Digital Energy Revolution - PDF Free Download

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

Why is this the digital energy revolution 5

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

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

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

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

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

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 (2013-04-17). "Toyota cumulative global hybrid sales pass 5M, nearly 2M in US". Green Car Congress. 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

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

SmartGrid & Microgrid Control Systems Inverters for smart grid and microgrid applications IEC 61850 interface for distributed control systems 17

*source wikipedia 19

Harnessing Electricity U.S. Patent Activity 100 000 90 000 80 000 70 000 60 000 50 000 40 000 30 000 20 000 10 000 0 20

Harnessing Electricity U.S. Patent Activity 600 000 500 000 400 000 300 000 200 000 Electricity Computers 100 000 0 1840 1871 1899 1930 1960 1991 21

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

Power Electronics Background The Cylinder and Piston of the Digital Energy Revolution 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 1835 1906 1950 1960 1995 24

Switching Applications *Toshiba Discrete IGBT guide 26

Energy Storage NiCd Lead Acid NiMH Li-ion Reusable Alkaline Li-ion polymer 1950 1970 1990 1991 1992 1999 27

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: http://batteryuniversity.com/learn/article/whats_the_best_battery 28 Li-ion polymer 45-80 30-50 60-120 110-160 80 (initial) 100-130 100 to 200 6V pack <100 12V pack 1500 200 to 300 200 to 300 6V pack 150 to 250 7.2V pack 200 to 2000 6V pack 300 to 500 500 to 1000 50 (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 300 7.2V pack 300 to 500 20% 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 $0.10-0.50 $0.29 $5 (9V) $100 (7.2V)

Calculations per Second per Dollar (log scale) 1.00E+11 1.00E+10 1.00E+09 1.00E+08 1.00E+07 1.00E+06 1.00E+05 1.00E+04 1.00E+03 1.00E+02 1.00E+01 1.00E+00 1.00E-01 1.00E-02 1.00E-03 1.00E-04 1.00E-05 1.00E-06 1.00E-07 1.00E-08 1.00E-09 Computing Price-Performance: 1910-2020 2013: Xilinx Zynq-7020x220 (FPGA+ARM x2+multicore DSP x220), CPS/$=369,478,000 2012: Xilinx Spartan-6 LX45x58 (FPGA+multicore DSP x58), CPS/$=183,544,000 2012: Raspberry Pi (ARM x1), CPS/$=58,824,000 Analog OpAmp, CPS/$=~22,000,000 2008: Mac_Pro/2.8GHz (multicore processor x8), CPS/$=18,286,000 2001: Dell WorkStation 340 (Pentium 4, 2.53 GHz x1), CPS/$=1,107,000 1995: PowerMac 8500/120 (RISC processor), CPS/$=45,000 1982: Commodore 64 (microprocessor), CPS/$=400 R 2 0.884 1976: Cray 1 (integrated circuit), CPS/$=15 1960: DEC PDP-1 (discrete transistors), CPS/$=0.83 1953: IBM 650 (vacuum tube), CPS/$=0.00483 1919: IBM Tabulator (mechanical gear calculator), CPS/$=0.0000021 1.00E-10 1910 1930 1950 1970 1990 2010 CPS/$ Data Used 29 for Fit (1946-2009) Fit CPS/$ Data Source: http://www.frc.ri.cmu.edu/~hpm/book97/ch3/processor.list

Impact of FPGA 30

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

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

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

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

Pulse Width Modulation 35

Simulation Speed Matters 36

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

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

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