Final Report Summary - ROSIC (Robust Silicon-Carbide Technology for Aerospace DC-DC Conversion)
Executive Summary:
The main aim of this project is to develop a silicon-carbide power module for application within a +/-270Vdc DC/DC conversion network on-board aircraft. This project will investigate the exact requirements and fix the specifications; it will generate the knowledge and understanding required to design and manufacture efficient and reliable power modules; it will deliver fully qualified modules compliant with the aircraft operational environment. Moreover, the project will assess the potential and the risks associated with silicon-carbide technology for the specific case of avionic applications and will provide a thorough and in-depth analysis of future development needs in order to ensure that the stringent requirements of high reliability applications can be met in a cost effective and competitive way. An important aspect of this project will be the investigation of the capability offered by silicon-carbide for the modularisation of power conversion equipment, a key aspect of exploitation for increased industrial competitiveness.
The work involved covers design, manufacturing and qualification. To ensure compliance with the applicable reliability requirements, the design will base on a built-in reliability approach during all stages of the workflow. The outcomes of this project will benefit European competitiveness in the field of power conversion system development for avionic applications and will have significant spin offs to other application domains. It is a 24 month project involving two partners, 3 investigators, 4 researchers and 2 technicians. The total value is €479,309 and the requested total contribution is €303,426.
Project Context and Objectives:
Wide band-gap semiconductor based power conversion technology (e.g. Silicon-Carbide, SiC; Gallium-Nitride, GaN) has been presented in recent years as a breakthrough technology for future applications. In particular, SiC is very attractive for its capability to withstand higher electric fields and operational temperatures than silicon (Si) components, enabling for greatly enhanced power density for a given voltage and current rating. So, the main interest for exploitation in power conversion equipment design lies in the potential it offers to reduce the weight and volume, enabling for higher levels of integration. Thus, the modularity of electrical power conversion equipment, that is, the combination of standardised basic power bricks to achieve the desired power rating according to the specific application, can also be enhanced, with significant gains in terms of component manufacturing and system maintenance. For the avionic and aerospace power electronics community, this technology is particularly important, since it can play a decisive role in supporting the evolution of aircraft systems towards more electrical solutions (e.g. flight control actuators, electrical environmental control system, electrical architecture), as has been the goal of recent major EU-funded programmes (e.g. MOET, CleanSky).
After years of research on device physics and manufacturing technology, engineering samples of SiC devices are presently becoming available in sufficient variety, quantity and with characteristics such as to stimulate a realistic interest in the development of power conversion solutions based entirely on this technology and taking full advantage of all its potentialities. In view of their advantages as compared with Si components, it can be now reasonably anticipated that SiC power conversion soon make its way into aerospace applications. So, this project was very timely contribution to research efforts in this area and was crucial for ensuring European competitiveness by enabling avionic system manufacturers to respond effectively to the new requirements and technology evolution trends in power electronics designs in terms of reliability, availability, robustness and safety and also to decrease development cycles and recurrent costs.
A number of technological issues still need to be addressed and solved in connection with the development and reliable application of SiC power conversion solutions. Three major aspects are identified: interconnection technology; switching performance (e.g. device drivers and protection needs); reliability. This project addressed all of these issues in a coherent and comprehensive manner, addressing design, manufacturing and qualification aspects. In doing so, a “built-in reliability” approach was adopted, based on an in-depth understanding of physics-of-failure mechanisms against the reliability requirements of the final converter. In order to achieve highly reliable design, continuous feedback between critical components of the work was implemented. Interconnect
and packaging technologies represent the main challenge and also directly affect the reliability of the module: for that reason, a considerable research effort was dedicated to developing advanced and reliable integration solutions, which were then qualified according to pre-defined specifications.
Project Results:
- New knowledge and understanding of SiC MOSFET performance and robustness
- Consolidated built-in-reliability design methodology
- Innovative power modules
- Thorough in-application characterisation and demonstration of potential system level impact
Potential Impact:
The deliverables of this project are strategic to further EU competitiveness in a very strategic area.
The industrialisation of the designed and built modules is straightforward.
These modules will enable the development of more lightweight and mroe compact power systems, enabling higher efficiency in avionic transportation.
Results of the project outcomes have been presented at a number of specialist international conferences and workshops.
List of Websites:
Contact details:
Dr. Alberto Castellazzi
Associate Professor of Power Electronics
PEMC Group
University of Nottingham
University Park
NG7 2RD, Nottingham, UK
Tel. +44-(0)115-951-5568
alberto.castellazzi@nottingham.ac.uk
Liam Mills BEng (Hons)
R&D Manager
Semelab Limited
Coventry Road | Lutterworth | Leicestershire | LE17 4JB | England
Office: +44 1455 552505 | liam.mills@semelab-tt.com | www.semelab-tt.com
The main aim of this project is to develop a silicon-carbide power module for application within a +/-270Vdc DC/DC conversion network on-board aircraft. This project will investigate the exact requirements and fix the specifications; it will generate the knowledge and understanding required to design and manufacture efficient and reliable power modules; it will deliver fully qualified modules compliant with the aircraft operational environment. Moreover, the project will assess the potential and the risks associated with silicon-carbide technology for the specific case of avionic applications and will provide a thorough and in-depth analysis of future development needs in order to ensure that the stringent requirements of high reliability applications can be met in a cost effective and competitive way. An important aspect of this project will be the investigation of the capability offered by silicon-carbide for the modularisation of power conversion equipment, a key aspect of exploitation for increased industrial competitiveness.
The work involved covers design, manufacturing and qualification. To ensure compliance with the applicable reliability requirements, the design will base on a built-in reliability approach during all stages of the workflow. The outcomes of this project will benefit European competitiveness in the field of power conversion system development for avionic applications and will have significant spin offs to other application domains. It is a 24 month project involving two partners, 3 investigators, 4 researchers and 2 technicians. The total value is €479,309 and the requested total contribution is €303,426.
Project Context and Objectives:
Wide band-gap semiconductor based power conversion technology (e.g. Silicon-Carbide, SiC; Gallium-Nitride, GaN) has been presented in recent years as a breakthrough technology for future applications. In particular, SiC is very attractive for its capability to withstand higher electric fields and operational temperatures than silicon (Si) components, enabling for greatly enhanced power density for a given voltage and current rating. So, the main interest for exploitation in power conversion equipment design lies in the potential it offers to reduce the weight and volume, enabling for higher levels of integration. Thus, the modularity of electrical power conversion equipment, that is, the combination of standardised basic power bricks to achieve the desired power rating according to the specific application, can also be enhanced, with significant gains in terms of component manufacturing and system maintenance. For the avionic and aerospace power electronics community, this technology is particularly important, since it can play a decisive role in supporting the evolution of aircraft systems towards more electrical solutions (e.g. flight control actuators, electrical environmental control system, electrical architecture), as has been the goal of recent major EU-funded programmes (e.g. MOET, CleanSky).
After years of research on device physics and manufacturing technology, engineering samples of SiC devices are presently becoming available in sufficient variety, quantity and with characteristics such as to stimulate a realistic interest in the development of power conversion solutions based entirely on this technology and taking full advantage of all its potentialities. In view of their advantages as compared with Si components, it can be now reasonably anticipated that SiC power conversion soon make its way into aerospace applications. So, this project was very timely contribution to research efforts in this area and was crucial for ensuring European competitiveness by enabling avionic system manufacturers to respond effectively to the new requirements and technology evolution trends in power electronics designs in terms of reliability, availability, robustness and safety and also to decrease development cycles and recurrent costs.
A number of technological issues still need to be addressed and solved in connection with the development and reliable application of SiC power conversion solutions. Three major aspects are identified: interconnection technology; switching performance (e.g. device drivers and protection needs); reliability. This project addressed all of these issues in a coherent and comprehensive manner, addressing design, manufacturing and qualification aspects. In doing so, a “built-in reliability” approach was adopted, based on an in-depth understanding of physics-of-failure mechanisms against the reliability requirements of the final converter. In order to achieve highly reliable design, continuous feedback between critical components of the work was implemented. Interconnect
and packaging technologies represent the main challenge and also directly affect the reliability of the module: for that reason, a considerable research effort was dedicated to developing advanced and reliable integration solutions, which were then qualified according to pre-defined specifications.
Project Results:
- New knowledge and understanding of SiC MOSFET performance and robustness
- Consolidated built-in-reliability design methodology
- Innovative power modules
- Thorough in-application characterisation and demonstration of potential system level impact
Potential Impact:
The deliverables of this project are strategic to further EU competitiveness in a very strategic area.
The industrialisation of the designed and built modules is straightforward.
These modules will enable the development of more lightweight and mroe compact power systems, enabling higher efficiency in avionic transportation.
Results of the project outcomes have been presented at a number of specialist international conferences and workshops.
List of Websites:
Contact details:
Dr. Alberto Castellazzi
Associate Professor of Power Electronics
PEMC Group
University of Nottingham
University Park
NG7 2RD, Nottingham, UK
Tel. +44-(0)115-951-5568
alberto.castellazzi@nottingham.ac.uk
Liam Mills BEng (Hons)
R&D Manager
Semelab Limited
Coventry Road | Lutterworth | Leicestershire | LE17 4JB | England
Office: +44 1455 552505 | liam.mills@semelab-tt.com | www.semelab-tt.com