Multi-Domain Virtual Prototyping Techniques for Wide-Bandgap Power Electronics
Lead Research Organisation:
University of Nottingham
Department Name: Faculty of Engineering
Abstract
Power electronics is a key component in a low-carbon future, enabling energy-efficient conversion and control solutions for a wide variety of energy and transportation applications. Power electronics technology enables electric and hybrid vehicles, it is the underpinning technology for the next generation of fuel-efficient "More Electric" Aircraft, and is essential for the operation of high speed rail services. It allows connection of renewable energy sources to the national grid and allows us to more efficiently use the electricity distribution networks we have. In summary, it has the potential to allow almost all electrical devices to become smaller, lighter or more efficient.
Until recently, power electronic systems have been based around Silicon transistors but inherent limitations of these devices present a limit to how small, light and efficient a power electronic enabled system can be. Next generation power electronics will utilise Wide Bandgap (WBG) power transistors, made from materials such as Silicon Carbide (SiC) and Gallium Nitride (GaN) which are able to overcome the limitations of Silicon. This is achieved by having transistors that can operate at much higher frequencies, operate at higher voltages and higher temperatures, and dissipate less of the power they process as heat.
The problem is that our current understanding and experience of power electronic system design is derived from Silicon systems, and that the design of Silicon systems is less critical to achieving optimal performance. To fully exploit the potential of WBG based systems we must understand the challenges posed by the more extreme operating range of WBG devices, and tailor system designs accordingly. High frequency operation means that the electromagnetic design of systems is critical, to avoid unreliable power electronic systems and to prevent power electronic systems affecting other devices through electromagnetic emissions. High frequency operation also theoretically allows the reduction in size of passive filter components (inductors and capacitors) which can significantly reduce system size and weight (increased power density), however the behaviour of smaller passive components operating at higher frequencies is difficult to predict and they can suffer from thermal management problems. High power density power electronic systems, with WBG semiconductors able to operate at higher temperatures place increased thermal stresses on packaging and interconnection methods that were originally developed to deal with Silicon based systems, and this can adversely affect system reliability. An optimal WBG based system design must consider how component choice, system geometry and construction techniques affects each of these challenges, but as the challenges are coupled, any changes to a design to try to solve one problem can cause new problems in another area. Effects such as electromagnetic interference and reliability are also notoriously difficult to predict with extensive experience, and the behaviour of the wide-bandgap semiconductors themselves is different to their Silicon counterparts.
This research will develop the tools that power electronic system designers need to be able to design optimal WBG systems, right-first-time, on a computer - Virtual Prototyping. This will allow faster design times, as fewer physical prototypes must be built, and it will allow engineers with Silicon system experience to quickly develop high performance WBG systems. We will do this by developing mathematical techniques that can be applied to predict how a potential system will behave in the electromagnetic, thermal, mechanical, reliability and semiconductor domains. These techniques will then be combined into a proof-of-concept design tool that will be demonstrated on real wide-bandgap systems developed at the partner institutions, and through parallel work in the linked CA, RHM, and HI projects.
Until recently, power electronic systems have been based around Silicon transistors but inherent limitations of these devices present a limit to how small, light and efficient a power electronic enabled system can be. Next generation power electronics will utilise Wide Bandgap (WBG) power transistors, made from materials such as Silicon Carbide (SiC) and Gallium Nitride (GaN) which are able to overcome the limitations of Silicon. This is achieved by having transistors that can operate at much higher frequencies, operate at higher voltages and higher temperatures, and dissipate less of the power they process as heat.
The problem is that our current understanding and experience of power electronic system design is derived from Silicon systems, and that the design of Silicon systems is less critical to achieving optimal performance. To fully exploit the potential of WBG based systems we must understand the challenges posed by the more extreme operating range of WBG devices, and tailor system designs accordingly. High frequency operation means that the electromagnetic design of systems is critical, to avoid unreliable power electronic systems and to prevent power electronic systems affecting other devices through electromagnetic emissions. High frequency operation also theoretically allows the reduction in size of passive filter components (inductors and capacitors) which can significantly reduce system size and weight (increased power density), however the behaviour of smaller passive components operating at higher frequencies is difficult to predict and they can suffer from thermal management problems. High power density power electronic systems, with WBG semiconductors able to operate at higher temperatures place increased thermal stresses on packaging and interconnection methods that were originally developed to deal with Silicon based systems, and this can adversely affect system reliability. An optimal WBG based system design must consider how component choice, system geometry and construction techniques affects each of these challenges, but as the challenges are coupled, any changes to a design to try to solve one problem can cause new problems in another area. Effects such as electromagnetic interference and reliability are also notoriously difficult to predict with extensive experience, and the behaviour of the wide-bandgap semiconductors themselves is different to their Silicon counterparts.
This research will develop the tools that power electronic system designers need to be able to design optimal WBG systems, right-first-time, on a computer - Virtual Prototyping. This will allow faster design times, as fewer physical prototypes must be built, and it will allow engineers with Silicon system experience to quickly develop high performance WBG systems. We will do this by developing mathematical techniques that can be applied to predict how a potential system will behave in the electromagnetic, thermal, mechanical, reliability and semiconductor domains. These techniques will then be combined into a proof-of-concept design tool that will be demonstrated on real wide-bandgap systems developed at the partner institutions, and through parallel work in the linked CA, RHM, and HI projects.
Planned Impact
This project will contribute to the delivery of the underpinning research undertaken within the UK EPSRC Centre for Power Electronics which will reinforce the UK Power Electronics industry by providing it with the knowledge, tools and techniques required to capitalise on the emergence of wide-bandgap semiconductors.
The global power electronic market was estimated to be worth £135bn (2011), growing at a rate of 10% per year[1]. Within this, there is significant interest for the adoption of WBG devices with the market for these alone estimated to increase from $0.25bn in 2016 to $1.25bn in 2020[2]. Knowledge and tools produced by this project have the potential to enable UK industry to capitalise on this growth market and provide significant benefits to the UK economy.
Specific technical outputs include: the development of efficient simulation techniques suited to the multi-domain simulation of power electronics; demonstration of how these techniques can improve the performance of wide-bandgap systems; and an understanding of the multi-domain physics that underpins the successful operation of high frequency, high temperature, and high reliability power electronic systems. Potential beneficiaries of these outputs in the UK are:
- Power electronics system and converter manufacturers who want to realise the true benefits of wide-bandgap power electronic systems
- Producers of design and simulation software who are interested in understanding how novel simulation techniques could improve the performance of their software and how their existing software offerings could be tailored to the power electronics market
- Wider engineering industry who may be interested in how optimally designed wide-bandgap power electronics enhance the performance of their existing products (e.g. automotive or aerospace organisations)
- Ultimately the wider public who will benefit from the small, lighter, more reliable power electronic enabled devices that can result from wide-bandgap power electronic systems, optimally designed using virtual prototyping techniques.
This project will enable the design of power electronic systems that: allow efficient power conversion; enable a cleaner environment through use in electric/hybrid vehicles, rail, 'more electric' aircraft, and ship propulsion; facilitate the use of renewable energy sources and more efficient electricity distribution systems. The project will therefore benefit society by reducing greenhouse emissions and providing opportunity for meeting future CO2 targets.
As part of the Centre for Power Electronics, the project will provide a greater supply of young researchers, PhD students, and engineers and help to address the skills shortage in power electronics through embedding the generated knowledge and skills into undergraduate and postgraduate teaching, technical workshops, and industrial lectures.
This impact plan will be managed as an activity of the Hub of the Centre, through the Executive Management Team and the affiliated Industry Advisory Group as well as through the five topics via four routes:
1. Establish the Centre brand as a natural point of contact for power electronics expertise through active dissemination; build the public image of power electronics/engineering and its importance to society.
2. Promote the transfer of knowledge and IP gained from the research to the UK industrial community and stimulate new business activity.
3. Contribute to the development of relevant policy through engagement with national government, national and international funding bodies and professional societies.
4. Build collaborative links with leading academic groups and other relevant industrial organisations around the world.
[1] "Power Electronics: A Strategy for Success,", UK Government, October, 2011.
[2] R. Eden, "The World Market for Silicon Carbide & Gallium Nitride Power Semiconductors - 2016, IHS Technology," 2016.
The global power electronic market was estimated to be worth £135bn (2011), growing at a rate of 10% per year[1]. Within this, there is significant interest for the adoption of WBG devices with the market for these alone estimated to increase from $0.25bn in 2016 to $1.25bn in 2020[2]. Knowledge and tools produced by this project have the potential to enable UK industry to capitalise on this growth market and provide significant benefits to the UK economy.
Specific technical outputs include: the development of efficient simulation techniques suited to the multi-domain simulation of power electronics; demonstration of how these techniques can improve the performance of wide-bandgap systems; and an understanding of the multi-domain physics that underpins the successful operation of high frequency, high temperature, and high reliability power electronic systems. Potential beneficiaries of these outputs in the UK are:
- Power electronics system and converter manufacturers who want to realise the true benefits of wide-bandgap power electronic systems
- Producers of design and simulation software who are interested in understanding how novel simulation techniques could improve the performance of their software and how their existing software offerings could be tailored to the power electronics market
- Wider engineering industry who may be interested in how optimally designed wide-bandgap power electronics enhance the performance of their existing products (e.g. automotive or aerospace organisations)
- Ultimately the wider public who will benefit from the small, lighter, more reliable power electronic enabled devices that can result from wide-bandgap power electronic systems, optimally designed using virtual prototyping techniques.
This project will enable the design of power electronic systems that: allow efficient power conversion; enable a cleaner environment through use in electric/hybrid vehicles, rail, 'more electric' aircraft, and ship propulsion; facilitate the use of renewable energy sources and more efficient electricity distribution systems. The project will therefore benefit society by reducing greenhouse emissions and providing opportunity for meeting future CO2 targets.
As part of the Centre for Power Electronics, the project will provide a greater supply of young researchers, PhD students, and engineers and help to address the skills shortage in power electronics through embedding the generated knowledge and skills into undergraduate and postgraduate teaching, technical workshops, and industrial lectures.
This impact plan will be managed as an activity of the Hub of the Centre, through the Executive Management Team and the affiliated Industry Advisory Group as well as through the five topics via four routes:
1. Establish the Centre brand as a natural point of contact for power electronics expertise through active dissemination; build the public image of power electronics/engineering and its importance to society.
2. Promote the transfer of knowledge and IP gained from the research to the UK industrial community and stimulate new business activity.
3. Contribute to the development of relevant policy through engagement with national government, national and international funding bodies and professional societies.
4. Build collaborative links with leading academic groups and other relevant industrial organisations around the world.
[1] "Power Electronics: A Strategy for Success,", UK Government, October, 2011.
[2] R. Eden, "The World Market for Silicon Carbide & Gallium Nitride Power Semiconductors - 2016, IHS Technology," 2016.
Publications
Xie L
(2020)
Thermal Modeling of Fan-Cooled Plate-Fin Heatsink Considering Air Temperature Rise for Virtual Prototyping of Power Electronics
in IEEE Transactions on Components, Packaging and Manufacturing Technology
Xie L
(2021)
Thermal-Flow Network Modeling for Virtual Prototyping of Power Electronics
in IEEE Transactions on Components, Packaging and Manufacturing Technology
Rajaguru P
(2024)
Damage Mechanics-Based Failure Prediction of Wirebond in Power Electronic Module
in IEEE Access
Rajaguru P
(2019)
Time Integration Damage Model for Sn3.5Ag Solder Interconnect in Power Electronic Module
in IEEE Transactions on Device and Materials Reliability
Li K
(2020)
Accurate Measurement of Dynamic on-State Resistances of GaN Devices Under Reverse and Forward Conduction in High Frequency Power Converter
in IEEE Transactions on Power Electronics
Description | This research project had the aim of investigating new, efficient computer simulation techniques that can allow virtual evaluation of potential power electronic system designs. Power electronic systems underpin many important technologies including renewable energy, electrified transportation, and industrial automation. The techniques developed in this work will enable designers to produce highly optimised power electronic systems, more quickly and at a significantly reduced cost by eliminating the need for construction and testing of physical prototypes. The work has made advancements in a number of areas: A fast implementation of the Partial Element Equivalent Circuit method for predicting electromagnetic effects in power electronic systems had been developed. The technique uses reduced order modelling techniques to rapidly evaluate the effect of a system's design on its electrical and electromagnetic performance, and efficiency. This method can produce computer generated predictions and 3D visualisations of a system's performance, under realistic operating conditions over 100 times faster than with a conventional implementation. Limitations of the method have also been explored and understood, and mitigation techniques devised. A new method for predicting how power electronic systems wear out and fail when subjected to realistic operating conditions has been investigated. Research has linked previous work on reduced order thermal modelling methods with new failure models for typical "weak points" in power electronic circuits, such as soldered and welded interfaces. The new model allows the effect of actual, rather than approximate, operating conditions to be used when predicting a system's expected lifetime which allows designs to be optimised for reliability in a particular application. This leads to increased confidence in reliability predictions and thereby reduces the required "safety margins" that must be built into designs, thus increasing system performance and reducing cost. These electromagnetic and reliability modelling techniques have been integrated into a software tool that will be released to support future research into power electronic system optimisation. Collaborations with two industrial partners are being used to evaluate the software against real-world power electronics design problems. The project has also developed strong working relationships between researchers at a three UK universities. A partnership with the University of Lille, France has been made which has resulted in three collaborative journal publications to date. Software developed in the project is also used to support an ongoing joint researcher supervision programme with Virginia Tech University, USA. |
Exploitation Route | Modelling techniques investigated in the project are being integrated into a proof-of-concept software design tool for power electronic system designers. This could ultimately be taken forward as a commerical product through a partnership with a software developer, but we are also actively exploiting shorter-term opportunities to utilise the software to support high TRL, industry led research projects (two industry led research projects are currently utilising software developed under this programme). Such software has the potential to reduce design costs and increase key performance metrics (size, weight, efficiency) of power electronic systems and offers insights into system behaviour not possible with commerical alternatives. Smaller, lighter, more efficient power electronic systems are an essential enabling technology in many areas such as the electrification of transportation. A follow on research project with the aim of integrating the techniques developed into commerical simulation software, and involving a simulation software developer, will begin in 2023 to take the work forward. |
Sectors | Digital/Communication/Information Technologies (including Software) Energy |
Description | Modelling methods and software generated by this project are being used in ongoing projects developing integrated power electronic systems for transportation applications. This includes: 1) Software developed in this EPSRC research project is being used by a UK power electronics design consultancy to assist in the design of a power electronic converter for use in a high power, high speed electric drive system for a luxury automotive application. 2) Design of power electronic components for use in a high power, marine drive system. Modelling techniques developed as part of this project are being used to understand the impact of power electronic component design on the performance of a high power (4MW) electric drive for ship propulsion by a UK power electronic component manufacturer. 3) A follow on research project will start in 2023 with the aim of integrating the techniques developed into commerical simulation software. This project involves a UK based simulation software developer. In all cases, findings from this project are being used to support UK businesses in the development of power electronic drive systems that will ultimately be manufactured in the UK, thus benefitting the UK economy. In addition, electric drive systems contribute to the reduction in CO2 emissions and reduce global reliance on fossil fuels bringing about indirect environmental and health benefits. |
First Year Of Impact | 2021 |
Sector | Aerospace, Defence and Marine,Digital/Communication/Information Technologies (including Software),Electronics,Transport |
Impact Types | Societal Economic |
Description | IEEE Heterogeneous Integration Roadmap |
Geographic Reach | Multiple continents/international |
Policy Influence Type | Membership of a guideline committee |
Impact | Prof Chris Bailey was leading author of the 2019 and 2020 IEEE Heterogeneous Integration Roadmap, Modelling and Simulation Chapter. Chris led an international team of researchers to produce guidelines for the adoption of integrated modelling and simulation techniques in heterogeneously integrated electronic systems, such as next-generation power electronics. The roadmap draws on findings from this EPSRC funded research and has been published by the IEEE. |
URL | https://eps.ieee.org/technology/heterogeneous-integration-roadmap/2019-edition.html |
Description | Differentiating UK capability: Reducing footprint and weight of high power, integrated PEMD |
Amount | £1,990,098 (GBP) |
Funding ID | 10012095 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 02/2022 |
End | 01/2024 |
Description | OCTOPUS: Optimised Components, Test and simulatiOn toolkits for Powertrains which integrate Ultra high speed motor Solutions |
Amount | £3,614,723 (GBP) |
Funding ID | 105389 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 12/2019 |
End | 02/2023 |
Description | Real-time Virtual Prototypes for the Power Electronics Supply Chain |
Amount | £1,036,589 (GBP) |
Funding ID | EP/X024377/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 06/2023 |
End | 03/2026 |
Description | 2021 International Researcher Exchange Programme with Virginia Tech |
Organisation | Virginia Polytechnique Institute and State University |
Department | Virginia Tech Carillion Research Institute |
Country | United States |
Sector | Academic/University |
PI Contribution | 1) Supervison of a VTech based PhD student for a summer research collaboration. 2) Provision of software developed under the Multi-Domain Virtual Prototyping Techniques for Wide-Bandgap Power Electronics award to support the research. |
Collaborator Contribution | 1) Financial support for PhD reseracher involved in the programme. 2) Project management support. |
Impact | 10.1109/COMPEL52922.2021.9645944 |
Start Year | 2021 |
Title | Virtual Prototyping Environment for Power Electronics |
Description | A software application written to demonstrate the technical advancements made by the Multi-domain Virtual Prototyping for Wide-Bandgap Power Electronics. It combines a tradition "SPICE" style circuit simulator with the 3D reduced order modelling methods developed in the project, and an interface for the integration of arbitrary semiconductor models. It can perform coupled 3D-circuit simulations of power electronic components over 100x faster than commerical software. It is currently used to support research projects and PhD studies within the research group, although wider release is currently being considered. |
Type Of Technology | Software |
Year Produced | 2021 |
Impact | The simulation sofware was used as the basis for work in an number of recent publications, including: 10.1109/DMC58182.2023.10412452 10.1109/DMC58182.2023.10412584 10.1109/COMPEL52922.2021.9645944 10.1109/DMC55175.2022.9906541 10.1109/DMC55175.2022.9906539 |
Description | EPSRC Challenge Network in Automotive Challenge Symposium |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | A presentation of the project's thermal modelling work was made at a symposium for the UK Automotive Industry. Since the meeting, discussions have been ongoing with a UK based engineering consulancy about a future industry led project. |
Year(s) Of Engagement Activity | 2018 |
Description | Invited Presentation - Centre for Power Electronics Conference 2021 |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | An audience of around 100 from industry and academic backgrounds attendend the online event. Key results from the project were disseminated as part of an invited presentation which results in questions and a discussion. The discussion has led to the formulation and submission of 2 follow on research proposals. |
Year(s) Of Engagement Activity | 2021 |
Description | Invited Presentation - Centre for Power Electronics Conference 2022 |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Dr Nick Simpson presented work on additive manufacturing techniques for electrical machine (motor) design optimisation. Simulation techniques developed as part of this research were showcased during the talk. The presentation resulted in increased industry interest and engagement in Dr Simpson's ongoing work. |
Year(s) Of Engagement Activity | 2022 |
Description | Invited presentation at APC Power Electronics and Electric Machines Spokes Symposium |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | A presentation was given on the topic of Modelling of Drives - Advances in Digital Design and Manufacture of Electrical Machines and Wound Components. This resulted in interest in the project's modelling and simulation work from audience members and requests for further information about the project. |
Year(s) Of Engagement Activity | 2019 |
URL | http://www.powerelectronics.ac.uk/events/event-records/apc-pe-em-spokes-symposium-2019.aspx |