Technology Roadmap Target Area

Power Electronics Systems and Distributed Energy Resources.

Project Summary

Electrical power converters are crucial in multi-source AC and DC energy systems, especially as demand rises for higher efficiency, reliability, flexibility, and cost and size reduction. Currently, multi-kilowatt converters use silicon (Si) and silicon carbide (SiC) technologies, but gallium nitride (GaN) devices, a new wide bandgap semiconductor, offer reduced losses, higher operating temperatures, and increased reliability. This project will develop a 25kW, 950VDC/480VAC three-level neutral point clamp (NPC) inverter using GaN field-effect transistors (FETs), advancing switching frequency and size reduction for applications in grid systems, automotive, and distributed generation.

Technology Gap/Market Need:

The industry needs efficient, compact, reliable and low-cost power converters for various applications. 

Target Application 

Generation, Distribution, End Use, Power Packaging, Modeling and Control

Circuits and Converters, Smart Inverters, Solar Inverter, UPS, Battery Storage Systems

Accomplishments/Deliverables

• Designed compact 25kW, 480VAC grid connected bidirectional converter.
• Tested 3-phase 3L-ANPC benchtop controlled with FPGA and verified converter output.
• Determined the EMI noise sources and modeled common and differential modes 
• Designed a PCB-based planar inductor to reduce size and tolerance on inductance 
• Designed air-cooled heat sinks for GaN switches of 3L-ANPC at two sides of the board.
• Developed a compact 12”x11”x3” PCB board including all power elements.

Impact/Benefits

 The outcomes of this project will generate valuable knowledge for GRAPES IAB and universities on high-frequency GaN-based converters. It will also establish a generalized process for designing and developing such converters, including control strategies, power stages, gate drives, EMI noise mitigation, and EMI filter design.