SiC VSD Controller for ESP Motors
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Solution Overview
Problem
Conventional electric submersible pump (ESP) variable speed drive (VSD) controllers suffer from high switching losses and large footprints due to limitations in silicon power semiconductor devices, particularly in offshore applications where space is limited and efficiency is crucial.
Innovation Solution
The implementation of silicon carbide (SiC) power semiconductor modules, including MOSFETs and IGBTs, in the VSD controller, which increases switching frequency and reduces footprint by minimizing switching losses, allowing for a more efficient and compact power system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If silicon power semiconductor devices are used in the VSD controller, then the device can operate reliably, but switching losses are high and the footprint is large
Solution Approach 1:
The patent applies parameter changes by transitioning from silicon power semiconductor devices to silicon carbide (SiC) devices, which fundamentally alter the material parameters including bandgap energy, thermal conductivity, and breakdown electric field strength. This material parameter change enables higher switching frequencies and lower switching losses while reducing the required footprint of the VSD controller and PWM filter inductors
Solution Approach 2:
The patent employs composite material strategy by integrating SiC power semiconductor modules with traditional copper windings and magnetic core materials in the PWM filter inductors. The SiC devices complement the passive components to create a hybrid system that achieves both compact size and high efficiency
2Area of stationary object
If switching frequency is increased to reduce footprint, then the VSD controller becomes more compact, but switching losses increase with conventional silicon devices
Solution Approach 1:
The patent resolves this contradiction by changing the material parameter of the power semiconductor from silicon to silicon carbide. SiC's wider bandgap and higher thermal conductivity allow the device to operate at higher switching frequencies with lower switching losses, breaking the traditional trade-off between frequency and losses that constrained silicon-based designs
3Reliability
If conventional silicon power semiconductor devices are used, then the system is proven reliable, but VSD efficiency is limited to 97% with significant power dissipation
Solution Approach 1:
The patent maintains reliability while reducing power dissipation by changing the material parameters of the power semiconductor. SiC devices offer higher thermal conductivity and higher breakdown electric field strength, enabling operation at higher temperatures and voltages with lower losses, thus improving efficiency to 98% while maintaining or enhancing reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances VSD efficiency to 98% and reduces the size of the PWM filter inductor footprint by 10-35%, providing a more efficient and compact power system for ESP motors.
Implementation Method 1
a DC link including a DC smoothing capacitor that smooths the direct current
Implementation Method 2
an inverter active switch section that converts the smoothed direct current to a pulse width modulated (PWM) output voltage, the inverter active switch section including at least one silicon carbide (SiC) power semiconductor module
Implementation Method 3
a PWM filter that filters the PWM output voltage to produce near sinusoidal voltages, the PWM filter including a plurality of inductors
Data Source
AI summary
An electric submersible pump (ESP) variable speed drive (VSD) controller is described. A VSD control system includes a pump assembly including an induction motor operatively coupled to a pump, a power cable and a transformer electrically coupled between the induction motor and a VSD controller that controls a speed of the induction motor, the VSD controller including a converter section that sends a direct current (DC), a DC link including a DC smoothing capacitor that smooths the DC, an inverter that converts the smoothed DC to a pulse width modulated (PWM) output voltage, the inverter including at least one silicon carbide (SiC) power semiconductor module, and a PWM filter that filters the PWM output voltage to produce near sinusoidal voltages, the PWM filter including inductors, and the PWM filter sending voltage to the transformer.