Electrical Efficiency

Eaton will build an ultra-high efficiency, medium voltage direct current (MVDC), electro-mechanical/solid-state hybrid circuit breaker (HCB) that offers both low conduction losses and fast response times. The team will also develop a high-speed actuator/vacuum switch (HSVS) combined with a novel transient commutation current injector (TCCI). This switch will transfer power to a separate solid-state device, interrupting the current in the event of a fault. The design should allow for scaling in voltage and current, enabling a range of circuit breakers across the MV application space.

Drexel University is proposing a solid-state MV circuit breaker based on silicon carbide devices, a resonant topology, and capacitive wireless power transfer that aims to significantly improve breaker performance for the MVDC ecosystem. The project combines innovations in using an active resonant circuit to realize zero-current switching, wireless capacitive coupling between the conduction and breaker branches to avoid direct metal-to-metal contact for rapid response speed, and wireless powering to drive the MV switches for improved system reliability.

Marquette University will leverage the technology gap presented by the lack of DC breaker technology. The project objective is to create an industry standard DC breaker that is compact, efficient, ultra-fast, lightweight, resilient, and scalable. The proposed solution will use a novel current source to force a zero current in the main current conduction path, providing a soft transition when turning on the DC breaker. A state-of-the-art actuator that can produce significantly more force than current solutions will also be used.

Southwest Research Institute (SwRI) is developing a battery management system to track the performance characteristics of lithium-ion batteries during charge and discharge cycles to help analyze battery capacity and health. No two battery cells are alike—they differ over their life-times in terms of charge and discharge rates, capacity, and temperature characteristics, among other things. In SwRI's design, a number of strain gauges would be strategically placed on the cells to monitor their state of charges and overall health during operation.

Feasible will develop a non-invasive, low-cost, ultrasonic diagnostic system that links the electrochemical reactions taking place inside a battery with changes in how sound waves propagate through the battery. This Electrochemical Acoustic Signal Interrogation (EASI) analysis will bridge the gap in battery diagnostics between structural insights and electrical measurements, offering both speed and scalability. The physical processes of a battery that affect performance are nearly impossible to monitor with standard diagnostic methods.

Lawrence Livermore National Laboratory (LLNL) is developing a wireless sensor system to improve the safety and reliability of lithium-ion (Li-Ion) battery systems by monitoring key operating parameters of Li-Ion cells and battery packs. This system can be used to control battery operation and provide early indicators of battery failure. LLNL's design will monitor every cell within a large Li-Ion battery pack without the need for large bundles of cables to carry sensor signals to the battery management system.

University of Washington (UW) is developing a predictive battery management system that uses innovative modeling software to manage how batteries are charged and discharged, helping to optimize battery use. A significant problem with today's battery packs is their lack of internal monitoring capabilities, which interferes with our ability to identify and manage performance issues as they arise.

Eaton is developing advanced battery and vehicle systems models that will enable fast, accurate estimation of battery health and remaining life. The batteries used in hybrid vehicles are highly complex and require advanced management systems to maximize their performance. Eaton's battery models will be coupled with hybrid powertrain control and power management systems of the vehicle enabling a broader, more comprehensive vehicle management system for better optimization of battery life and fuel economy.

Robert Bosch is developing battery monitoring and control software to improve the capacity, safety, and charge rate of electric vehicle batteries. Conventional methods for preventing premature aging and failures in electric vehicle batteries involve expensive and heavy overdesign of the battery and tend to result in inefficient use of available battery capacity.

Det Norske Veritas (DNV KEMA) is testing a new gas monitoring system developed by NexTech Materials to provide early warning signals that a battery is operating under stressful conditions and at risk of premature failure. As batteries degrade, they emit low level quantities of gas that can be measured over the course of a battery's life-time. DNV KEMA is working with NexTech to develop technology to accurately measure these gas emissions.