CAREER: A Dual-Core Control Framework for the Next-Generation SiC Motor Drives

职位：职业：下一代SiC电机驱动器的双核控制框架摘要：大功率电机驱动器是移动的电气化系统的核心。硅（Si）功率半导体器件所施加的限制使得实现未来牵引和推进驱动所需的功率密度、效率和可靠性具有挑战性。幸运的是，新兴的碳化硅（SiC）功率器件为开发下一代电机驱动器提供了一条途径。然而，控制实践必须从现有的Si基电机驱动器的方法发展，以利用SiC功率器件的优势。还期望创新来解决与由于SiC器件固有的更快切换而引起的电磁干扰（EMI）问题以及针对更高热通量的热管理相关的挑战。在实践方面，大功率推进驱动器的研究和开发受到缺乏全功率测试设施的阻碍。这个教师早期职业发展计划（CAREER）项目将开发和展示一种新型的双核控制概念，包括下一代SiC电机驱动器的电磁热协同优化框架。拟议的研究计划将导致一个创新的解决方案，克服目前的控制实践的局限性，从而有可能改变现有的方式来建模，监测和控制SiC电机驱动器。该研究将与阿肯色州大学国家可靠电力传输中心（NCREPT）的几门本科生和研究生课程以及K-12外展活动无缝集成。主要目标是利用研究作为推动力，建立一个蓬勃发展和多样化的电力电子计划，并激励年轻人追求STEM职业。因此，将有各种机会让学生参与研究计划，无论是在课堂内外，以发展电力电子专业所需的一整套技能。 本项目的研究目标是开发一个双核控制框架，以共同优化SiC电机驱动器的电磁热权衡。与电机和逆变器性能相关的控制和优化功能将在两个控制核心中实现。关键信息将在控制核之间交换，以实现协同优化目标。具体而言，研究重点包括：1）开发一种新的基于模型的电流涟漪预测方法，并研究基于纹波的开关序列优化，以减轻EMI并降低开关损耗; 2）开发一种可靠的实时SiC功率模块结温监测方法和一种新的主动热管理方法; 3）研究了一种新的混合时间尺度建模方法，为研究电力电子系统的稳定性提供了一种新的工具;（4）改造兆瓦级NCREPT试验设备，为推进功率级的试验研究开发一个独特的试验台。作为一种电磁热协同优化框架，提出的双核控制将颠覆当今基于模型的电机控制器设计实践。这将促进我们对实时多目标优化集成到电机驱动控制器的理解。它还将创造一种范式转变，从根本上解决EMI缓解和热管理问题，这与使用仅解决症状的EMI滤波器和散热器有很大不同。总之，本计画将在最佳控制、状态估测、可变开关频率调变、热管理等多个方面的理论与应用上有所贡献。非常重要的是，由于电机驱动系统是各种工业应用的核心，因此该研究成果将使国家经济的各个部门受益。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

Title:CAREER: A Dual-Core Control Framework for the Next-Generation SiC Motor DrivesAbstract:High-power motor drives lie at the heart of mobile electrified systems. Limitations imposed by silicon (Si) power semiconductor devices make it challenging to achieve the desired power density, efficiency, and reliability for future traction and propulsion drives. Fortunately, emerging silicon carbide (SiC) power devices enable a pathway to develop the next-generation motor drives. However, control practices must evolve from the existing approaches for Si-based motor drives to take advantages of SiC power devices. Innovations are also desired to address challenges related to the electromagnetic interference (EMI) issues due to the inherently faster switching of SiC devices, and the thermal management for higher heat fluxes. On the practical side, the research and development of high-power propulsion drives is hampered by the lack of testing facilities at a full power scale. This Faculty Early Career Development Program (CAREER) project will develop and demonstrate a novel dual-core control concept comprising an electro-magnetic-thermal co-optimization framework for the next generation SiC motor drives. The proposed research plan will lead to an innovative solution overcoming the limitations of present control practices, and thus having the potential to transform the existing ways to model, monitor, and control the SiC motor drives. The research will be seamlessly integrated with several undergraduate and graduate courses as well as K-12 outreach activities at National Center for Reliable Electric Power Transmission (NCREPT) at the University of Arkansas. The main objective is to utilize research as a driving force to build a thriving and diversified power electronics program, and to inspire young individuals to pursue STEM careers. Thus, there will be various opportunities for student involvement in the research program, both in and out of the classroom, to develop a complete set of skills required in the power electronic profession. The research goal of this project is to develop a dual-core control framework to co-optimize the electro-magnetic-thermal tradeoffs for the SiC motor drives. Control and optimization functions related to the performance of the motor and inverter will be implemented in two control cores. Critical information will be exchanged between the control cores to achieve the co-optimization objectives. More specifically, the research thrusts will include: 1) developing a novel model-based current ripple prediction approach and investigate ripple-based switching sequence optimization to mitigate EMI and reduce switching losses; 2) developing a reliable real-time junction temperature monitoring approach for SiC power modules and a new active thermal management method; 3) investigating a novel mixed-timescale modeling for the proposed dual-core control that also enables a new tool to study the stability of a power electronic system; and 4) revamping the megawatt-class NCREPT testing facility to develop a unique testbed for experimental studies at propulsion power levels. As an electro-magnetic-thermal co-optimization framework, the proposed dual-core control will disrupt today's model-based motor controller design practice. It will advance our understanding on the integration of real-time multi-objective optimization into motor drive controllers. It will also create a paradigm shift to address EMI mitigation and thermal management from the root causes, which are significantly different from the use of EMI filters and heat sinks that address only symptoms. In summary, this project will contribute to the theories and applications of optimal control, state estimation, variable switching frequency modulation, and thermal management in several aspects. Very importantly, the outcome of this research will benefit various sectors of the nation's economy because motor drive systems lie at the heart of a wide variety of industrial applications.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.