute 12 Now
STEM Outreach 259 Precollege
Recruiting 5000+Career Fair / Special
PowerAmerica events
SMTA Student Chapter 10+ Established
EWD Portal – Operational & Growing NA Gathering Analytics
Students Enrolled in Power Electronics Courses at All Affiliate UniversitiesGraduates Undergraduates
401 263
7
Click on a logo to go to that university’s engineering program
8
PowerAmerica’s Employment Webpage for Students
PROJECT_TITLE
UNDERGRADUATE RESEARCH SCHOLARS
Eric Giewont Timothy Sonnenberg Armian Hanelli
PROJECT_TITLE
Principal Investigator: NAME
UNIVERSITY_NAME
GRADUATE STUDENTS
Nikolas Nexteer Jinia Roy Wenjie Miao
PROJECT_TITLE
Principal Investigator: NAME
UNIVERSITY_NAME
FEATURED GRADUATE STUDENT
2017 EWD Focus
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WBG Instructional
Content Creation and
Delivery
Workforce
Development
Student Recruitment Outreach
&
EngagementGraduate Undergraduate
Collaborating with IES’s
(Industrial Expansion
Solutions *) experts in
Adult Instructional
Design, PowerAmerica
faculty, postdocs, and
advanced PhD students:
• Mobile
• Online
• Blended
• NC State
Power
Programs
• PowerAmerica
WBG Wiki
(PA Wiki)
• IES is part of the NC State
College of Engineering.
WBG-specific:
• Workshops
• Short courses
• Webinars
• PA Wiki
• NC State COE
Marketing
• Collaborate with all
PA universities
• URS Program
• EWD Portal:• Internships
• Full-time jobs
• Marketing
Collateral for PA
Universities
• Summer Institutes
• Online multimedia
recruitment
• NC State COE
Academic Affairs
• Engineering First-Year
• Education Information
Sessions
• URS Program
• EWD Portal:• Internships
• Full-time jobs
• Marketing Collateral
for PA Universities
• Online multimedia
recruitment
• Marketing Collateral
• SAE Formula-1 Electric
Car Challenge
PowerAmerica Forum
PA Wiki
Educational resources for:
• Targeted NSF ATE and NIST
MEP Centers (Community
College Instructors & SMEs)
• STEM Ed Teachers
Train-the-Trainer Summer
Institutes
Participate in regional precollege
science events.
(For example, the Congressional
App Challenge Pitch Competition
hosted by Congressman Price.)
IES Programs:
• Dr. Fiona Baxter,
Associate Executive Director
• Ms. Wendy Laing Director, IES
Professional Learning
• Ms. Lindsey Frazier, IES
Strategic Resource Development
PowerHouse
Graduate Year-long Capstone Design Courses
Undergraduate Year-long
Capstone Design
Workforce Development
Industry Mentors
Teach Design for Manufacturing
Principals
PowerHouse will only use currently available university resources.
EWD Advisory Board members have signed on:
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Professor
Department of ECE at NC State University
Program Director
Dr. Mesut Baran
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NC State’s Power Programs – Robust & Growing!
Dr. Mesut Baran
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PE – Power Electronics & Power Semiconductor Devices
Fall Semester Spring Semester
ECE 534: Power Electronics ECE 592-45: Packaging
ECE 553: Semiconductor Power Devices
ECE 792-1: Advanced Power Electronics
or
ECE 792-30: WBG Power Devices
ECE 554: Motor Drives ECE 583: Practicum
Capstone: 584 or 592-34 (Summer or Fall)
Electives: Select 4 courses from the following for sub-specialization
ECE 732: Dynamics & Control of Electric
MachinesECE 792-1: Advanced Power Electronics
ECE 739: IC Fabrication ECE 552: Renewable Energy Systems
ISE 589-04: Manufacturing Systems ECE 734: Power Management
ECE 536: Digital Control ECE 560: Embedded Systems
ECE 511: Analog Electronics ECE 792-30: WBG Power Devices
ECE 535: Design of Electro Mechanical Systems ECE 516: Control
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EPSE – Electric Power Systems Engineering
Fall Semester Spring Semester
ECE 550: Power Systems Optimization and
ControlECE 552: REES
ECE 534: Power Electronics ECE 551: Smart Distribution Systems
ECE 586: Communications and SCADA Systems
for Smart Grid ECE 583: Power Engineering Practicum I
ECE 584: Capstone (Summer and Fall)
Electives: Select 3 courses for sub-specialization in power engineering
ECE 585: The Business of Electric Utility ECE 581: PS Protection
ECE 753: Computational Methods ECE 736: PS Stability
ECE 554: Electric Motor Drives ECE 734: Advanced Power Electronics
ECE 732: Machine Control ECE 516: Control
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Graduate Student
Research Presentations
Undergraduate Research Scholars
“Perfect Pitch”
Presentations
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PowerAmerica’s
Undergraduate Research Scholars (URS)
The Perfect Pitch
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James Hutchinson
Design & Verification of Thermal Management
for SiC PV Converter
URS STUDENTPHOTO GOES HERE
Principal Investigator: Dr. Li
Graduate Mentor: Thierry Kayiranga
FAMU-FSU College of Engineering
POWERAMERICA’S UNDERGRADUATE RESEARCH SCHOLARS PROGRAM
Impact
Our team will provide a novel heatsink design and testing method at an early stage of the SiC converter
design. This will enable future converters to achieve
ultimate optimal system performance .
Problem
Many power converters contain large and heavy heat
sinks. Even though these heat sinks displace the heat produced effectively, it can account for nearly half of
the total weight of the converter.
Approach
By applying the latest heatsink design technology our team plans to reduce
the size and weight of heatsink. This involves
implementing and thermally testing geometrically
optimized designs for the power modules being used
in the converter.
Thermal Management for PV Converter
James Hutchinson, Colleen Kidder, Leslie Dunn, Tianna Lentino, Melanie
Gonzalez, Principal Investigator: Dr. Li
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Julien Chomette
Demonstration of a Medium Voltage Power Module
for High Density Conversion
Principal Investigator: Dr. Douglas Hopkins
Graduate Mentor: Yang Xu
North Carolina State University
POWERAMERICA’S UNDERGRADUATE RESEARCH SCHOLARS PROGRAM
IMPACT
More reliable module
Simulation platform established for future development
PROBLEM
Heat -> Mechanical Stress
Stress on power deviceStress on packaging
Mechanical Failure
Die Fracture
SOLUTION
FEA-based Multiphysics Simulations
High Density Conversion Module Simulations
Julien Chomette, Dr. Douglas Hopkins, Yang Xu
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Daniel Jeziorski
Effect of High Temp Oxidation on Silicon Dioxide Silicon
Carbide Interface
URS STUDENTPHOTO GOES HERE
Principal Investigator: Sarit Dhar
Graduate Mentor: Ben Schoenek
Auburn University
POWERAMERICA’S UNDERGRADUATE RESEARCH SCHOLARS PROGRAM
• This process will reduce the density of interface traps improving• Channel mobility • Stability
• Impacts include • Higher efficiency• Lower device processing costs, • lower safety requirements• non-exclusiveness of the IP
• SiC MOSFETs are attractive for high power switching applications.
• Current SiC MOSFETs are superior to Si, but low channel mobility in SiC is a fundamental limitation for further improvement.
• Annealing in NO is the industry standard for obtaining acceptable SiC MOSFET performance.
• We are exploring ‘Nitrogen Free’ dielectric/channel processes to improve performance and reliability.
• One approach involves oxidation of SiC at temperatures greater than 1400 C.
Silicon Carbide MOSFETs Daniel Jeziorski, Sarit Dhar, and Ben Schoenek
ApproachProblem ImpactSiC DMOSFET
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Timothy Sonnenberg
Wireless Transfer of Energy EcoPRT
URS STUDENTPHOTO GOES HERE
Principal Investigator: Dr. Lukic
Graduate Mentor: Alireza Dayerizadeh
North Carolina State University
POWERAMERICA’S UNDERGRADUATE RESEARCH SCHOLARS PROGRAM
EcoPRT will have a reliable and efficient way of charging without need
for on-site personnel.
EcoPRT is in need of an efficient and safe way to charge while
remaining completely autonomous. Charging system
must be able to plug into conventional 120V AC outlet.
Wireless Charging brings over 90%
efficiency, security and reliability to the
Autonomous Vehicle
Short title for your “Perfect Pitch” goes here
Tim Sonnenberg, Dr. Lukic, Alireza Dayerizadeh, Alexander Nowinski, Michael Spears
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Armian Hanelli
DC Data Center with High Frequency Isolation
URS STUDENT
PHOTO GOES HERE
Principal Investigators: Dr. Fred C.
Lee, Dr. Qiang Li
Graduate Mentors: Shishuo Zhao,
Rimon Gadelrab, Yuchen Yang
Virginia Tech
POWERAMERICA’S UNDERGRADUATE RESEARCH SCHOLARS PROGRAM
Christopher Salvo
Data Center of the Future
PIs: Dr. Fred C. Lee, Dr. Qiang Li, Graduate students: Shishuo Zhao, Rimon Gadelrab, Yuchen Yang
Undergraduate students: Chris Salvo and Armian Hanelli
Conventional AC Distribution in Data Centers
Problem: Low efficiency due to too many stages
Proposed System Architecture
High Frequency Modular Power Conversionfrom Medium Voltage AC to 400V DC
• Power saving of200 TWH annually
• Single-StagePower Conversion
• No bulky 60HzTransformer
>97%Total efficiency >85%
Impact
30
Eric Giewont
EMI Mitigation and Containment in 3 Level SiC Modular
Uninterruptible Power Supply For Commercial Applications
Principal Investigator: Dr. Rolando Burgos
Graduate Mentors: Sungjae Ohn andJianghui Yu
Virginia Polytechnic Institute and State University
POWERAMERICA’S UNDERGRADUATE RESEARCH SCHOLARS PROGRAM
John Noon
Impact
The increase in efficiency (96% → 98%) will decrease energy
consumption while providing an
environmental benefit. The increase in switching frequency enables more
compact, high power density designs.
Problem
In critical applications, such as health care and
data centers, continuous power must be ensured. UPS systems represent a cost-effective solution to
achieve this.
Approach
Applying new silicon carbide technology to existing architecture
allows it to become more efficient. The
autonomous modular design provides
flexibility, scalability, and maximum reliability.
Efficiency and Utility are Increased with SiC Modular
Uninterruptible Power Supply
Eric Giewont, John Noon, Dr. Rolando Burgos, Sungjae Ohn, Jianghui Yu
32
Kijeong Han
A 1200 V 4H-SiC Planar MOSFET Optimization
for High Frequency Figure-of-merit
Principal Investigator: Dr. Jayant Baliga
North Carolina State University (NCSU)
Objective
Structure Optimization
4H-SiC Power MOSFET with improved high frequency Figure-of-merit
- Figure-of-merit (FOM) : R x C, R x Q
- Structure optimization : R Conduction loss
C, Q Switching loss
Gate
JFET
N- Drift
P+ body
N+ source
N+ sub
Drain
GateSource
LA
BP1 structure
Objective
① JFET width + doping
② Channel length
③ P+ body contact
Cell pitch
Gate
N- Drift
P+ body
N+ source
N+ sub
Drain
GateS
BP2 structure
JFETLA
P+ body contact
Orthogonal to
cross section
33
FOM
Simulation ResultsWcell
[m]
BV[V]
CGD,sp
[nF/cm2]
QGD,sp
[nC/cm2]
Ron,sp
[m cm2]
FOM (= CGD x Ron)[m nF]
BP1 11 1392 0.168 355 6.75 1.134
BP1 Characteristics
[ Qg simulation ]
[ BV simulation ]
[ IV simulation ]
@freq. : 100 kHz
7.54 pF
@area : 4.5 mm2
7.68 pF[ CGD simulation
& CGD measurement ]
34
Simulation Results
LA : 1.7 m (BP1) LA : 0.7 m
< E-field (BV = 1392 V) > < E-field (BV = 1620 V) >
@Limit of Oxide Field : 4 MV/cm
@JFET doping : 8x1015 cm-3
JFET Optimization (1/2)
< Current flow (Ron,sp = 6.75 mcm2) > < Current flow (Ron,sp = 10.84 mcm2) > 35
: FOM
@freq. : 100 kHz
: Cgd,sp
: Ron,sp
JFET doping
(cm-3)
LA
(m)
BV
(V)
Ron,sp
(m-cm2)
Cgd,sp
(pF/cm2)
FOM (Ron,sp x Cgd,sp)
(m-pF)
~4e16
0.7 1614 4.55 81.46 370.6 (x 3)
1 1526 4.04 113.92 460.2
1.5 1192 4.06 155.84 632.7
2 988 4.17 208.9 871.1
2.5 875 4.31 254.29 1096.0
3 808 4.43 293.72 1301.2
@VDrain : 1000 V
: BV
JFET Optimization (2/2)
Cgd,sp simulation
36
Summary of Characteristics
Wcell
[m]
BV[V]
CGD,sp
[nF/cm2]
QGD,sp
[nC/cm2]
Ron,sp
[mcm2]
FOM(= CGD x Ron)
[m nF]
FOM (= QGD x Ron)
[m nC]
BP1 11 1392 0.168 355 6.75 1.134 2398
BP2 5.6 1613 0.0928 233 3.47 0.322 (x3.52) 808.86 (x2.96)
Figure-Of-Merit (FOM)
BP1 structure
① JFET width + doping
② Channel length
③ P+ body contact
BP2 structure
NJFET : 0.8e16 cm-3
LA : 1.7 m
LCH : 0.8 m
Wcell : 11 m
NJFET : ~4e16 cm-3
LA : 0.7 m
LCH : 0.5 m
Wcell : 5.6 m
37
38
Xinyu Liang
Medium Voltage Fast Charger
Principal Investigator: Dr. Srdjan Lukic
North Carolina State University
GRADUATE STUDENT
PHOTO GOES HERE
39
Why Medium Voltage Fast Charger?
● Substantial Installation Cost Savings (simplified wiring, concrete slab)
● Substantial Efficiency Improvement; Weight and Volume Reduction
1.9m
0.6m0.96m
1.6m 1.6m
1.2m
Prolec GE Transformer3-φ 75kVA 4160V-480V
3,100L 1200kg ABB Terra 5150kW Fast Charger
1200L; 400kg
Power America50kW MV Fast Charger
100L; 60kg*
*projected packaged weight and volume
40
System Specifications
MV Fast ChargerV = 81.5 L m = 60 kg
Commercial Fast ChargerV = 1200 L m = 400 kg
● 50kW (25kw demo in BP1)
● 2400 Vac to 400 Vdc
● η ≥ 95%, PF ≥ 0.98, THD ≤ 2%
● 10x size reduction
● 4x weight reduction
● Simple install w/o step-down transformer
41
Topology & Component Selection
Multi-cell Boost Topology
42
System Prototype
43
Predictive PFC Control
Proposed new predictive current control of the input PFC stage (NCSU Invention Disclosure # 17083, Filed 10/2016)
● The proposed control strategy can be applied to N-level topology
● Concept experimentally validated on the Fast Charger prototype.
● Improved controller enables the boost stage to operate with lower switching frequency
Test result with predictive control for single module with full DC bus voltage (1600 V) and light load (4.65 kW)
Rectified input voltage
Input current
THD = 2.8%
44
ASHISH KUMAR
Intelligent Medium Voltage Gate Driver
Principal Investigator: Subhashish Bhattacharya
North Carolina State University
45
WBG Devices in Medium Voltage Applications
Transformerless Intelligent Power Substation
AC/AC Asynchronous Grid Connector
• Oil and gas• Marine• Power generation• Pulp and paper• Wind turbine
• Voltage: 4160V – 13.8kV• Power: 1MW – 100MW
46
Objectives and Challenges
10kV SiC MOSFET• No commercial gate drivers available for 10kV devices
• 20V DC power supply with >15kV isolation
• Short circuit protection at >6kV dc bus• Device voltage, current and
temperature sensing for fault diagnosis and prognosis.
47
Proposed solution
Schematic of intelligent gate driver for medium-voltage applications
48
Experimental Results
1kV/div
10V/div
50 A/div
Device voltage, current and temperature sensing Short-circuit protection
Switching waveform at 6kVExperimental setup
Lunch: 12:00-1:00 (Sandwiches – Buffet at the back of the room)
• IMPORTANT: During lunch this room will be divided in two…
• Track-1 Foundry and Device Development – Suite A&B to my right
• Track-2 Power Module Development and Manufacturing & WBG
Commercialization Applications – Suite C&D to my left
• Choose your lunch seat accordingly, but feel free to move back and
forth when you desire
• Lunchtime Keynote Speaker: Capt. Lynn J. Peterson, Program
Officer, Office of Naval Research.
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