Design and Qualification of a 100-kW Three-Phase SiC-Based Generator Rectifier Unit Rated for 50 000-Ft Altitude

Hu, Jiewen; Zhao, Xingchen; Ravi, Lakshmi; Burgos, Rolando; Dong, Dong; Eddins, Richard; Chandrasekaran, Sriram; Alipour, Saeed

doi:10.1109/jestpe.2022.3223415

Design and Qualification of a 100-kW Three-Phase SiC-Based Generator Rectifier Unit Rated for 50 000-Ft Altitude

Journal Article · Fri Nov 18 00:00:00 EST 2022 · IEEE Journal of Emerging and Selected Topics in Power Electronics

DOI:https://doi.org/10.1109/jestpe.2022.3223415· OSTI ID:2446561

^[1]; ^[2]; ^[2]; ^[2]; ^[2]; Eddins, Richard ^[3]; Chandrasekaran, Sriram ^[4]; Alipour, Saeed ^[5]

Apple Inc., Cupertino, CA (United States); Virginia Polytechnic Institute and State University
Virginia Polytechnic Institute and State University (Virginia Tech), Blacksburg, VA (United States)
GE Aviation, Evendale, OH (United States)
Raytheon Company, Dallas, TX (United States)
Raytheon Company, Laguna Niguel, CA (United States)

Featuring higher blocking voltage, smaller parasitic elements, faster switching speed, and a more compact package, wide-bandgap semiconductor devices like Silicon Carbide devices (SiC), can enable compact aircraft generator-rectifier units (GRUs) thus making them highly desirable. Yet, the combination of the increased voltages, high power density, and the lower pressure environment associated with aircrafts can pose a significant threat to the converter operation due to the increased sensitivity to electric field (E-field) intensity inside the GRU components and their assembly. To this end, a comprehensive design and qualification of a 100 kW three-phase SiC-based GRU rated for a flight altitude of 50,000 ft (11.6 kPa) is presented in this paper. First, an insulation coordination that based on Paschen-curve is proposed to improve the power density. High E-field areas of the GRU are determined and preemptively solved with the use of an E-field control methodology to prevent partial discharge (PD) under normal operating conditions. Second, the gate-driver and EMI filter components are optimized for operation at 70 kHz. Lastly, the insulation design is qualified through low-pressure PD tests, and it is verified that the unit successfully operates at rated conditions to achieve 33.3 kW/l power density, 99.2 % efficiency, and PD-free operation at 50,000 ft.

View Accepted Manuscript (DOE)

Research Organization:: Virginia Polytechnic Institute and State University (Virginia Tech), Blacksburg, VA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: EE0006521

OSTI ID:: 2446561

Alternate ID(s):: OSTI ID: 2418494

Journal Information:: IEEE Journal of Emerging and Selected Topics in Power Electronics, Journal Name: IEEE Journal of Emerging and Selected Topics in Power Electronics Journal Issue: 2 Vol. 11; ISSN 2168-6777

Publisher:: IEEECopyright Statement

Country of Publication:: United States

Language:: English

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Design and Qualification of a 100-kW Three-Phase SiC-Based Generator Rectifier Unit Rated for 50 000-Ft Altitude

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