BND 31303 / BNE 35203 / BNE 33603 POWER ELECTRONICS / POWER ELECTRONIC CONVERTERS : CHAPTER 1 INTRODUCTION DR. FARAHIYAH MUSTAFA Doctor of Philosophy (Electrical Engineering) ROOM NO. : 2.A1.1.146 Introduction, Power Electronics By Dr. Farahiyah Mustafa © FTK UTHM 2021 Introduction : Power Electronic Tree Introduction, Power Electronics By Dr. Farahiyah Mustafa 2 © FTK UTHM 2021 Introduction What is Power Electronics? • Power Electronics is a branch of electrical / electronics engineering that is concerned with the conversion and control of electrical power for various applications. • Utility systems usually generate, transmit, and distribute power at a fixed frequency (50 or 60 Hz), and a fixed voltage is maintained at the consumer terminals. • A consumer, however, may need power at DC or AC, at the same, higher or lower or variable frequency. Frequently, the power is to be controlled with precision. • A power electronics system interfaces between the utility system and consumer load to satisfy this need. Power electronics may be defined as the applications of solid-state electronics for the control and conversion of state electronics for the control and conversion of electrical power. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 3 © FTK UTHM 2021 2020 Introduction DEFINITION: To convert, i.e to process and control the flow of electric power by supplying voltage s and currents in a form that is optimally suited for user loads. BASIC BLOCK DIAGRAM: Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 4 © FTK UTHM 2021 2020 PE System • To convert electrical energy from one form to another, i.e. from the source to load with: • lowest cost • highest efficiency • smallest size • highest availability • least weight • highest reliability • Static applications • involves non-rotating or moving mechanical components. • Examples: • DC Power supply, Power generation and transmission (HVDC), Electroplating, Welding, Heating, Cooling, Electronic ballast • Drive applications • intimately contains moving or rotating components such as motors. • Examples: • Electric trains, Electric vehicles, Air-conditioning System, Pumps, Compressor, Conveyer Belt (Factory automation). Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 5 © FTK UTHM 2021 2020 Application Example Static Application: DC Power Supply AC voltage DIODE RECTIFIER FILTER DC-DC LOAD CONVERTER AC LINE VOLTAGE (1F or 3 F ) V control (derived from feedback circuit) Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 6 © FTK UTHM 2021 2020 Application Example Drive Application: Air-Conditioning System Power Source Power Electronics Converter Desired temperature Desired humidity System Controller Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa Variable speed drive Motor Indoor temperature and humidity Air conditioner Temperature and humidity Building Cooling Indoor sensors 7 © FTK UTHM 2021 2020 Power Conversion Concept Vs (Volt) • Supply from TNB: 50Hz, 240V RMS (340V peak). Customer need DC voltage for welding purpose, say. time • TNB sine-wave supply gives zero DC component • We can use simple half-wave rectifier. A fixed DC voltage is now obtained. This is a simple PE system. + Vs _ Vo Vdc time Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 8 © FTK UTHM 2021 2020 Power Conversion Concept How if customer wants variable DC voltage? More complex circuit using SCR is required. vs ig ωt ia + vs _ + vo _ Average output voltage : Vm 1 π ( ) [1 + cos α ] Vo = V t d t = sin ω ω m ∫ 2π α 2π vo ωt ig α ωt By controlling the firing angle, α, the output DC voltage (after conversion) can be varied.. Obviously this needs a complicated electronic system to set the firing current 9 Introduction, Power Electronics BNE 33603 PE SCR. Converters pulses for the By Dr. Farahiyah Mustafa © FTK UTHM 2021 By Dr. Farahiyah Mustafa © FTK UTHM 2020 Current Issues 1. Energy Scenario • Need to reduce dependence on fossil fuel • coal, natural gas, oil, and nuclear power resource Depletion of these sources is expected. • Tap renewable energy resources: • solar, wind, fuel-cell, ocean-wave • Energy saving by PE applications. Examples: • Variable speed compressor air-conditioning system: 30% savings compared to thermostat-controlled system. • Lighting using electronics ballast boost efficiency of fluorescent lamp by 20%. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 10 © FTK UTHM 2021 2020 Current Issues 2. Environment Issues • Nuclear safety. • Nuclear plants remain radioactive for thousands of years. • Burning of fossil fuel • emits gases such as CO2, CO (oil burning), SO2, NOX (coal burning) etc. • Creates global warming (green house effect), acid rain and urban pollution from smokes. • Possible Solutions by application of PE. Examples: • Renewable energy resources. • Centralization of power stations to remote non-urban area. (mitigation). • Electric vehicles. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 11 © FTK UTHM 2021 2020 PE Growth • PE rapid growth due to: • Advances in power (semiconductor) switches • Advances in microelectronics (DSP, VLSI, microprocessor/microcontroller, ASIC) • New ideas in control algorithms • Demand for new applications • PE is an interdisciplinary field: • • • • Digital/analogue electronics Power and energy Microelectronics Control system Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa • Computer, simulation and software • Solid-state physics and devices • Packaging • Heat transfer 12 © FTK UTHM 2021 2020 Types of Converters Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 13 © FTK UTHM 2021 2020 Power Electronic Devices The Concept • Power electronic devices: are the electronic devices that can be directly used in the power processing circuits to convert or control electric power. • In broad sense power electronic devices • Very often: Vacuum devices: Mercury arc rectifier thyratron, etc. . seldom in use today Semiconductor devices: major power electronic devices since late 1950s Power electronic devices = Power semiconductor devices • Major material used in power semiconductor devices — Silicon Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 14 © FTK UTHM 2021 2020 Power Electronic Devices The Concept • Also known as power switches: work-horses of PE systems. • Operates in two states: • Fully on. i.e. switch closed. • Conducting state POWER SWITCH I Vswitch= 0 Vin SWITCH ON (fully closed) I=0 • Fully off , i.e. switch opened. • Blocking state Vswitch= Vin Vin SWITCH OFF (fully opened) • Power switch never operates in linear mode. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 15 © FTK UTHM 2021 2020 Power Electronic Devices Features • Need to be controlled by information electronic circuits. Very often, drive circuits are necessary to interface between information circuits and power circuits. • Dissipated power electronic devices are necessary. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa loss usually larger special packaging than and information heat sink 16 © FTK UTHM 2021 2020 Power Electronic Devices Power Losses v t i t p On-state (conduction state) turningoff Off-state (blocking state) turning -on t (usually very small and can be neglected) Total power loss on = conduction loss + turn-off loss + off-state loss + turn-on loss a power semiconductor (on-state loss) device Switching loss Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 17 © FTK UTHM 2021 2020 Power Electronic Devices Configuration of System Electric isolation: optical or magnetic Control circuit (in a broad sense) Control circuit Detection (measurement) circuit drive circuit Power circuit (power stage, main circuit) Protection circuit is also very often used in power electronic system especially for the expensive power semiconductors. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 18 © FTK UTHM 2021 2020 Power Electronic Devices Terminal A power electronic device usually has a third terminal — control terminal to control the states of the device. C A power electronic device must have at least two terminals allowing power circuit current flow through. G Drive Circuit E The control signal from drive circuit must be connected between the control terminal and a fixed power circuit terminal (therefore called common terminal). Introduction, BNE 33603 PE Converters By Dr. Farahiyah Mustafa 19 © FTK UTHM 2020 Power Electronic Devices Classification Uncontrolled device: diode (Uncontrollable device) has only two terminals and can not be controlled by control signal. The on and off states of the device are determined by the power circuit. Half-controlled device: thyristor (Half-controllable device) is turned-on by a control signal and turned-off by the power circuit Fully-controlled device: Power MOSFET, IGBT,GTO, IGCT (Fullycontrollable device) The on and off states of the device are controlled by control signals. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 20 © FTK UTHM 2021 2020 Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 21 © FTK UTHM 2021 2020 Power Electronic Devices Introduction to Device Fabrication 1. Oxidation 2. Lithography & Etching 3. Ion Implantation Introduction, BNE Power Electronics 33603 PE Converters By Dr. Farahiyah Mustafa 4. Annealing & Diffusion 2021 © FTK UTHM 2020 Power Electronic Devices Oxidation of Silicon Quartz tube Si Wafers Flow controller O N H O or TCE(trichloroethylene) 2 Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa 2 Resistance-heated furnace © FTK UTHM 2021 2020 Power Electronic Devices Oxidation of Silicon Dry Oxidation : Si + O2 → SiO2 Wet Oxidation : Si +2H2O → SiO2 + 2H2 Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa © FTK UTHM 2021 2020 Power Electronic Devices Lithography Photo Mask Water Photoresist Wafer conventional dry lithography Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa wet or immersion lithography © FTK UTHM 2021 2020 Power Electronic Devices Lithography (c) Development (a) Resist Coating Positive resist Photoresist Si Oxide (b) Exposure Si Deep Ultraviolet Light Optical Lens system Si (d) Etching and Resist Strip Photomask with opaque and clear patterns Si Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa Negative resist Si © FTK UTHM 2021 2020 Power Electronic Devices Isotropic etching (wet) Etching Anisotropic etching (dry) photoresist SiO SiO photoresist SiO 2 2 (1) (1) photoresist photoresist SiO 2 2 (2) SiO 2 Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa (2) SiO 2 © FTK UTHM 2021 2020 Power Electronic Devices Etching Scanning electron microscope view of a plasma-etched 0.16 mm pattern in polycrystalline silicon film. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa © FTK UTHM 2021 2020 Power Electronic Devices Doping Dopant ions • • • • The dominant doping method Excellent control of dose (cm-2) Good control of implant depth with energy (KeV to MeV) Repairing crystal damage and dopant activation requires annealing, which can cause dopant diffusion and loss of depth control. Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa © FTK UTHM 2021 2020 Power Electronic Devices Sputtering Sputtering target Atoms sputtered out of the target Ion (Ar +) YY Y YY YYYYY YY Y YY YYYYYYYY YYYYYYYY YYYYYY YYYY YYYYYY YYYYYYYY YYYYYY YYYYYYYYYYYY YYYYYY YY YYYYYY YYYYYYYYYYYY YY Y YYYY YYYYY YYYYYYY YYYYYYY YY YYY Y YYYYYY YYYYYYY YY YYYY Y YYYYYYY YYYYYYY YYYYY YYY YYYYYY Y YY Target material deposited on wafer Si Wafer Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa Slide 3-30 © FTK UTHM 2021 2020 Power Electronic Devices Summary – A Device Fabrication Arsenic implantation P-Si (0) Si Wafer (4) SiO2 P-Si SiO2 (1) P-Si Oxidation (5) SiO2 UV UV (2) (6) M ask Lithography SiO 2 P-Si N Al SiO2 SiO2 N+ Ion Implantation Annealing & Diffusion P Al Sputtering P Positive resist SiO2 SiO2 SiO2 + UVUV P-Si (3) Etching SiO2 M as k SiO2 (7) Res is t Al SiO2 N+ SiO2 Al Lithography P Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa Slide 3-31 © FTK UTHM 2021 2020 Power Electronic Devices Summary – A Device Fabrication Metal etching (8) S iO2 N+ S iO2 Al Si3 N4 (12) P (9) CVD nitride deposition (10) Lithography and etching Si3 N4 SiO2 N Al SiO 2 N+ P Al SiO2 P Si3 N4 SiO2 wire Al N+ SiO2 P Introduction, Power Electronics BNE 33603 PE Converters By Dr. Farahiyah Mustafa SiO2 P Al N+ Al SiO2 N Photoresist SiO2 Si3N 4 (13) + P Si3 N4 Back side metallization Au + (11) Back Side milling SiO2 SiO 2 Au Plastic package metal leads Dicing, wire bonding, and packaging © FTK UTHM 2021 2020
