Download Final Report - UNIFLEX-PM

Project no. 019794
Project acronym: UNIFLEX-PM
Project title: Advanced Power Converters for Universal and Flexible Power Management in Future
Electricity Networks
Instrument: Specific Targeted Research or Innovation Project
Thematic Priority: 6.1.ii Sustainable Energy Systems
Publishable Final Activity Report
Period covered: from 1 March 2006 to 31 August 2009
Date of preparation: 30/11/2009
Start date of project: 1 March 2006
Duration: 3.5 years
Project coordinator name: Andrew R Hyde
Project coordinator organisation name: AREVA
Issue A
EC Contract n°: 019794 (SES6)
EUROPEAN COMMISSION
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Publishable Final Activity Report
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EC DIRECTORATE J – ENERGY
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01/01/2010
A R Hyde
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30/11/2009
A R Hyde
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REVISION
First issue
Issue A: 1 January 2010
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1. Project Execution
The overall objective of UNIFLEX-PM was the development and experimental verification of new,
innovative modular power conversion architectures for universal application in the future European
electricity network. The research focused on technology suitable for addressing emerging problems
and requirements in electricity networks. More importantly, the project sought to establish
technology that supported implementation of certain SmartGrids scenarios and deep penetration of
distributed energy generation technologies. The work conducted in the project was at the cutting
edge of research in modular, high-power converters for grid applications and the 3-phase, AC-AC
modular converter assembled in the project is a “world first”.
The UNIFLEX-PM team of partners are world-class in their fields of expertise and combine leaders
in R&D and major OEMs.
Partner
AREVA T&D, UK
University of Nottingham, UK
Aalborg University, DK
Ecole Polytechnique Federale de Lausanne, CH
Uniersita degli Studi di Genova, IT
ABB, CH
Dynex Semiconductor, UK
European Power Electronics Association, BE
Role
Coordinator
Beneficiary
Beneficiary
Beneficiary
Beneficiary
Beneficiary
Beneficiary
Beneficiary
The work has been performed in seven interconnected work packages that focused on:
 Emerging and future application requirements and priorities
 Converter structures
 Isolation modules
 Control and grid interaction
 Reliability and economics
 Technology validation
1.1 Emerging and future application requirements and priorities
The overall objective of this unit of work was to determine the performance requirements, electrical
specifications and control requirements for innovative power electronic converters, represented by
the UNIFLEX-PM logo in figure 1, in the future European electricity network.
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Figure 1: Power electronic converters represented by the UNIFLEX-PM logo
Functionalities considered included:
 Voltage ratio adjustment
 Frequency changing
 Phase changing
 Asymmetric load current cancellation
 Voltage asymmetry cancellation
 Reactive power control
 Active power control
 Harmonic cancellation
 UPFC like function
 Low voltage ride-through capabilities
 PMU like function
 Individual control of active and reactive power per phase in all ports, e.g. Enhanced lowvoltage fault ride-through, Enhanced grid support during asymmetrical faults.
 Island operation
 Black-start capability
Potential uses of the UNIFLEX-PM system include Active Node and DG Interface. In both, the
UNIFLEX-PM system is “seen” as an “intelligent” transformer that can replace the classical iron
based solutions. However, due to the unique features of this system, more flexibility in the power
management and control of the distribution networks is obtained.
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Figure 2: UNIFLEX-PM system as an Active Node in Future Distribution Networks.
1.2 Converter structures
The overall objective of this unit of work was to develop, and validate through simulation, multicellular, modular and scalable converter concept(s) that can be used in various configurations to
meet the requirements defined in WP2. The work included:
 developing multi-cellular, modular converter structures, using a common set of "building
blocks" to meet various application requirements
 establishing simulation models of proposed converter structures and validating their basic
operation.
 develop local converter control and modulation concepts for energy flow control within the
converter
 Investigation of the incorporation of redundancy into the modular converter concept.
The study included investigation of optimised modulation strategies such as Selective Harmonic
Elimination (SHE), and focussed on the application of these modulation strategies to multi-cellular
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converters in an effort to control the power flow between the cells of the structure. Also, the
potential increase in waveform quality at low device switching frequency was investigated. Such
modulation strategies may perform better than other approaches, e.g.Phase Shifted Carrier PWM
(PSC-PWM) methods.
1.3 Isolation Modules
Two different variants of the UNIFLEX-PM can be considered, based on either DC-DC isolation or
on AC-DC (cycloconverter) isolation. This required the study of two different isolation modules,
the first using a transformer operating between two voltage sources, the second with a voltagesource converter at the primary side, and a current-source at the secondary side as illustrated in
Figure 3
Figure 3: Voltage Source Inverter Basic Module (VSIBM) which provides DC-DC isolation
Figure 4: Cycloconverter Basic Module (CBM) which provides AC-DC isolation
These were examined in detail and their performance compared, collating information such as
efficiency and performance to define which one is the best for use in the technology validation
phase.
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Two Medium Frequency Transformers (MFT) were constructed for each isolation module
examined. A picture of the core and windings of the two constructed MFTs are given in Figure 4.
Figures 4(a) shows the active part of VSIBM. Figure 4(b) shows the active part of CBM.
Both isolation transformers utilized the same tank dimensions. A picture of the final assemblage of
CBM MFT is depicted in Figure 5. The VSIBM MFT has the same physical appearance.
(a)
(b)
Figure 4: Pictures of the medium frequency transformers. (a) VSIBM, (b) CBM.
Figure 5: Picture of final assemblage of MFT.
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The final construction of VSIBM (DC-DC isolation module) is depicted in Figure 6. The medium
frequency transformer is naturally cooled and oil insulated.
Figure 6: 25 kVA VSIBM prototype.
Illustrative experimental results of the MFT converter are shown in Figure 7. This converter was
also tested at a higher switching frequency.
Figure 7: Experimental results - MFT voltages and currents at rated power (25 kW).
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Comparisons were made between the different modules in terms of electrical conversion efficiency,
operation complexity, commutations, etc. The theoretical efficiency comparison is depicted in
Figure 8. This figure presents the results of VSIBM and CBM operating with two different
modulations (CBM-2n means CBM at two-level modulation, CBM-3n means CBM operating with
3-level modulation). This led to the selection of the module to use in the technology validation
platform.
Efficiency (no inductors)
95.00%
94.50%
94.00%
93.50%
93.00%
92.50%
92.00%
VSIBM
CBM-2n
CBM-3n
Figure 8: Isolation module efficiency comparison.
1.5 Control and Grid Integration
The objective of this unit of work was to research overall control structures for the projects modular
converters to achieve:
 High power quality interface with the grid with minimised converter losses.
 Controlled interaction with the grid and energy sources/storage
 Energy management of intermittent generation and energy storage.
 Enhanced network stability and reliability.
 Possibility of coordinated control of converters across a network.
The control strategies investigated were based on a two port structure of the UNIFLEX-PM system
as shown in
Figure 9. The rated parameters used in modelling were similar to those included in the technology
validation platform.
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Figure 9: Two port structure of the Uniflex-PM with DC-link interleaving.
Comprehensive analysis of control strategies employed in multilevel cascaded H-bridge converters
was undertaken. Based on the analysis of this study and partners experience four control structures
were considered:
 Natural reference frame control with resonant controllers – with neutral treated
 Stationary reference frame control with resonant controllers – with neutral un-treated
 Natural reference frame control with Predictive controllers– with neutral treated
 Synchronous reference frame control with PI controllers– with neutral un-treated
The general structures of a single-phase and three-phase PLL including the grid voltage monitoring
are presented in Figure 10, respectively.
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Figure 10: Structure of the single phase PLL system.
Figure 11: Structure of a three-phase PLL system.
Typically, the main variation between the different single-phase PLL methods examined was the
generation structure of the orthogonal voltage system.
Performance of the four control structures was critically analysed with the result informing the
approach used for the technology validation platform.
1.6 Reliability and Economics
The key objectives of the reliability and economics study were:
 definition and parameterisation of reliability models for the analysed configurations, taking
into account conditions related to the operating environment
 preliminary assessment of the impacts deriving from the adoption of the proposed solution
through a technical and economic comparison with a reference case
The work involved identification of the basic components reliability performances in real operating
conditions, based on field test results and models. This was followed by a phase that dealt with
developing the models for different UNIFLEX-PM architectures, to identify the reliability and
availability (performability) characteristics of each basic configuration by combinatorial methods
(based for instance on Reliability Block Diagrams) and a state-space analysis. The final stage of the
study focused on Impact Analysis, which developed an estimate of the impact on availability of
different architectures and methods of use.
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The study included comparison of the reliability of UNIFLEX-PMagainst a reference case. The
example chosen was a High Voltage Direct Current (HVDC) converter, having a four quadrant
operation capability.
Figure 12 shows the complete system structure breakdown for the evaluated M2LC based HVDC
architecture, where a red box refers to the subsystem hierarchical level, a green box refers to the
assembly hierarchical level and a yellow box refers to the item hierarchical level.
M2LC based HVDC
application
Input
filter
AC/DC
Converter
IGBT
module
Resistor
Inductor
Inductor
Gate
driver
Capacitor
DC/AC
Converter
IGBT
module
Inductor
Isolation I/O
transformer
Output
filter
Gate
driver
Capacitor
Control
FPGA
board
Resistor
Inductor
Transducers
system
DSP
board
Voltage
transducer
Current
transducer
Figure 12: Breakdown of the M2LC based HVDC application
Using the project software availability analysis of UNIFLEX-PM and the reference case were
performed. In order to make a fair comparison between the two solutions, simulations were carried
out taking into account different working conditions, different architectures, different technologies
for DC link capacitors and different maintenance policies.
The first set of simulations sought to:
 estimate the basic availability performances of the two solutions and evaluate if they are
comparable or not. This was important because it allows assessment whether UNIFLEXPM has the potential for becoming a competitive product in identified market sectors
 investigate the impact of different technological and architectural solutions on UNIFLEXPM availability performances.
Examples of studies included evaluation of the impact of preventive maintenance actions on
electrolytic capacitors and the effect of logistic delays.
In Table 1 an illustration of results of simulations is reported; with each simulation covering a time
interval of 90,000 hours.
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Mean Availability
MTTFF
Value [%]
SD [%]
Value [h]
SD [h]
UNIFLEX-PM (electrolytic capacitors) – base working conditions
No redundancy
99.1
2e-5
22367
151
4-out-of-5 redundancy
99.8
1e-5
35686
126
12-out-of-13 redundancy
99.7
1e-5
32598
132
UNIFLEX-PM (electrolytic capacitors) – rated working conditions
No redundancy
99.1
2e-5
22965
151
4-out-of-5 redundancy
99.8
1e-5
36103
124
12-out-of-13 redundancy
99.7
1e-5
33052
131
UNIFLEX-PM (electrolytic capacitors) – real working conditions
No redundancy
99.2
2e-5
25182
154
4-out-of-5 redundancy
99.8
1e-5
37012
120
12-out-of-13 redundancy
99.8
1e-5
34573
127
UNIFLEX-PM (film capacitors) – base working conditions
No redundancy
99.8
1e-5
27196
242
4-out-of-5 redundancy
99.9
7e-6
56826
306
12-out-of-13 redundancy
99.9
9e-6
46760
287
UNIFLEX-PM (film capacitors) – rated working conditions
No redundancy
99.8
1e-5
28233
249
4-out-of-5 redundancy
99.9
6e-6
58513
303
12-out-of-13 redundancy
99.9
8e-6
49391
289
UNIFLEX-PM (film capacitors) – real working conditions
No redundancy
99.9
1e-5
31874
270
4-out-of-5 redundancy
99.9
6e-6
62091
309
12-out-of-13 redundancy
99.9
7e-6
54111
300
M2LC based HVDC system
Base
99.9
1e-5
28314
250
Rated conditions
99.9
1e-5
28660
254
Real working conditions
99.9
1e-5
29188
256
Failures
29.4
8.1
8.3
29.2
8.2
8.2
28.8
8.0
8.1
4.0
0.9
1.5
3.9
0.9
1.4
3.4
0.8
1.3
3.5
3.4
3.4
Table 1: Summary of the dependability performances
The results show that the performance of the UNIFLEX-PM system (base architecture, no
redundancy) and the M2LC solution are comparable in terms of availability and MTTFF and
indicate that the UNIFLEX-PM architecture could be successfully industrialized. More detailed
analysis allowed identification of design and operational windows plus approaches to be taken to
maximise reliability whilst seeking to minimise cost of ownership.
1.7 Technology Validation
The purpose of this unit or work was to build and evaluate a UNIFLEX-PM converter to validate
the modular converter concept and its control. Specific objectives are:
 Detailed design of hardware converter.
 Construction of converter hardware.
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Performance evaluation and validation of converter hardware and its control.
Validation of modelling studies
Detailed design of the final converter structure was performed, with completion in the first half of
the project. In the same period, twelve medium frequency transformers, based on the DC/DC
converter isolation module were fabricated. These were combined with the isolation modules.
Construction and assembly of the final complete multi-cellular converter was carried out at the
University of Nottingham, see figures 13 - 16.
Figure 13: Eleven UNIFLEX-PM cells mounted on the transformer base plate
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Figure 14: MV switchgear, pre-charge circuit
and fuses for the UNIFLEX-PM prototype
Figure 15: Medium Voltage gate drive and
current transformer, the single turn silicone
cable may be observed.
Figure 16: DSP/FPGA control stack and fibre optic interface cards
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The converter was commissioned in sections over a period of six months. The first three months of
this involved testing and adjusting of the DC/DC converters using the PI controllers and ensuring
that the modulation produced from the control cards was of the required quality when produced at
the converter terminals.
Figure 17: UNIFLEX-PM prototype converter in
Medium Voltage test facility
Figure 18: UNIFLEX-PM converter two port
configuration for Medium Voltage testing
The operation of the converter with port one connected as a rectifier to a 415V power system
required finalisation of the memory mapping of three FGPA cards into the DSP memory space.
Once this was achieved the operation of the nine H-Bridges configured as a three phase seven level
converter with DC side isolation provided by the DC/DC converters was achieved.
This was followed by results for a two port converter connected to two 415V grids. This
configuration was used for the following tests:
 Testing of the connection of two asynchronous grids
 Testing of the independent power control of the two converter ports
 Validation of the current and voltage control methods for the two port converter
 Validation of the voltage balancing strategy which ensure energy is distributed amongst
the converter cells equally
Once completed, configuration of the converter for operation at Medium Voltage was carried out.
The final configuration of the converter in the Medium voltage test facility is shown in Figures 17
and 18. This allowed completion of the planned testing of the two port configuration under
different working conditions. An example of such a test is shown in Figure 19 with its simulated
result in Figure 20. Figure 19 shows the supply voltage, converter voltage and supply current for
the two converter ports when about 205kW of power is being drawn from the grid at port one and
delivered to the grid at port two. The simulation results for the same conditions are shown in Figure
20 and it is observed that there is a close matching of the results for these two figures.
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Post project work continues on building the experimental knowledge base, which will support the
UNIFLEX-PM technology exploitation stage.
Figure 19: Experimental AC waveforms for port 1 (top) and port 2 (bottom) with power flowing
from port 1 to port 2 (205kW approx.)
Figure 20: Simulated AC waveforms for port 1 (top) and port 2 (bottom) with power flowing from
port 1 to port 2 (205kW approx.)
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Additional information on UNIFLEX-PM, including the public deliverables (Table 2) that arise
from the different work packages can be downloaded from the project website:
http://www.eee.nott.ac.uk/uniflex/. This site includes contact details for further information.
Deliverable
D2.1
D3.1
D4.1
D6.1
D5.1
D1.1
D6.2
D7.2
Deliverable Name
Report detailing converter applications in Future
European Electricity Network
Report on converter structures
Final report on comparison of modules
Report on reliability models
Report on control strategies
Reality Check report
Final report on reliability and impact
Report detailing performance of technology
validation hardware and validation of modelling
studies
Table 2: Summary of public deliverables
2. Dissemination and Use
The prime exploitable result from UNIFLEX-PM is the overall design of the multi-port UNIFLEXPM converter which has potential application in a range of future distribution grid scenarios, which
include SmartGrid and the deep penetration of zero CO2 distributed energy resources. Industrial
partners ABB and AREVA have all of the necessary skills and facilities to commercially exploit this
developed technology.
The second exploitable result arising from the project is the advanced reliability/availability
modelling tools. These can be adapted to other network equipment to allow evaluation of network
acceptability and routes to minimise cost of ownership and design and exploitation risks. The
University of Genova are available to work with organisations on use of these tools.
The University partners have developed and retained their global leading knowledge in power
electronic systems for medium voltage network applications. This represents the third exploitable
result. They will use this to further advance UNIFLEX-PM, e.g. through timely establishment of
modules containing high voltage, wide-band semiconductors and investigating other competing,
advanced solutions.
Extensive dissemination of UNIFLEX-PM has already been undertaken by a series of meetings and
colloquium, this includes focused sessions at EPE 2007, CIRED 2007 and EPE 2009 and separate
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discussions with key exploitation stakeholders. In addition, a total of 29 technical papers have
already been published by the partners (table 3).
Paper Title
Lead
Partner
Partners
Conference
Location &
Date
Advanced Power Converter for Universal and
Flexible Power Management in Future Electricity
Network
Predictive current control of a 7-level AC-DC
back-to-back converter for Universal and
Flexible Power Management system
Power flow control through a multi-level Hbridge based power converter for Universal and
Flexible Power Management in future electrical
grids
A stationary reference frame current control for a
multi-level H-bridge power converter for
universal and flexible power management in
future electricity
Sliding mode observer design for universal
flexible power management (Uniflex-PM)
structure
Advanced integration of multilevel converters
into power system
AAU
Consortium
currently no info
available
UNOTT
UNOTT,
AAU
UNOTT
UNOTT,
AAU
Translation of the CIRED
paper in the Brasilian Journal
“Eletricidade Moderna”
Power Electronics and
Motion Control Conference,
2008. EPE-PEMC 2008. 13th
Power Electronics and
Motion Control Conference,
2008. EPE-PEMC 2008. 13th
AAU
AAU,
UNOTT,
EPFL
Power Electronics Specialists
Conference, 2008. PESC
2008. IEEE
Rhodes, Greece,
June 2008
UNOTT
UNOTT
Orlando, Florida,
November 2008
UNOTT
UNOTT,
EPFL
UNOTT
UNOTT
Industrial Electronics, 2008.
IECON 2008. 34th Annual
Conference of IEEE
Industrial Electronics, 2008.
IECON 2008. 34th Annual
Conference of IEEE
IEEE Transactions on
Industrial Electronics
UNOTT
UNOTT
European Power Electronics
Conference, EPE 2007
UNOTT
UNOTT,
EPFL
European Power Electronics
Conference, EPE 2009
Aalborg,
Denmark, Sept.
2007
Barcelona, Spain ,
Sept. 2009
UNOTT
UNOTT
European Power Electronics
Conference, EPE 2009
Barcelona, Spain ,
Sept. 2009
AAU
(F. Iov)
Consortium
Vienna, Austria,
May 2007
UNOTT
(J. Clare)
UNOTT
(J. Clare)
UNOTT,
AREVA
UNOTT,
AREVA
CIRED 2007
19th International Conference
on Electricity Distribution
CIRED 2007
UNOTT
(J. Clare)
UNOTT
(J. Clare)
UNOTT
A Complete Harmonic Elimination Approach to
DC Link Voltage Balancing for a Cascaded
Multilevel Rectifier
A selective harmonic elimination system for
restoring and equalising DC link voltages in a
multilevel active rectifier
A Novel Multilevel Converter Structure
Integrated into Power Systems and its
Performance Evaluation
A Phase Shift Selective Harmonic Elimination
Method for balancing capacitor voltages in a
seven level Cascaded H-Bridge Rectifier
Advanced Power Converter for Universal and
Flexible Power Management in Future Electricity
Network
UNIFLEX-PM Workshop at CIRED 2007
UNIFLEX-PM Workshop at EPE 2007
The UNIFLEX project
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
UNOTT
European Power Electronics
Conference, EPE 2007
CPES Workshop, Invited
Seminar
PEMC Group Conference
2007
Poznan, Poland
Sept. 2008
Poznan, Poland
Sept. 2008
Orlando, Florida,
November 2008
Dec. 2007
Vienna, Austria,
May 2007
Aalborg,
Denmark,
Sept. 2007
Lake Louise,
Canada, Oct. 2008
Nottingham, UK
Sept. 2007
UNIFLEX-PM REFERENCE
W1 AR
DV
0009
A
01/01/10
Internal partner reference:
Filing N°
Doc.Type
Order N°
Rev. N°
Date
_________________________________________________________________________________________________________
AREVA – UNOTT – AAU - EPFL – UGDIE – ABB – DSL – EPE
EC Contract n°: 019794 (SES6)
EUROPEAN COMMISSION
DIRECTORATE J – ENERGY
Page :
UNIFLEX-PM
21 of 21
EPE Conference, EPE 2009,
Invited Contribution
CRISTAL FP6 Project
Meeting, Cambridge, UK,
Invited Seminar
Universidad de Magallanes,
Invited Seminar
Barcelona, Spain ,
Sept. 2009
Cambridge, UK,
Dec. 2008
UNOTT
Universidad Tecnica Federico
Santa Maria, Invited Seminar
Valparaiso, Chile,
March 2009
UNOTT
(J. Clare)
UNOTT
Universidad de Conception,
Invited Seminar
Chile , April 2009
UNOTT
(J. Clare)
UNOTT
University of Malta, Invited
Seminar
Malta, April 2009
UNOTT
Power Converter Topologies - the UNIFLEX
project
UNOTT
(J. Clare)
UNOTT
(J. Clare)
Nottingham, UK,
Sept. 2009
Birmingham, UK,
April 2009
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
UNOTT
(P.
Wheeler)
UNOTT
Base reliability analysis for an universal and
flexible power management system
UGDIE
-
High Power IGBT module technology for
SmartGrid applications
Today’s and Tomorrow’s Meaning of Power
Electronics within the Grid
Interconnection
Rendements Energétiques de Convertisseurs DCAC
25kVA Isolés à Deux ou Trois Etages
Study and Analysis of a Natural Reference Frame
Current Controller for a Multi-Level H-Bridge
Power Converter
DSL
DSL
PEMC Group Conference
2009
IET Colloquium of Power
Electronics in the Grid,
Invited Seminar
1st ECPE Megawatt Power
Electronics Workshop,
Zurich, March 5-6, Invited
Seminar
25th IEEE Convention of
Electrical and Electronics
Engineers
Conference in China
EPE 2007 : 12th European
Conference on Power
Electronics and Applications
EPF 2008 : XIIème colloque
Electronique de Puissance du
Futur
PESC 2008 : 39th IEEE
Annual Power Electronics
Specialists Conference
Aalborg,
Denemark, 2 - 5
September 2007
Tours, France, 2 et
3 juillet 2008
The UNIFLEX project - latest results
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
UNIFLEX PM - Advanced Power Converters for
Universal and Flexible Power Management in
Future Electricity Networks
The UNIFLEX project - latest results
UNOTT
(J. Clare)
UNOTT
(J. Clare)
UNOTT
UNOTT
(J. Clare)
UNOTT
UNOTT
(J. Clare)
UNOTT
UNOTT
EPFL
EPFL
AAU
Consortium
Chile , March
2009
Zurich,
Switzerland,
March 2009
Eliat, Israel. 3-5
Dec 2008
2008
Rhodes, Greece,
15-19 June 2008.
Table 3: Papers presented on UNIFLEX-PM
UNIFLEX-PM REFERENCE
W1 AR
DV
0009
A
01/01/10
Internal partner reference:
Filing N°
Doc.Type
Order N°
Rev. N°
Date
_________________________________________________________________________________________________________
AREVA – UNOTT – AAU - EPFL – UGDIE – ABB – DSL – EPE