Digital Energy Revolution

Transcription

1 1

2 2

3 Digital Energy Revolution The impact of digital energy on system design and test Mike Hutton Market Develop Manager Real-Time Test

4 Why is this the digital energy revolution 5

5 Why is this the digital energy revolution Transition from analog to digital control 6

6 Why is this the digital energy revolution Transition from analog to digital control Local monitoring with Smart sensors 7

7 Why is this the digital energy revolution Transition from analog to digital control Local monitoring with Smart sensors High speed computing 8

8 Why is this the digital energy revolution Transition from analog to digital control Local monitoring with Smart sensors High speed computing Strides in Switching Technology 9

9 Why is this the digital energy revolution Transition from analog to digital control Local monitoring with Smart sensors High speed computing Strides in Switching Technology Networkable and reconfigurable 10

10 Why is this the digital energy revolution Transition from analog to digital control Local monitoring with Smart sensors High speed computing Strides in Switching Technology Networkable and reconfigurable Energy Storage (Lithium Ion cells) 11

11 Why is this the digital energy revolution Transition from analog to digital control Local monitoring with Smart sensors High speed computing Strides in Switching Technology Networkable and reconfigurable Energy Storage (Lithium Ion cells) Ability to simulate and model systems 12

12 EXTENDED POWER ELECTRONICS APPS LIST Alternative Energy Flywheel Fuel Cell Microturbine Photovoltaic Wind Other Defense & Aerospace Flight Surface Power Generator Traction Device Other Power Conversion Battery Chargers Electroplating Induction Heating & Melting Laser Power Supply > 2KW Uninterruptible Power Supply Welding Other 13 Transportation Automotive EV & Hybrid Elec. Vehicle Forklift Locomotive Mass Transit Other Process Control DC or Chopper Drives Machine Tool/Servo Control Motor Starters & Controls Servo Drives Switchgear/Static Transfer Switch Variable Speed Drives Other Systems Control Consumer Products Elevator Lighting Systems Material Handling Equipment Medical Electronics Telecommunications

13 Electrification - Automotive 6.3M hybrid electric vehicles sold as of March 31, 2013 (5.1M from Lexus / Toyota) With more than 50 hybrid vehicle models from various manufacturers available in the US today, hybrids on the road are saving nearly 500 million gallons of petroleum annually in this country. Tony Markel, senior engineer with the National Renewable Energy Laboratory (NREL) Source: Toyota Press Room ( ). "Toyota cumulative global hybrid sales pass 5M, nearly 2M in US". Green Car Congress. 14

14 Electrification - Aerospace Energy Efficiency More efficient and less wasteful, even when many of the resulting aircraft may be heavier and have more drag Lower energy losses during conversion Engines are freed from the constraints of a bleed off-take, improved SFC Environmental Issues Reduction in fuel consumption which relates to the energy efficiency effect Elimination of hydraulic fluids Logistics and Operational Maintenance Deletion of hydraulic and pneumatic systems Easier interfaces to the aircraft than with hydraulic or pneumatic connections Reduction of variety of support equipment used today. Decreased life-cycle costs 15

15 Electrification Off Highway John Deere 644K Hybrid Wheel Loader Average fuel usage reduction of 25% Up to 50% reduction for certain tasks Estimated 2x increase in life of tires Roughly 50% decrease in cab noise Only 20% higher upfront cost 16

16 SmartGrid & Microgrid Control Systems Inverters for smart grid and microgrid applications IEC interface for distributed control systems 17

17 18

18 *source wikipedia 19

19 Harnessing Electricity U.S. Patent Activity

20 Harnessing Electricity U.S. Patent Activity Electricity Computers

21 Power Electronics Background The Cylinder and Piston of the Digital Energy Revolution 22

22 Power Electronics Background The Cylinder and Piston of the Digital Energy Revolution 23

23 Electrical Switch Electromechanical relay Invented by American scientist Joseph Henry in order to improve his version of the electrical telegraph Vacuum Tube Invented by American Lee de Forest Transistor BJT Semiconductor William Shockley MOSFET IGBT

24 Switching Applications *Toshiba Discrete IGBT guide 26

25 Energy Storage NiCd Lead Acid NiMH Li-ion Reusable Alkaline Li-ion polymer

26 Energy Storage Gravimetric Energy Density(Wh/kg) Internal Resistance (includes peripheral circuits) in mω Cycle Life (to 80% of initial capacity) NiCd Lead Acid NiMH Li-ion Reusable Alkaline *source: 28 Li-ion polymer (initial) to 200 6V pack <100 12V pack to to 300 6V pack 150 to V pack 200 to V pack 300 to to (to 50%) Fast Charge Time 1h typical 8-16h 2-4h 2-4h 2-3h 2-4h Overcharge Tolerance moderate high low very low moderate low Self-discharge / Month (room temperature) 200 to V pack 300 to % 5% 30% 10% 0.3% ~10% Cell Voltage(nominal) 1.25V 6 2V 1.25V 6 3.6V 1.5V 3.6V Load Current - peak - best result Operating Temperature(discharge only) Maintenance Requirement Typical Battery Cost (US$, reference only) 20C 1C -40 to 60 C 5C 0.2C -20 to 60 C 5C 0.5C or lower -20 to 60 C >2C 1C or lower -20 to 60 C 0.5C 0.2C or lower 0 to 65 C >2C 1C or lower 0 to 60 C 30 to 60 days 3 to 6 months 9 60 to 90 days not req. not req. not req. $50 (7.2V) $25 (6V) $60 (7.2V) $100 (7.2V) Cost per Cycle(US$) $0.04 $0.10 $0.12 $0.14 $ $0.29 $5 (9V) $100 (7.2V)

27 Calculations per Second per Dollar (log scale) 1.00E E E E E E E E E E E E E E E E E E E E E-09 Computing Price-Performance: : Xilinx Zynq-7020x220 (FPGA+ARM x2+multicore DSP x220), CPS/$=369,478, : Xilinx Spartan-6 LX45x58 (FPGA+multicore DSP x58), CPS/$=183,544, : Raspberry Pi (ARM x1), CPS/$=58,824,000 Analog OpAmp, CPS/$=~22,000, : Mac_Pro/2.8GHz (multicore processor x8), CPS/$=18,286, : Dell WorkStation 340 (Pentium 4, 2.53 GHz x1), CPS/$=1,107, : PowerMac 8500/120 (RISC processor), CPS/$=45, : Commodore 64 (microprocessor), CPS/$=400 R : Cray 1 (integrated circuit), CPS/$= : DEC PDP-1 (discrete transistors), CPS/$= : IBM 650 (vacuum tube), CPS/$= : IBM Tabulator (mechanical gear calculator), CPS/$= E CPS/$ Data Used 29 for Fit ( ) Fit CPS/$ Data Source:

28 Impact of FPGA 30

29 The Digital Energy Revolution Digitized and digitally controlled Networked Field reconfigurable Modeled and simulated Improving at exponential rates Today, approximately 30 percent of all power generation utilizes power electronics between the point of generation and consumption. By 2030, it is expected that up to 80 percent of all generated electricity will utilize power electronics. US Dept. of Energy Join the developer community at /powerdev 31

30 Common Theme Among All Applications Battery Stack, Solar Array DC DC Management System GRID Transformer Converter/Rectifier Inverter/Drive AC DC DC AC Power System Control Systems Inverter/Converter/Drive Motor/Generator/Load 32

31 Power Electronics Design and Test K c K p Design Physical Testing Prototyping HIL Validation K c K p K c K p Deployment 33

32 Improving Model Based Design Traditional Methodology Proposed Methodology Plant Model (Analog) Circuit Design & PCB Layout Mechanical Design Magnetic & Thermal Analysis Closed Loop Simulation FPGA SW Cost Algo- I/O rithm (70%) Full-Custom Circuit Design Software Model (Analog) Continuous to Discrete Time Float to Fixed- Point Math System Level to Register Level Code 34 Plant Model (Analog) Circuit Design & PCB Layout Mechanical Design Magnetic & Thermal Analysis Closed Loop Simulation FPGA SW Cost I/O Algorithm (90%) Chip-On-Board with I/O Support Graphical Implementation Code (Discrete-Time, Fixed Point) Automatic Synthesis Simulation Context Deployment Context

33 Pulse Width Modulation 35

34 Simulation Speed Matters 36

35 For negligible error, the simulation timestep should be 100 times faster than the PWM switching frequency 37 Image courtesy Prof. Reza Iravani, University of Toronto

36 Signal Level Testing for Electric Motor Systems (EMSIM) High fidelity models Non-linear Time varying us timing High speed I/O (1-10x the loop rate) Real-Time HIL Simulator 38

37 39

38 Key Resources /emsim NI Electric Motor Simulation Toolkit Case studies /powerdev Evaluation Software and Design Guide Power Electronics Platform Guide NI ELVIS Experiential Learning System Open Source State-Space HIL Reference /GPIC Papers NI General Purpose Inverter Controller (GPIC) evaluation kit GPIC Factsheet, SmartPower Stack Factsheet NI GPIC Frequently Asked Questions (FAQ) ECCE 2012: New Platform and Method for System-Level Design of Next-Generation FPGAbased Digital Power Electronics DesignCon 2012: An Improved Co-Simulation Approach to Rapidly Prototype, Verify, and Implement Dynamic FPGA-based Embedded Control Systems Q2 INL: The Digital Energy Revolution 40