SBIR-STTR Award

We propose to develop an Inverter Test Facility to evaluate the performance of Silicon vs. Silicon Carbide power devices. In Phase-I, we will use this Test Facility to measure the performance of a baseline Silicon-based 5 HP inverter; in Phase-II, we will use this data as bench mark to evaluate the superiority of Silicon Carbide devices. The intent is to demonstrate key benefits of high temperature capability, small-size or higher efficiency of SiC devices over existing Si devices. In Phase-I, we will (i) develop an Inverter Test Facility that can accept either Si or SiC devices or modules and (ii) develop a high speed CAN-based DSP controller card that drives the test bed (iii) develop DSP software to control a 5 HP 3-phase motor, (iv) develop a dyno test rig to measure its performance and (v) test the full-power performance of the Si inverter, including the effect of temperature on efficiency. We will also review the advances in SiC power device development and identify leading suppliers or developers. In addition, in Phase-I Option, we will continue the preliminary design of the All-SiC inverter and will finalize the procurement or engineering sample development strategies for the All-SiC devices and modules. With SiC devices inverters can operate at higher temperatures than those possible by the current technology Si inverters. They also reduce size or increase efficiency. Applications include military vehicles, mining industry motors, More Electric Aircraft , Navy and Pulse Power as well as numerous commercial markets.

We propose to develop a Silicon Carbide Inverter that can drive typical fan, pump or other motors of Future Combat System Vehicles. It will use recently developed SiC switches as well as SiC diodes. Under this project we will (i) develop the design configuration of the SiC Inverter, (ii) procure SiC devices needed by the All-SiC Inverter, (iii) package the SiC devices to form a H-bridge, (iii) develop a heat sink that can remove heat from packaged SiC devices (iv) develop inverter-on-Printed Circuit Board and (v) fabricate and test the performance of the SiC Inverter when driving a permanent magnet motor. We also plan to demonstrate SiC inverter driving the cooling fan of prototypical army hybrid vehicle. Performance tests will be conducted to quantify the benefits of the Silicon Carbide Inverter over Silicon inverter. Potential benefits include high temperature operation, smaller radiator, or higher efficiency. The key benefits of the All-SiC Inverter will be identified. Quantification and demonstration of key benefits will pave way for insertion of SiC Inverters in Future Combat System vehicles. SiC Inverters can operate better in harsh military environment than current Si inverters. They can also potentially reduce the size of the radiator or allow higher ambient temperature operation. Applications include Future Combat Systems, army hybrid vehicles, aerospace motors, air conditioning systems, ship propulsion motors and pulse power systems.

Keywords:
inverter, power converter, heat sink, power modules, silicon carbide, hybrid vehicle, future combat system