> mitsubishi’s differentiation strategy > highlights of latest sic...
TRANSCRIPT
Gourab Majumdar, PhDSenior Fellow
Semiconductor and Device Group Mitsubishi Electric
Power Devices indispensable for Advancing Power Electronics
November 5, 2018Shenzhen, China
IEEE PEAC’2018 Plenary Session
Keynote Presentation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. ConclusionM-181025-01
0IEEE PEAC 2018 No Reprint Without Authorization
1© Mitsubishi Electric Corporation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. Conclusion
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
2© Mitsubishi Electric Corporation
Predominant Climate Change issue: CO2 Emission
Data : IPCC Fifth Assessment Report 2014
M-181025-01
NDCs: Nationally Determined Contributions
201432 Gton
About 5.5 to 6.0 Giga ton(17% to 18.5% of the total) was generated by Automobiles
IEEE PEAC 2018 No Reprint Without Authorization
3© Mitsubishi Electric Corporation
Application of Power Electronics- status and future outlook -
Electric power generation
Electric power transmission & distribution
Electric power consumption(transport, equipment, appliances, etc.)
Expected growth area of PE application PE application growth depends on policy-makers motivation. Higher speed in establishing renewable sources, e.g. Wind, PV (x100s of GWs by 2025?) is essential.
Expected growth area of PE applicationPE application growth depends on advancement of new technologies, e.g.; HVDC/MVDC/LVDC
High growth area of PE applicationModerate and sustainable growth of power electronics application continues, driven by energy saving needs from consumption sides.
Power electronics (PE) technology is considered indispensable for building infrastructures featuring efficient energy usage, and contributing to protection of the environment.
[for the entire electricity supply-chain infrastructure]
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
4© Mitsubishi Electric Corporation
Transition of Inverter Technology - a barometer of power electronics' growth
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
5© Mitsubishi Electric Corporation
10 100 1K 10K 100K 1M
10
100
1K
10K
100K
1M
10M
100M
Operation Frequency (Hz)
MOSFET
Discrete IGBT
Thyristor
TriacApplication Trend
Bipolar Transistor
Module
Out
put C
apac
ity o
f PE
Syst
em (V
A)
GTOGCT
Si
IPMIGBT Module Unipolar SiC device
Bipolar blended SiC device ? SiC
AutomotiveInverterUPS
Power SupplyCommunication
Power Transmission
Large DriveTraction
SiC potentialGaN device ?
Si and SiC (GaN) devices: how they would likely share application arena
GaN potential
M-181025-01
The key perspective is
“Coexistence” for at least a decade
more.
IEEE PEAC 2018 No Reprint Without Authorization
6© Mitsubishi Electric Corporation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. Conclusion
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
7© Mitsubishi Electric Corporation
Miniaturization- High-current-density packages- High-heat-dissipation substratesLonger life- Low-stress structure at heat cycle- Low-thermal-resistance materials
(bonding materials & encapsulants)Higher functionality- Integrated radiators- Incorporation of peripheral circuits
Power capacity
Large
HighCarrier frequency
SiC
SiCSi*
Switching power source, etc.
EV, etc.SiC
Traction/DC power transmission
Si: Balance performance and cost- Low power loss- Wide application range- High reliability
SiCTM: High performance for value-added applications
- Lower power loss (70% less than Si)- High-frequency switching (100kHz class)- High temp. operation (200 ºC class)
Chip developm
ent
Package development
High performanceLow
cost
Miniaturization Increased capacity
Next generation
Integrated water cooler
New structures
- Smaller packages- Less peripheral
circuits- Lower losses for
energy savings
- Easy installation- Industry-standard package- Incorporation of peripheral
functions
- Miniaturization & High power density
- Incorporation of cooling functions
- Operation in high-temp environments
Home appliances Industry / Renewable energy
Automotive
Traction / Electric power- Large current- High reliability- Industry-standard packages
Mitsubishi’s Differentiation Strategy
* Si: Silicon
Developing high-efficiency power devices (chips) and packages that match market needs are inseparable for differentiation
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
8© Mitsubishi Electric Corporation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. Conclusion
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
9© Mitsubishi Electric Corporation
Structural changes of IGBT cell design
Rated current density (exp. 1200V)40~50A/cm2 150~180A/cm2
N- N- N-N-
N
Emitter
Collector
Gate
N+N+
P
N
Emitter
Collector
Gate
P
N
Collector
Planer IGBT Trench IGBT
P+ P+
Planer IGBT(Finer patterning)
N
CollectorP+
P
Trench-IGBT
Gate
Emitter
Gate
Emitter
N-
N
Collector
P
Gate
Emitter
CSTBT
(with Thin Wafer)
N
・Trench gate, IEGT (IGBT with IE effect), CSTBT, and thin wafer technology led to immense improvement of IGBT making it to be the core active power switch.
・Rated current density of the latest IGBT is four times higher than that of the 1st generation devices introduced in the mid-1980s
Source: G. Majumdar, et. al. CIPS – International Conference on Integrated Power Systems, March 2016, Nuremberg, Germany M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
10© Mitsubishi Electric Corporation
0
5
10
15
20
25
30
1985 1990 1995 2000 2005 2010 2015 2020 2025
Rela
tive F
OM[n
orm
alize
d by
1st
Gen
.]
Fiscal year
175℃(Tj(max)=200℃)Under investigation
150℃Tj(operation)=125℃
Fine patternprocess
1st Gen.2nd Gen.
3rd Gen.
4th Gen.
5th Gen.Trench structure
CSTBT structure
1200V class IGBT
7th Gen.
6th Gen.
Thin wafer & fine pattern process
Figure Of Merit (FOM) = JC / {Von × Eoff}JC = Device’s rated current density [A/㎝2 ]Von = On-state voltage [V] Eoff = Turn-off energy [mJ/pulse/A]
8th Gen.
IGBT1st Gen
’80 ’85 ’90 ’95 ’00 ’05 ’08 ’11 ’13
2nd Gen 3rd Gen 4th Gen 5th Gen 6th Gen Next step7th Gen
IGBT structure (1200V class)
’14
Key technologies
Loss reduction(ratio of 4 Gen. value)
Fine design-rule Tench-gate cell
100%
C
n- layer (Epi)n+ buffer layer (Epi)
CSTBT structureThin backside(PT->LPT)
35% less
n- layer (no Epi)
np
n+ buffer layer
p+
C
GE
CS layer
Wafer thinning Design rule refining
50% less
np
p+C
GE
n- layer (no Epi)
n+ Buffer layer
Ultra thin wafer process Ultra-fine design rule
65% less
n- layer np
p+
C
GE
n+ Buffer layer
4th Gen IGBT 5th Gen IGBT 6th Gen IGBT 7th Gen IGBT
Si Power Chip Technology (IGBT)
Next step
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
11© Mitsubishi Electric Corporation
Keys1. Improve efficiency (Low loss) : Thinner N- drift layer2. EMC design easier : Better controllability of dv/dt with RG6th gen. 7th gen.
Keys1. Improve efficiency (Low loss) : Thinner N- drift layer2. EMC design easier : N+/P cathode structure
※RFC diode: Relaxed Field of Cathode diode
np
p+
C
GE
n+ bufferlayer
n- layern- layer
np
p+
GE
C n+ bufferlayer
Thicknesswafer,
Advancedprocesses
Power lossreduction
ThicknessWafer
(N buffer diode)
A
K
pn-
nn+
(RFC diode)
A
K
pn-
nn+ p
6th gen. 7th gen.
Enhancing Silicon chip Technologies
IGBT
Diode
PreviousPIN DiodeRFCDiode
0
10
20
30
40
50
60
70
80
1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0
Eoff
[mJ/
pulse
]
VCEsat [V]
7th
Gen.
6.1th
Gen.
5th
Gen.
Company A
0
5
10
15
20
25
30
35
40
1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8VEC [V]
E rr[m
J/pu
lse]
7th
Gen.5/6.1th
Gen.
Company A
2
4
6
8
10
12
30 35 40 45 50 55 60
dv/d
t (of
f) [k
V/µs
]
Eoff[mJ/pulse]
RG=2Ω
RG=5.1ΩRG=7.5Ω
RG=10Ω
RG=2~10Ω
7th Gen. 6.1th Gen.
@max-dv/dt=10kV/µs
@max-dv/dt=10kV/µs @max-dv/dt=10kV/µs
IEEE PEAC 2018 No Reprint Without Authorization
12© Mitsubishi Electric Corporation
Evolution of Si IGBT chips
Switc
hing
loss
Conduction lossNext step
7th Gen.
6th Gen.
5th Gen.
4th Gen.
3rd Gen.
6th gen 7th gen Next step
RC-IGBT*
(Merge functions)
RC-IGBT(Next step)
Ultra-thinning (higher performance & easier use)
Optimization of structure
IGBT chip (1200V industrial use)
* RC-IGBT: Reverse conducting IGBT
Combine IGBT and diode onto one chip to improve manufacturability
and module power density
Silicon Chip Technology Trend
Low costCooling conscious
Small footprintHigh density packaging
One rank upModule current
RAC / fan motor
Servo, PV (3-level) Motion control
xEV
Under consideration
Home Appliances
Industry
Automotive
TractionTransmission
Under development Under development
Under development
In mass-production
Ultra-thinning (higher performance & easier use)
p+ nn-np
n-
np
p+
Toward higher usability, performance and reliability(more room to improve until theoretical limit)
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
13© Mitsubishi Electric Corporation
SiC-MOSFET & SiC-SBD (600V – 3300V)Planner-gate ===================================== Refined Planar-gate Novel Trench-gate
Railcar traction inverter Dec. 2013
2015~SiC Expansion
1994~2004Technology development
2005~2009R&D effort validation
2010~2014Practical development & commercialization
SiC chip technology
SiC Module
Applications 50% loss reduction
70% loss reduction
90% loss reduction
3.7KW World’s firstJan. 2006
11KW World’s highestFeb. 2009
20KW World’s highestNov. 2009
1700V/1200ASiC hybrid Jan. 2010
Sample delivery July 2012
Mass production May 2013
Air conditioner Oct. 2010
PV power convertor Jan. 2011
APS for railcars Mar. 2013
CNC drive Dec. 2012
PV power convertor Jan. 2015
Increase production New technologiesNew applications
Solar farms Factory Automation
Locomotive Electric Vehicle
Building Equipment
Power transmission
Wind mills
Development of these modules and applications has been partially supported by Japan’s Ministry of Economy, Trade and Industry(METI) and New Energy and Industrial Technology development Organization(NEDO).
50A/600V DIPIPMTM for PV system
Mitsubishi’s SiC device R&D milestones
SiC Inverter
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
14© Mitsubishi Electric Corporation
600/650V 1200V 1.7kV 3.3kV 6.5kV
Mas
s pro
duct
ion
(4 in
ch)Te
chno
logy
stat
us
SBD
JBS
SBD
JBS
2nd Gen MOSFET
1st GenMOSFET
SBD-embedded
MOSFET
High Vth2nd GenMOSFET
Trench-gateMOSFET
JBS
For the next Gen HV module
JBS
2017/2018
SBD & JBS Diodes, and MOSFETs in Planar, Trench, SBD-embedded forms getting ready for advanced SiC-transistor Module and SiC-IPM applications
For high freq. high Vth applications
Und
er d
evel
opm
ent (
6 in
ch)
1st GenMOSFET
High Vth2nd GenMOSFET
SiC chip tech footprints by voltage class (2018)
2nd GenMOSFET
SBD-embedded
MOSFET
(NEDO R&D project)
SBD
1st GenMOSFET
Trench-gateMOSFET
As a standard Hi-Rel technology
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
15© Mitsubishi Electric Corporation
➢ MOSFET with built-in SBD* ⇒Smaller size- Mitsubishi Electric original technology where chip is
miniaturized by embedding SBD into MOS - Effective especially for high-voltage devices, and
approx. 60% chip area reduction for 3.3kV
➢ Trench MOSFET ⇒ Smaller size / Lower loss / High reliability
- Gate placed on wall of trench formed downward and cell density improved/refined with aim of lowest loss in the industry
- Original field alleviating structure employed to improve reliability
Item Si SiC Customer benefits Combined uses
Power loss 1 1/3 High efficiency, higher output andenergy savings
EVs, air conditioner, railways, and DC power transmission
High temp. operation 175℃ Tj>200℃ Reduced heat-dissipation fins EVs and special inverters
High-speed switch 30KHz Fc>100KHz High efficiency and smaller size Power sources and non-contact power supply
Features of SiC chips
Advancement of SiC chips
* SBD: Schottky barrier diode
Trench
MOSFET structure comparison
Chip area reduction by embedded SBD (image)
Planar MOSFET Trench MOSFETMOSFET with embedded SBD
n-type drift layern-type drift layer
Drain electrode
p-type well
n-type SiC substrate
Gat
e el
ectro
de
Gate electrode
n-type source
Source electrode Source electrode
n-type SiC substrate
Drain electrode
Continuous development of SiC to lower costs and improve performance
Forward-looking R&D is pursuing new-material power devices, such as vertical GaN and gallium oxide based power semiconductors, in addition to SiC-IGBT (currently, MOSFET)
Advancing SiC-MOSFET technology (2018)
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
16© Mitsubishi Electric Corporation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. Conclusion
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
17© Mitsubishi Electric Corporation
Reviewing the fundamentals of IPM Concept:Local monitoring and safe control of IGBT operation on a real time basis
Integrated Intelligence - A vital aspect for future growth of power devices
Integrated scheme for a fast over-current detection & a speed-controlled turn-off
Advantages:(1) Improvement of IGBT saturation voltage
=> Achieving lower power loss(2) Slowed over-current shutdown
=> Controlling voltage over-shoot and noise(3) Monolithic integration of drive and protection
circuit => Miniaturization
Operation by a simple unipolar power source
Advantages:(1) Simplification of driving circuit
=> Miniaturization(2) Fast turn-off at normal switching
=> Achieving lower power loss(3) Monolithic integration of drive and
protection circuit => Miniaturization
Fundamental concept of Intelligent Power Module (IPM)
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
18© Mitsubishi Electric Corporation
-User benefits-
◆ Easier unit layout for multi axis servo drive ⇒ Same height* and narrow width packages
◆ Higher reliability and lower weight ⇒ SLC-Technology
◆ Smooth trouble shooting⇒ Error mode identification
◆ Lower EMC⇒ Integrated switching control
◆ Over temperature, e.g. lock mode, protected⇒ IGBT on chip Tj sensor available
SW speed changing point
Low current area High current area
Normal dv/dt
Controlled dv/dt
Low dv/dt
SW loss: Eon
■Error mode identification (FO) ■Integrated switching control
50-450A/650V25-200A/1200V
G1-series Intelligent Power Module (IPM)
* A,B and D package are h=22mm
DC lock mode (VP IGBT)
Highest temperature spotCenter of IGBT chip
Tj sensingDiode
Location of Tj sensing DiodeCenter of IGBT chip
IR Camera temperature analysis
Control board
Heat sink
Can protect w/ On-chip-sensor !!
Latest Power Module for Industrial Use
IEEE PEAC 2018 No Reprint Without Authorization
19© Mitsubishi Electric Corporation
DIPIPM growth: de facto for home appliances
All-silicon IPM solution in Transfer-Molded Package
CPU
Gate DriveLevel ShiftProtection
HVICAC line
MLVICGate DriveProtection
Load(e.g. compressor for
air-conditioner)
DIPIPMTM
Power Block
HVIC chip
All-silicon solution
LVIC chipTransfer-molding
Power chips (IGBT, Diode)
Frame
Configuration◆ 3-phase power circuit (IGBT + Diode)◆ Circuitry for IGBT gate drive, protection
and isolation (HVIC and LVIC)◆ Dual-In-Line type package outline
White goods
Energy saved by DIPIPM (RAC applications)
Total electric power consumption by Tokyo metropolitan homes
50G
(kW
H)
Estimated by Mitsubishi Electric
By applying DIPIPMs, billions of Room Air Conditioners (RAC) world wide have improved energy efficiency
On a yearly basis, energy saved amounts to more than twice the total power consumed by 8 million homes in Tokyo metropolitan
Significant Energy Saving Impact
21G
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
20© Mitsubishi Electric Corporation
DIPIPM: Wide Line up for Home appliances
Super miniDIP ver.65~35A/600V
0.2kW2kW5kW 0.2kW 2kW 5kWOutput power Output power
• Air conditioner• Air to Water
• Washer / Dryer• Fridge
• Dish washer• Fan
*:Under development
IEEE PEAC 2018 No Reprint Without Authorization
21© Mitsubishi Electric Corporation
DIPIPM: Wide Line up for Industrial use
1.5kW5kW 1.5kW 5kW 12kWOutput power Output power
• Inverter• Servo• Robot
• Commercial A/C
• Fan for Commercial A/C
12kW
*:Under development
IEEE PEAC 2018 No Reprint Without Authorization
22© Mitsubishi Electric Corporation
Circuit Diagram and Functions
All necessary functions needed for general purpose inverters are integrated.
Control Board
RST
UVW
Output Currentand Temearture
Detection
DC -linkVoltage
Detection
Gate Drive
Signal Isolation
CPU●Ptotection: Short Circuit/ Ground Fault/ Over Temperature●Break Control●Dead Time Compensation●PWM Signal Genaration
Highly Integrated Power Module
M-181025-01Source: G. Majumdar, et. al. CIPS – International Conference on Integrated Power Systems, March 2016, Nuremberg, Germany
IEEE PEAC 2018 No Reprint Without Authorization
23© Mitsubishi Electric Corporation
Integration & Heat Dissipation Aspects
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
24© Mitsubishi Electric Corporation
Features of J1 series Power ModuleDirectly cooled new power Module J1 series 40% footprint reduction 76% weight reduction 30% heat dissipation improvement
J1 series
(conventional)
Comparison of weight
J1 series
Conventional (TPM)
Comparison of footprint
30% reduction
(Electrified vehicle application)
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
25© Mitsubishi Electric Corporation
1980 2000 2010 2020 20301990
Insulation sheetTransfer molding
Insulation sheetTransfer molding*DLB connection
Al2O3 substrateAl-Wire
Silicone Gel
Cur
rent
den
sity
*[A
.U.]
Al-fin integrated AlN*DLB connection
*DP-resin encapsulation
Insulated Material Baseplate
Future technologyHigher current density
Higher reliability
Power module current density trend
AlN substrateAl-Wire
Silicone Gel
BIP IGBT(Planner)
Thinner lead flameRCIGBT
SiCIGBT(Trench) 7gen.~
Package technology
Chip technology
1
5
RCIGBT
* Current density is a value in terms of 6in1
Year
*DLB : Direct Lead Bond *DP : Direct Potting
10
Automobile:T-PM
Automobile:J1-Series
Higher temperature
Merits forAutomobileApplication
IEEE PEAC 2018 No Reprint Without Authorization
26© Mitsubishi Electric Corporation
-User benefits-
◆ Higher reliability and lower weight
⇒ SLC-Technology
◆ Easy designing for EMC with wider dv/dt controllability
⇒ 7th Gen. chipsets
◆ Suitable products for the system
⇒ Wide product lineup
Previous~ 6th structure
Silicone gel
SLC-Technology7th NX structure
■SLC's FeaturesReduce internal inductanceIncreasing reliability of thermal cycling
Resin
→ Single parts including resin insulation
After 7k cycles: Corner of Cu foil
Solder Cracking No Cracking Sign
NX type T-series and T1-series 7th Gen IGBT Modules
NX type 50- 600A/ 650V35-1000A/1200V
100- 600A/1700V
CeramicSolder
base plateInsulated Metal Baseplate
Latest Power Module for Industrial Use
IEEE PEAC 2018 No Reprint Without Authorization
27© Mitsubishi Electric Corporation
solder Ag sinter
Au/Ag wire
Coating
Al Pin-Fin
Silicone gel
US weldLaser
Compression
Wiring
Cooler jacket integration
Epoxy (T-mold )Epoxy (DP)
Die attachment
Encapsulation
Substrate
Cu sinter
Cu wireAl wire
Ceramic (AlN/SiN)
DI (Direct Injection)
Cu/AlSiC PC-TIM
Insulation sheetIMB
(Insulated Metal Baseplate)
PCB embedded
Higher λ
Development
Current capability
Operation temperature
Thermal conductivity
Mechanical stress
Parasitic inductance
Embedding
High power density
Reliable package
Low thermal resistance
Robustness
Fast switching
Intelligent integration
TLP(Transient Liquid
Phase)
Focus Value
DLB(Direct Lead Bond)
Trends of package element technology
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
28© Mitsubishi Electric Corporation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. Conclusion
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
29© Mitsubishi Electric Corporation
SiC based advanced power module: SiC-IPM
Features☆ Low power loss operation☆ High frequency operation capability☆ Lower EMI ☆ Reliability enhanced by
embedded protection schemes
Integrated functions
Tch sensor
Current sensor
Source
Gate
SiC-MOSFET power chip/package(1200V, 75A)
TypeSpecifications
Sample nameVoltage Current Circuit
Hybrid SiC-IPM 1200V 75A 6in1 PMH75-120-S002
Full SiC-IPM 1200V 75A 6in1 PMH75-120-S002
SiC-IPM
Base plate size120x55mm
S
D
Over current detection
Over heat detection
Under voltage detection
GateDriver
Errorsignal
UV
OT
SC
GND
Vcc
In
Fo
SiC-MOSFET/Diode
On-chiptemp. sensor
Current sensorRTC
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
30© Mitsubishi Electric Corporation
Approx. 70% reduction of power dissipation compared to conventional type in case of full SiC-IPM
Comparison of switching energy Comparison of power dissipation
Conventional type:PM75CL1A120 (Mitsubishi L1 series)
0 10 20 30 40 50 60 70 80
Esw
(mJ/
puls
e)
IC,ID(A)
Hybrid SiC-IPM
Si-IPM
FullSiC-IPM
Condition:Vcc=600V Tj=125℃
approx.70% reduced
Condition:Vcc=600V、lo=31Arms(equivalent for15kW inverter)、fc=15kHz; P.F.=0.9; Modulation=1;Three phase sinsoidal PWM; Tj=125℃
Si-IPM HybridSiC-IPM
FullSiC-IPM
Loss
[W]
FWDi_SWFWDi_DCTr_SWTr_DC
approx.25%
reduced
approx.70%
reduced
Performance of 1200V/75A SiC-IPM devices Application: 3-phase Motor Controls
The full-SiC solution can reduce losses drastically.M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
31© Mitsubishi Electric Corporation
Rail Applications’ Requirements Energy saving concept based system designs Utilize underfloor space effectively by miniaturized inverters/converters
Propulsion InverterFull-SiC power module
(3300V 2in1)
SiCMOS
SiC-SBD
Limited space
Railway Application of High Power SiC Module
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
32© Mitsubishi Electric Corporation
電圧
モータ電流
理想正弦波
電圧
モータ電流
理想正弦波
Waveform of conventional inverter
Waveform of high frequency switching SiC inverter
Motor power loss improvement
Current
voltageIdeal sine wave
Current
voltage Ideal sine wave
harmonic loss reduction
Motor harmonic loss could be reduced by application of high frequency control based converter design using SiC power module
Current distortion
M-181025-01
Result of SiC application in railway (2)
IEEE PEAC 2018 No Reprint Without Authorization
33© Mitsubishi Electric Corporation
By virtue of applying SiC power module, regenerative braking power of the traction system greatly expanded even with a smaller cooling fin.
Mechanical loss improvement Regenerative braking area expansion
speedBrak
ing
pow
er
high0
speedBrak
ing
pow
er
high0
Conventional braking system
Developed braking system
Mechanical braking
Regenerative braking
Mechanical braking
Regenerative braking
SiC helped to expand regenerative braking power
Regenerative braking power can return kinetic energy to catenary
Synchronous rectification Switching
deviceDiode
M-181025-01
Result of SiC application in railway (3)
IEEE PEAC 2018 No Reprint Without Authorization
34© Mitsubishi Electric Corporation
motor harmonic loss reduction
Conventional inverter
Full-SiCinverter
Regenerative power expansion
Energy consumptioncomparison
Results on SiC power module
Drastic energy saving together with huge size/weight reduction by use of SiC power module M-181025-01
Result of SiC application in railway (4)
IEEE PEAC 2018 No Reprint Without Authorization
35© Mitsubishi Electric Corporation
State-of-the-art 3.3kV LV100 SiC module with Advanced Integrated Assembly
Type Product Model Specification DimensionsLV100
(6kV isol.)Full-SiCModule FMF750DC-66A 3.3kV/750A/2in1 100×140×40mm3
New HF Film DC-link Cap integrated 3.3kV LV100 paired 3-parallel assembly
High Frequency Film Capacitor Tech2000Vdc / 130uF / 120Arms ESL < 10nH (per unit)
3.3KV LV100x3p SiC Module
HF Film Cap x 3p
Laminated Bus-bar
Snubber-less, fast transient surge protection possible
Mitsubishi & TDK Collaborative R&D
IEEE PEAC 2018 No Reprint Without Authorization
36© Mitsubishi Electric Corporation
SiC Applied Powertrain for HEV (R&D work)
Power conversion system topology
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
37© Mitsubishi Electric Corporation
SiC Applied Powertrain for HEV (R&D work)
Full-SiC Power Module structural features
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
38© Mitsubishi Electric Corporation
Offshore substationLandOffshore
HVDC
Wind Power Generator
HVDC Transmission/Solid-state Transformer
<SiC Contribution>◆ Reduction of power loss
Downsizing of power unit / lower spaceEfficiency of system components
Prospective new application of SiC module
ExampleExample
SST
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
39© Mitsubishi Electric Corporation
Example
Wind power converter
Converter Inverter
Full-SiC
Higher conversion efficiency thanks to power loss reduction
Downsizing of filter/transformer thanks to high-frequency switching
<SiC Contribution>◆High frequency switching
Light weight on top of tower◆Reduction of power loss
Higher conversion efficiencyHeatsink size reduction
Transformer
Grid→G
Full-SiCFilter Filter
Full-SiC module contribute to reduce filter and transformer size by ~20% when double the switching frequency.
容量を入れる
M-181025-01
Prospective new application of SiC module
IEEE PEAC 2018 No Reprint Without Authorization
40© Mitsubishi Electric Corporation
Contents:
1. Introduction: > Impact of global issues and importance of power electronics/devices > Status and future outlook on power electronics applications
2. Advanced power semiconductor technologies > Mitsubishi’s differentiation strategy > Silicon chip technologies> SiC chip technologies > Power module integrated functionalities and structural aspects > Highlights of latest SiC power module applications
3. Conclusion
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
41© Mitsubishi Electric Corporation
Conclusion1. Power electronics and Power semiconductors are expected to be appropriate
solutions for global issues such as climate change and energy efficiency.
2. Power electronic circuits make the system smaller and lighter and, therefore, provide the basis to improve efficiency.
3. Hybrid and Electric vehicles are solutions for higher fuel efficiency standards amid ever increasing concerns over CO2 emission, climate change and alarming reduction of fossil fuel reserve.
4. One of the key enabler of power electronics’ growth domain is power semiconductor, which is progressing rapidly to steer through and satisfy the environmental, social and economical requirements.
5. Mitsubishi Electric has provided power electronics systems, appliances and power devices contributing in improvement of energy utilization and conversion efficiency over several decades.
6. Power device evolution will continue in the future bringing in advanced packaging solutions, new functionalities compatible with IoT trends and new device technology platforms by use of WBG materials such as SiC and GaN.
M-181025-01
IEEE PEAC 2018 No Reprint Without Authorization
42© Mitsubishi Electric CorporationM-181025-01
IEEE PEAC 2018 No Reprint Without Authorization