Dr. Anant Agarwal

Senior Advisor, Wide Band Gap Technology

US Department of Energy

DOE Advanced Manufacturing Office -

Wide Band-Gap Power Electronics Programs

Allen Hefner (NIST)Acting Technology Manager, WBG Power Electronics

Advance Manufacturing Office

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AMO Vision and Mission

AMO Vision and Mission

Vision: U.S. global leadership in sustainable and

efficient manufacturing for a growing and

competitive economy.

Mission: Catalyze research, development and

adoption of energy-related advanced

manufacturing technologies and practices to drive

U.S. economic competitiveness and energy

productivity.

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• AMO pursues its goals through three subprogram approaches:– Advanced Manufacturing R&D Projects

– Advanced Manufacturing R&D Consortia

– Industrial Technical Assistance

AMO Activities Bridge the Technology Development Gap

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AMO: Three Subprogram Approaches

Technical Assistance: Engagement with Industry

Driving a corporate culture of continuous improvement and wide scale adoption of proven technologies to reduce energy use in the industrial sector

R&D Projects: Bridging technology innovation gaps

Research and Development Projects to support innovative manufacturing processes and next-generation materials and systems

R&D Consortia: Public-Private R&D Partnerships

Shared R&D Consortia offer affordable access to physical and virtual tools, and expertise, to foster innovation and adoption of promising technologies

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PowerAmerica

AMO R&D Consortia

White House Report

NNMI Framework Design

January 2013

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The Institute DesignCreating the space for Industry & Academia to collaborate

Interagency Advanced Manufacturing National Program Office AMNPO

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NSTC - Subcommittee

on Advanced

Manufacturing

Executive Office of the President

Advanced Manufacturing

Partnership

(AMP/PCAST)

Advanced Manufacturing

National Program Office(hosted by DOC - NIST)

Frank W. Gayle, Sc.D.Advanced Manufacturing National Program Office

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Two upcoming DOE-led NNMI Institutes Network Status and 2016/17 Plans

• Open topic: 1 or 2 institutes

Planned 2016/17

• Adv. Tissue Biofabrication

• Robots in Mfg. Environments

• Modular Chemical Process Intensification

• REMADE (Sustainable Mfg)

Wide Bandgap Semiconductors

Raleigh, NC

Digital Mfg& Design

Chicago, IL

Advanced Fiber-

Reinforced Polymer

CompositesKnoxville, TN

Lightweight Metals

Detroit, MI

AIM PhotonicsRochester,

NY

Flexible Hybrid Electronics

San Jose, CA

Additive MfgYoungstown,

OHAFFOA - Fibers and Textiles,

Cambridge MA

Smart ManufacturingLos Angeles, CA

Highlighted states have major participants

in Manufacturing USA Institutes

Since launching in 2012: • $600M+ Fed matched by

$1.3B+ non-Fed• 1,300+ companies,

universities, and non-profits involved

• 30+ states

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PowerAmerica Institute at NC State University

Vision

Energy savings through deployment of WBG Power Electronics & Development of a Manufacturing Base in the US through:

• Achieving low prices of WBG devices in 5 years

• Power Electronics Demonstrations

• Training Graduate students in the use of WBG Semiconductors

PowerAmerica started operations on Feb. 01, 2015with $140 M funding over 5 years

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Institute Lead North Carolina State University

UniversitiesArizona State UniversityAuburn University Florida State UniversityKettering UniversityThe Ohio State University Rensselaer Polytechnic InstituteUniversity of California, SantaBarbaraUniversity of California, DavisUniversity of Tenneesee, Knoxville Virginia Polytechnic Institute

LaboratoriesNational Renewable Energy LaboratoryU.S. Naval Research LaboratoryArgonne National Laboratory

Current and Pending PowerAmerica Partners

IndustryABBAgileSwitchAtom PowerCoolCad ElectronicsDelphiGeneSiCInfineon Technologies Americas Corp.InnoCitJENOPTIK Advanced Systems, LLCJohn Deere Electronic SolutionsLockheed MartinMonolith SemiconductorNavitasPower Electronics Industry CollaborativeQorvoRaytheonToshibaTransphormUnited Silicon Carbide, IncWolfspeed (formerly CREE + APEI)X-Fab

PendingGeneral Motors – PowertrainOak Ridge National Laboratory

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• Reduce chip costs 50% every 2 years with improved

performance ‒ Achieve WBG cost parity with Si in 5 years

‒ Reduce WBG cost below today’s silicon price in 5-8 years

‒ Manufacturing 8-inch wafers in 5-8 years

• WBG devices replacing 600V-1700 V Si in mainstream

applications within 5 years

• Development of 10-15 kV devices enabling new applications

in MV motor and Grid Power Control

The market for WBG devices will double every 2 years from

$100M to $3B in 10 years

New Systems, enabled by WBG, will create $20B in new global

markets

WBG Power Semiconductor Roadmap

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WBG Power Electronics Traineeships

AMO Workforce Development

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• Purpose• Provide hands-on training of students in WBG power electronic devices and

their application.• Benefits• Ensure a pipeline of well-trained professionals entering industry and academia• Enable a ‘chain reaction’ of higher education in WBG technology for decades

Wide Bandgap Traineeship--$ 5M for 5 Yrs

Goal: Train at least 100 Graduate students in 5 years

Program Impact:• > 45 U.S. citizen M.S. and Ph.D. graduates in power engineering over 5 years• 7 new graduate courses developed focusing on WBG

• Converters, electrical systems packaging, WBG characterization and applications

• Students involved with National Laboratory and Industrial Internships

University of Tennessee Virginia Polytechnic Institute

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Next Generation of Electric Machines

AMO R&D Projects

Opportunities for WBG: Electric Motors (1-50 MW)

Approx. 14% of total electricity in COG flows through Large Motors

– Hydrogen Gas Compressors (Hydro-cracking in Oil Refineries)

– Booster Stations in NG Pipelines, High density polypropylene extruders

– Ethylene Gas Compressors, Sea water injection and lift, etc.

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Opportunity for significant Energy Savings:

2-4% of Electricity through WBG Variable Speed

Drive

500 kW, 3000 lb Motor Drive

More Expensive than the motor

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500 kW SiC MOSFET Based Drive

Much Cheaper than Si Solution15 kV SiC

MOSFET/Diode

Size and weight reduction, increased efficiency, lower cost

17Courtesy of Subhashish Bhattacharya (North Carolina State University)

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US Manufacturing Advantage by combining Several Key Technologiesin an Integrated Approach

13.8 kV

3 phase

60 Hz

1-50 MW

60 Hz Motor

1800 RPM

Compressor

Fixed Speed

9 K-18 K RPM

Traditional20-40% energy is wastedwith throttles andother mechanical devices

4.16 kV

3 phase

60 Hz

Big

60 Hz

Transformer

Gear

Box1:G(5-10)

13.8 kV

3 phase

60 Hz

Variable

Speed Drive

SiC Based

1-50 MW

Gx60 Hz Motor

G x smaller

Volume

Compressor

Variable Speed

9 K-18 K RPM

Delivered as

one box

New Approach

• Big 60 Hz Transformer replaced by small high frequency Transformer

• Motor size reduced by 5x – cheaper, less magnets

• 20-40% energy per motor system is saved due to Variable Speed Drive – pay-back < 3 years

• Gear Box eliminated

• Smaller Foot-print (up to 5x)

NGEM 2:EnablingTechnologies($25M)

http://www.nist.gov/pml/high_megawatt/sept2014_workshop.cfm

NGEM: 1IntegratedSystem($22M)

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NGEM I – Megawatt Class Machines

Objective:• Establish US manufacturing advantage by combining Wide Band Gap

technology in a drive integrated, gear free, high speed motor approach.

Impact:• 90% deployment of MV VSDs to motors used in >500 HP applications

throughout the industrial sector would present an energy savings opportunity of up to 1.2% to 3.2% of total U.S. electricity consumption, assuming 30% to 80% energy savings by using MV VSDs.

Metrics Si-based VSD integrated

motor system

WBG-based VSD

integrated motor system

NGEM 1 improvement

targets

Efficiency 90% 93% 30% loss reduction

Inverse volumetric

power density

13.72 m3/MW 6.31 m3/MW 217% increase in power

density

Foot print 7.44 m2/MW 3.061 m2/MW 243% decrease in foot

print.

FOA Targets:

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NGEM II – Key Enabling Technologies

Objective:• Leverage advancements in key technologies enabling more efficient use of

electricity, as well as reduce system size and weight in a cost effective way, while addressing the limitations of traditional conductive metals and electrical steels.

Topic Areas Technical Target Performance Metrics

High performance conductors

>33% reduction in stator I2R losses Electrical conductivity at 150C > 59.52 MS/m

Low loss electrical steels

>37.5% reduction in core losses Electrical resistivity > 80 μΩ-cm in > 0.5mm thick lams

Amorphous materials >50% reduction in core losses Efficiency 96% in 5kW RE free industrial motors

Superconducting electric machines

>3x improvement in Je at 77K, 1.5T Je > 1440A/cm-width at 77K, 1.5T

Other Enabling Technologies Key to NGEM I and Technical TargetsInsulation materials High temperature (>300°C) insulation materials for WBG MV (>4.16kV). high

frequency (>500Hz,) megawatt class motorsBearings Lead and Bismuth free journal bearings and bushings for WBG MV (>4.16kV),

high frequency (>500Hz), megawatt class motors

Impact and FOA Targets: