POWER MODULES Achieving CISPR conducted emission compliance for autos with a single stage filter ISSUE 3 – November 2024 www.power-mag.com Also inside this issue Industry News | Market News Semiconductor Materials | Energy Efficiency Connected Electronics | Capacitive digital isolators Switched-mode power supplies | Products | Web Locator
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CONTENTS www.power-mag.com Issue 3 2024 Power Electronics Europe 3 News & Features Editor Leslah Garland Tel: +44 (0)1732 370340 Email: leslah@dfamedia.co.uk Publisher Ian Atkinson Tel: +44 (0)1732 370340 Email: ian@dfamedia.co.uk www.power-mag.com Production Editor Chris Davis Tel: +44 (0)1732 370340 Email: chris@dfamedia.co.uk Financial Manager Joanne Morgan Tel: +44 (0)1732 370340 Email: accounts@dfamedia.co.uk Reader/Circulation Enquiries Perception Tel: +44 (0) 1825 701520 Email: dfamedia@dmags.co.uk INTERNATIONAL SALES OFFICES Mainland Europe: Victoria Hufmann Norbert Hufmann Tel: +49 911 9397 643 Fax: +49 911 9397 6459 Email: pee@hufmann.info Eastern US Ian Atkinson Tel: +44 (0)1732 370340 Email: ian@dfamedia.co.uk Western US and Canada Ian Atkinson Tel: +44 (0)1732 370340 Email: ian@dfamedia.co.uk Japan: Yoshinori Ikeda, Pacific Business Inc Tel: 81-(0)3-3661-6138 Fax: 81-(0)3-3661-6139 Email: pbi2010@gol.com Taiwan Prisco Ind. Service Corp. Tel: 886 2 2322 5266 Fax: 886 2 2322 2205 Circulation and subscription: Power Electronics Europe is available for the following subscription charges. Power Electronics Europe: annual charge UK/NI £95, overseas $160, EUR 150. Contact: DFA Manufacturing Media, 192 High Street, Tonbridge, Kent TN9 1BE Great Britain. Tel: +44 (0)1732 370340. Refunds on cancelled subscriptions will only be provided at the Publisher’s discretion, unless specifically guaranteed within the terms of subscription offer. Editorial information should be sent to The Editor, Power Electronics Europe, 192 High Street, Tonbridge TN9 1BE U.K. The contents of Power Electronics Europe are subject to reproduction in information storage and retrieval systems. All rights reserved. No part of this publication may be reproduced in any form or by any means, electronic or mechanical including photocopying, recording or any information storage or retrieval system without the express prior written consent of the publisher. Printed by: Warners. ISSN 1748-3530 PAGE 4 Industry News PEE looks at the latest Market News and company developments PAGE 7 Market News PEE looks at the latest Market News and company developments PAGE 11 Four mid-voltage applications where GaN will transform electronic designs Srijan Ashok - Product Marketing Engineer, GaN, at Texas Instruments PAGE 14 Ecodesign, Reuse, Repair, Prolonging Lifetime and New Technology – Is it the new paradox? Patrick Le Fèvre, PRBX, Chief Marketing and Communication Officer PAGE 18 Reimagining the Holdover Oscillator MEMS-based Precision Timing Delivers Accurate, Reliable, Ultra-Stable Clock Signals for the Era of Intelligent, Connected Electronics. By Piyush Sevalia, Executive VP Marketing, SiTime PAGE 21 Ensure Interference-free data communication Galvanic isolation of circuit components is required in many cases, especially in industrial environments. Capacitive digital isolators can be used to safely and reliably transmit user signals across an isolation barrier. The following circuit example shows how capacitive digital isolators can be used to galvanically isolate remote industrial equipment. PAGE 25 Passive components in modern switched-mode power supplies. PAGE 28 Products PAGE 31 Web Locator MHz switching frequency-based devices enable miniaturization of the DC-DC converter and EMI filters Achieving EMI conducted emission compliance for automobiles with a single stage filter. By Nicola Rosano, Sr. Strategic FA/System Engineer at Vicor More details on page 8. FEATURE STORY Subscribe for your FREE copy now
4 INDUSTRY NEWS Issue 3 2024 Power Electronics Europe www.power-mag.com The electronics industry will soon be expected to play a big part in the European Union’s (EU) measures to create a more circular economy. The Ecodesign for Sustainable Products Regulation (ESPR) entered into force earlier this year to ensure the sustainability and traceability of electronics amongst other priority product groups. Currently, more than 50 million tonnes of e-waste are produced every year, contributing to it being the fastest-growing solid waste stream in the world. This is likely why the EU has named it as one of the priority product groups. The ESPR will apply to businesses placing electronics within the EU market even if those products weren’t produced in the EU. Businesses will be expected to implement Digital Product Passports (DPPs) to comply. In a nutshell, DPPs act as a digital record of a physical product, securely keeping track of information across a product’s lifecycle, including event or transactional data, or even data concerning its sustainability credentials. For example, the carbon footprint of its production. Through a data carrier like a QR code, a barcode, or an NFC tag attached to a physical product, information can be accessed by a device such as a smartphone. Through the implementation of DPPs and the digital record they provide on a product’s lifecycle and credentials, the EU hopes to encourage manufacturers and producers to adopt more sustainable practices and inspire circular thinking past the point of manufacture. Crucially for the electronics industry, it will provide insight into the effective disposal of end-of-life (EOL) electronics, which is expected to encourage recycling and circularity. The delegated acts - specific compliance requirements for each product group impacted - are expected to be announced next year. These will include specific timing requirements for compliance for the priority groups. DPP solution provider Protokol is currently working with businesses that are getting ahead of the delegated acts to ensure they are in the best shape to meet compliance standards for what will require a more streamlined approach to collecting and sharing product data. The advised first steps are to create a team that will track regulatory updates, begin taking stock of data points that may be required and engage with stakeholders to understand their current planning for compliance. For more information, visit: https://www.protokol.com/services/digitalproduct-passport-consulting/ The EU’s Ecodesign for Sustainable Products Regulation enters into force Infineon launches ultra-high current density power modules to enable high-performance AI computing Data centres are currently responsible for more than 2% of global energy consumption. Fuelled by AI, this number is expected to grow to up to around 7% in 2030, matching the current energy consumption of India. Enabling efficient power conversion from grid-to-core is vital to enable superior power densities and thereby advance compute performance while reducing total cost of ownership (TCO). Infineon Technologies has announced it has therefore launched the TDM2354xD and TDM2354xT dual-phase power modules with best-inclass power density for high-performance AI data centres. The company says these modules enable true vertical power delivery (VPD) and offer industry’s best current density of 1.6 A/mm 2. They follow the TDM2254xD dual-phase power modules introduced by Infineon earlier this year. “We are proud to enable high-performance AI data centres with our TDM2354xT and TDM2354xD VPD modules. These devices will maximise system performance with Infineon’s trademark quality and robustness, thereby enabling best TCO for data centres,” said Rakesh Renganathan, Vice President Power ICs at Infineon Technologies. “Our industry-leading power devices and packaging technologies, combined with our extensive systems expertise, will further advance high-performance and green computing as part of our mission to drive digitalisation and decarbonisation.” Infineon says the TDM2354xD and TDM2354xT modules combine its robust OptiMOS 6 trench technology, a chip-embedded package that enables superior power density through enhanced electrical and thermal efficiencies, and a new inductor technology to enable lower profile and therefore, true vertical power delivery. As a result, the modules set new standards in power density and quality to maximise the compute performance and efficiency of AI data centres. The TDM2354xT modules support up to 160 A and are said to be the industry’s first Trans-Inductor Voltage Regulator (TLVR) modules in a small 8 x 8 mm? form factor. Combined with Infineon’s XDP controllers, they offer extremely fast transient response and minimise on-board output capacitance by up to 50%, further increasing system power density. The new modules will be showcased at Infineon’s global technology forum OktoberTech 2024 in Silicon Valley on 17 October and at electronica 2024 in Munich from November 12 to 14 (hall C3, booth 502).
INDUSTRY NEWS 5 www.power-mag.com Issue 3 2024 Power Electronics Europe At the upcoming electronica trade show in Munich, Infineon Technologies has announced it will illustrate how its innovative solutions are driving the global trends of decarbonisation and digitalisation. The company says it will show how its semiconductors are paving the way to a net-zero economy and to unlocking the full potential of artificial intelligence (AI). From 12 to 15 November at booth 502 in hall C3, Infineon will present highlights from its extensive portfolio and offer the opportunity to talk to its experts. “Decarbonisation and digitalisation are the key drivers on the way to a climate-neutral future,” said Andreas Urschitz, Member of the Board and Chief Marketing Officer at Infineon. “Semiconductors contribute in many ways to the green and digital transformation and are at the heart of every connected application. At electronica, we’ll be showcasing how our leading technologies and innovative solutions are helping master the central challenges of our time.” World’s first 300 mm gallium nitride wafers Infineon says it will present its technological breakthrough, reportedly the world’s first 300 mm power gallium nitride (GaN) wafer technology, to the general public for the first time. This technological milestone will significantly advance the market for GaN-based power semiconductors. Leveraging 300 mm GaN will strengthen existing solutions and application fields and create new ones, with an increasingly cost-effective value proposition and the ability to address the full range of customer systems. Shaping the future of mobility Infineon says it is focused on the development of innovative solutions that drive the transition to clean, safe and intelligent mobility. Products and solutions on display at electronica include the new AURIX TC4x microcontrollers, which support the implementation of future-proof E/E architectures and software-defined vehicles, as well as the main inverter CoolSiC Kit, battery management system solutions, on-board chargers with GaN, steer-bywire system solutions and H 2 sensors for fuel cell applications. Greener and smarter buildings and homes Semiconductors play a crucial role in the development of smarter and more sustainable living spaces. Infineon’s advanced technologies based on silicon carbide (SiC) and GaN can enable maximum energy efficiency and reliability for energy generation and consumption. With advanced sensors, power semiconductors, security solutions such as OPTIGA Trust and microcontrollers such as PSOC Control, Infineon enables the efficient use of green energy while bringing smart automation to modern homes and commercial buildings. The company’s booth will showcase comprehensive system solutions including various solar inverter topologies (microinverters and string inverters), as well as demos for optimizing power and boosting heat pump output. Enabling AI – Efficient, reliable and on the edge Semiconductors also play a crucial role in unlocking the full potential of AI. Infineon says its solutions make it possible for customers to deploy new AI applications quickly, efficiently and at scale. The company’s broad range of products, software, tools and services enables energy-efficient data centres, smarter devices and optimised AI edge applications. Demos will include high-performance, low-power AI-enabled microcontrollers from the PSOC family, advanced sensors from the XENSIV portfolio as well as vertical power module architectures, advanced liquid cooling modules and power supply units for AI data centres. Infineon at electronica 2024: Solutions for decarbonisation and digitalisation ROHM at electronica 2024: Empowering Growth, Inspiring Innovation ROHM Semiconductor Europe has announced it will be exhibiting at electronica 2024 – a leading world trade fair and conference for electronic components, systems, applications, and solutions. The event will take place between November 12th to 15th in Munich. At booth C3-520, ROHM says it will showcase its advanced power and analogue technologies designed to enhance power density, efficiency, and reliability in both automotive and industrial applications. These advancements are crucial for addressing the increasing demands of modern electronic systems, particularly in the context of sustainability and innovation. Under the theme “Empowering Growth, Inspiring Innovation”, ROHM says it will highlight
6 INDUSTRY NEWS Issue 3 2024 Power Electronics Europe www.power-mag.com To receive your own copy of Power Electronics Europe subscribe today at: www.power-mag.com via its various demo application stations in “tree style” how its high-quality semiconductor technologies contribute to solving critical social and ecological challenges. The focus will be on driving sustainability in electronic design and innovation, which aligns with the growing emphasis on creating environmentally responsible solutions within the industry. At electronica 2024, the exhibition space has been greatly expanded and the number of items on display has been increased to 30 – more than three times compared to the previous show. The latest solutions will be exhibited under the three themes of “for E-Mobility”, “for Automotive”, and “for Industrial”. For E-Mobility * TRCDRIVE pack with 2-in-1 SiC Molded Module to improve the efficiency of traction inverters * New EcoIGBT products for electric compressors * New EcoSiC Schottky Barrier Diodes for onboard chargers For Automotive * New configurable PMIC with supporting functional safety features for application processors, SoCs and FPGAs * LED Driver ICs for Exterior Lighting / Head Lamps * Advanced solutions on the ADAS cockpit demo For Industrial Equipment * Industrial AC-DC PWM Controller ICs – support a wide range of power transistors from Si MOSFETs and IGBTs to SiC MOSFETs * The EcoGaN family of 150V and 650V class GaN HEMTs in several EVKs * Latest R&D project on Terahertz In addition to product showcases, ROHM says it is committed to fostering technical exchange and collaboration at electronica 2024. “For us, electronica is more than just a showcase – it’s an opportunity to forge new connections, strengthen existing partnerships, and reunite with industry peers,” says Wolfram Harnack, President of ROHM Semiconductor Europe. “We are excited to welcome our guests to Munich as we work together to shape the future of electronics.” Danfoss Power Solutions launches high-performance GH493 four-wire spiral hose in Europe Danfoss Power Solutions has announced the launch of its Aeroquip by Danfoss GH493 fourwire spiral hose in Europe, the Middle East, and Africa. The company says this premium hydraulic hose meets or exceeds four key industry standards in flexibility, lifetime, and working pressure — EN856 Type R12, EN856 Type 4SP, SAE 100R12, and ISO 18752 — offering reliable performance in demanding high-pressure mobile and industrial machinery applications. With its tighter minimum bend radius, GH493 hose offers greater flexibility for use in cramped spaces. This flexibility provides more design freedom and easier installation. It can also reduce the hose lengths required, which lowers costs and machine weight. The hose’s minimum bend radius is, on average, 58% tighter than EN856 Type 4SP and 50% tighter than EN856 Type R12 standards. GH493 hose offers long in-application lifetime, maximising machine uptime and reducing maintenance and hose replacement costs. Hose sizes -6 to -16 are tested up to 1 million impulse cycles, and hose sizes -20 to -32 are tested up to 500,000 impulse cycles, higher than the requirements of SAE 100R12, EN856 Type 4SP, and EN856 Type R12. GH493 hose reportedly delivers better average pressure performance than industry standards, enabling use in a broad range of hydraulic systems as well as the creation of more power-dense machines. The hose exceeds the requirements, on average, of SAE 100R12 by 30%, EN856 Type 4SP by 19% (sizes -10 to -32), and EN856 Type R12 by 32%. It meets ISO 18752 constant pressure standards. “It’s rare to find a hose with outstanding flexibility plus higher pressure performance and long lifetime. This combination makes our Aeroquip by Danfoss GH493 hose a versatile solution that maximises uptime and minimises maintenance in a wide range of high-pressure machinery,” said Salih Karayagiz, Product Manager, Rubber Hydraulic Hose and Fittings, Danfoss Power Solutions. “GH493 is our most popular four-wire spiral hose in the Americas, proven over the years in a wide range of applications. Its introduction in EMEA opens new application possibilities while helping our customers drive inventory standardisation.” For increased durability, GH493 hose incorporates the Danfoss Dura-Tuff cover, which is said to be up to eight times more abrasion resistant than standard synthetic hose covers. The material extends hose lifetime while reducing the chances of a hose failure due to abrasion. GH493 hose is compatible with Danfoss 4S series spiral fittings. Featuring Dura-Seal technology, these high-performance fittings enable better sealing and leak-free operations (Class 0 leakage per SAE J1176). Customised multi-bent fittings are also available. GH493 hose is available in sizes -6 to -32. It is suitable for operating temperatures of -40°C to 126°C and features working pressures ranging from 275 to 448 bar, depending on size. The hose is ideal for higher pressure hydraulic systems in construction and mining machinery as well as oil and gas and wind power equipment.
MARKET NEWS 7 Specialist film capacitors Metallised polypropylene and polyester 昀lm capacitors meet the demands of power electronics in high-end applications. • Fast UK manufacturing • Small minimum order quantity (MoQ) • Flexible customisation & value add • For DC link, power conversion, 昀ltering and signalling • Precision applications: • Audio • Defence & aerospace • Motor sport • Rail & transport www.icwltd.co.uk Tel: +44 (0) 1591 610408 sales@charcroft.com www.charcroft.com Part of the Charcroft family of companies Manufactured in the UK Y E A R S Infineon announces the next milestone in semiconductor manufacturing technology Infineon technologies says after announcing the world’s first 300-millimeter gallium nitride (GaN) power wafer and opening the world’s largest 200-millimeter silicon carbide (SiC) power fab in Kulim, Malaysia, it has unveiled the next milestone in semiconductor manufacturing technology. The company says it has reached a breakthrough in handling and processing the thinnest silicon power wafers ever manufactured, with a thickness of only 20 micrometres and a diameter of 300 millimetres, in a high-scale semiconductor fab. The ultra-thin silicon wafers are only a quarter as thick as a human hair and half as thick as current state-of-the-art wafers of 40-60 micrometres. “The world’s thinnest silicon wafer is proof of our dedication to deliver outstanding customer value by pushing the technical boundaries of power semiconductor technology,” said Jochen Hanebeck, CEO at Infineon Technologies. “Infineon’s breakthrough in ultra-thin wafer technology marks a significant step forward in energy-efficient power solutions and helps us leverage the full potential of the global trends decarbonisation and digitalisation. With this technological masterpiece, we are solidifying our position as the industry’s innovation leader by mastering all three relevant semiconductor materials: Si, SiC and GaN.” The company says this innovation will significantly help increase energy efficiency, power density and reliability in power conversion solutions for applications in AI data centres as well as consumer, motor control and computing applications. For more information visit www.infineon.com
8 CONDUCTED EMISSION COMPLIANCE www.vicorpower.com Issue 3 2024 Power Electronics Europe www.power-mag.com MHz switching frequency-based devices enable miniaturization of the DC-DC converter and EMI filters Achieving EMI conducted emission compliance for automobiles with a single stage filter. By Nicola Rosano, Sr. Strategic FA/System Engineer at Vicor When it comes to electric vehicles (EVs), all OEMs want to design lighter, smaller and more affordable solutions. Additionally, utilities, regulatory agencies and OEM’s are seeking to leverage a vehicle to grid (V2G) connection to enable energy, period exchange with the distribution network From a power electronics perspective, this pursuit entails power conversion circuitry with greater power densities and the ability to meet the requirements for connecting the vehicle to the grid. With respect to DC-DC power converters, one notable way to miniaturize the system and increase overall power density is through higher-frequency switching. Yet, despite the potential benefits of systems with switching frequencies over 1.3MHz, technical challenges have kept many designers to working at lower frequencies, such as 100kHz or below. Imagine having a DC-DC power conversion solutions that harness the benefits of high-frequency switching without incurring conventional shortcomings. That could go a long way toward achieving smaller and lightweight EV power design goals of the OEM while adding V2G capability. The benefits of high-frequency DC-DC power conversion In the pursuit of lighter, smaller and more affordable automotive systems, highfrequency power conversion offers a promising solution. The primary benefit of moving to higherfrequency power conversion systems is a reduction in component size in both the physical device and the supporting input and output EMI filters. Some of the most space-consuming components in the converter itself are the passives, such as inductors and capacitors. Inductors and capacitors store and release energy in each switching cycle to smooth out current and voltage waveforms, respectively. When the converter’s switching frequency is higher, these components store less energy per cycle, allowing for smaller-value components allowing a decrease in the overall system size and enabling more power-dense systems for the same power level target. Beyond the converter, the associated input EMI filters are a major space consumer related to DC-DC conversion. DC-DC converters generate EMI due to the rapid switching of currents and voltages, which can create noise at the switching frequency and its harmonics. To mitigate this noise, EMI filters are employed at the input with cutoff frequencies typically dependent by the power stage requirements. (Figure 1) These filters also rely on passive components where size is directly correlated to switching frequency. By shifting the converter’s switching frequency to the MHz order, the desired EMI filter cutoff frequency can be increased. At higher cutoff frequencies, designers can make the passive components in the EMI filter much smaller, decreasing overall system size and weight while increasing system power density. Not only does switching to higherfrequency DC-DC conversion reduce component size and weight, but it also enables systems with improved transient responses. In DC-DC converters, the control loop bandwidth is typically a fraction of the switching frequency. Higher switching frequencies enable higher control loop bandwidth, allowing the feedback loop to react more rapidly to disturbances. A higher bandwidth allows the converter to correct output deviations quicker, ensuring that the output voltage remains stable even with sudden load or input voltage changes. Figure 1: An active EMI filter (labeled QPI) is often employed at the input of a DC-DC converter, with its cutoff frequency determined by the switching frequency of the converter.
www.vicorpower.com CONDUCTED EMISSION COMPLIANCE 9 www.power-mag.com Issue 3 2024 Power Electronics Europe Conventional challenges facing highfrequency DC-DC power conversion Although moving to higher-frequency DCDC conversion can yield many tangible benefits, a number of technical challenges have historically prevented this pursuit. First, moving to higher frequency operation may present a barrier to achieving EMC compliance. For conducted emissions standards such as CISPR32 (required for V2G applications), the frequency range evaluated by the standard is from 150kHz to 30MHz. Operating at a higher fundamental frequency, such as above 1MHz, creates the largest harmonics within the frequency range of interest, running the risk of compliance failure. For this reason, many power converter designers choose to operate at lower frequencies, such as 100kHz, ensuring that their first harmonic falls below the frequency range of interest. Same issues can found if the power stage is called to be compliant with the CISPR25 reference standard. Also, fear of increased losses is another potential drawback when using higherfrequency switching converters. Switching losses occur when a switch, such as a MOSFET, transitions from its on-state to its off-state and vice versa. These losses are significant because both the voltage across the switch and the current through the switch are non-zero during the transition period. (Figure 2) All else being equal, higher switching frequencies result in more frequent transitions per unit of time, leading to increased switching losses. Since the energy dissipated per switching event is proportional to the crossover time and the product of the voltage and current, increasing the frequency means that these energy losses accumulate more quickly. Therefore, the total power loss due to switching is directly proportional to the switching frequency, making higherfrequency operation associated with higher switching losses. Finally, issues concerning the selfresonance of passive components occur during high-frequency operations. Selfresonance is a phenomenon in which electrical components exhibit resonant behavior due to their parasitic properties. This leads to unpredictable behavior, impedance peaks, efficiency losses and signal integrity issues. Self-resonance becomes a significant problem at higher switching frequencies as these frequencies approach the self-resonant frequencies of components, amplifying noise and EMI and complicating circuit design. Also working beyond the self resonant frequency an inductor exhibits a capacitor behavior and vice-versa a capacitor Figure 2: Switching losses occur during “hard switching”, where the MOSFET transitions while voltage and current waveforms are both non-zero. Figure 3: Zero-current switching is achieved through a set of dedicated circuitry, which avoids high-frequency switching losses through specially timed MOSFET transitions.
10 CONDUCTED EMISSION COMPLIANCE www.vicorpower.com Issue 3 2024 Power Electronics Europe www.power-mag.com behaves like an inductor. Solving high-frequency power conversion With decades of industry-leading experience in power electronics design, Vicor has developed DC-DC conversion solutions that harness all the benefits of high-frequency conversion without the negative side effects. Specifically, the Vicor NBM™ family of non-isolated bus converter modules successfully switch at frequencies above 1.3MHz. With respect to efficiency, the NBM™ line of products can realize minimal power losses at high frequency by using zero voltage switching (ZVS) and zero current switching (ZCS) technology. Zero-voltage switching works by carefully timing the switch’s operation so that the switching aligns with the moments when the voltage across the switch is zero. Similarly, zerocurrent switching works by timing the switch’s operation so that it coincides with the moments when the current through the switch is zero. (Figure 3) Vicor ZVS and ZCS are achieved by introducing a separate phase to the pulsewidth modulation (PWM) timing. Utilizing the added phase, the solutions use a clamp switch and circuit resonance to efficiently operate the high side and synchronous MOSFETs with soft switching, avoiding losses incurred during conventional PWM hard switching operation and timing. Thanks to ZVS and ZCS, products like the NBM line of DC-DC converters can operate at 1.5 to 1.7 MHz while still achieving peak efficiencies of up to 99%. The combination of high switching frequencies and efficiency enables solutions with unparalleled power density, up to 550 kW / liter. In terms of EMC, the NBM™ products can achieve compliance, even at unusually high frequencies. In a recent set of tests, conducted emission compliance of the NBM9280 power module was evaluated. This Vicor module is capable of converting 37.5kW, with a power density of 550 kW/ liter, for electrified vehicle applications. The testing found that, even at a switching frequency of 1.3MHz, the NBM9280 could satisfy CISPR32 limits with a combination of Pi filtering and introducing a ferrite core around the input power cables. (Figure 4) The resulting filtering components were significantly smaller than what is necessary for a lower-frequency (i.e., 100kHz) solution, yet the same compliance was achieved. All things considered, automotive designers can simply replace their existing DC-DC conversion systems with the NBM™ line of products and immediately realize the benefits of smaller size and greater power density without risk of compliance failure or efficiency losses. Higher frequency supports today’s EV demand period. With a shift to EVs the automotive industry is demanding smaller, lighter and more power-dense solutions which can support vehicle to grid interfaces. For power electronics designers, a switch to higherfrequency DC-DC conversion solutions is an ideal way to meet these demands. Vicor has been able to develop DC-DC conversion solutions that operate with switching frequencies as high as 1.74MHz without incurring the conventional shortcomings of high switching frequencies. With products like the NBM™ family of DC-DC converters, automotive designers can realize a future where vehicles are efficient, lightweight and high performing, without the design complexity or expertise that often accompany these results. ! Figure 4: The NBM9280 passed conducted emission compliance with the addition of a dedicated PI filter.
www.ti.com SEMICONDUCTOR MATERIALS 11 www.power-mag.com Issue 3 2024 Power Electronics Europe Four mid-voltage applications where GaN will transform electronic designs Srijan Ashok - Product Marketing Engineer, GaN, at Texas Instruments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ntroduction The rapid technological expansion means that the appetite for power is increasing. In order to fuel this expansion sustainably, renewable energy sources such as solar are being deployed to power grids increasingly. Similarly, the need for servers is increasing exponentially to enable faster data processing, big data storage and artificial intelligence (AI). As a result of worldwide trends, designers have a big task at hand: keep increasing efficiency in their designs while delivering more power in the same footprint. This challenge has already pushed the adoption of gallium nitride (GaN) in highvoltage power designs because GaN has two major advantages: Increased power density. GaN’s higher switching frequencies enable designers to use smaller-sized passives such as inductors and capacitors, thereby reducing board dimensions. Increased efficiency. Compared to silicon designs, GaN’s superior switching and conduction-loss performance reduce losses by >50%. Alongside the industry-adopted high voltage GaN (rated >=600V), new midvoltage GaN solutions (rated 80V-200V)
12 SEMICONDUCTOR MATERIALS www.ti.com Issue 3 2024 Power Electronics Europe www.power-mag.com are becoming increasingly popular to achieve higher power density and efficiency in power systems that high voltage GaN previously could not support. In this article, I’ll describe four major mid-voltage application areas where the adoption of GaN is spreading. Application No. 1: Solar energy Solar energy is the fastest-growing source of renewable energy, rising 26% from 2021 to 2022 with a projection to expand capacity at a compound annual growth rate of approximately 11.5% in the next seven to eight years. As solar panel installations increase, so will the need for system efficiency and power density, as it is a space-intensive technology. For solar panel subsystems, the LMG2100R044 and LMG3100R017 devices can help reduce system size by over 40%. Solar power is enabled primarily by two types of subsystems at the solar panel: a boost stage followed by an inverter stage to convert a DC voltage range to an AC voltage (see Figure 1), and a buck and boost stage in which a power optimizer converts a varying DC voltage to a common DC voltage level (using maximum power-point tracking) for delivery to a string inverter (see Figure 2). Application No. 2: Servers Given that we are still in the early stages of the artificial intelligence revolution, the demand for servers to run complicated enable these enhanced processing and storage needs. As illustrated in Figure 3, three primary systems in server power applications can employ the use of 100V to 200V GaN: Power-supply units (PSUs). Changes from the Open Compute Project are increasing the popularity of 48V outputs; however, the required 80V and 100V silicon solutions have significantly higher losses (gate drive and overlap losses) compared to previous solutions. GaN solutions such as the LMG3100 can help minimize these losses in the synchronous rectifier on the secondary of the inductor-inductor-capacitor stage (LLC stage). Intermediate bus converters (IBCs). This system converts the intermediate voltage (48V) from the output of the PSU to a lower voltage, which then goes to the server. As the 48V voltage level becomes popular, IBCs help reduce I2R losses during distribution in server subsystems and enable both size and cost reductions of bus bars and power-carrying wires. The drawback of IBCs is that they add another step to power conversion which may dent efficiency. Therefore, it is important to leverage high-efficiency GaN devices such as the LMG2100 and LMG3100, in addition to several new topologies that OEMs are testing for the best combination of high efficiency and power density. Battery backup units. A buck-boost stage Uninterruptible power supplies use this stage because it avoids losses caused by DC-to-AC-to- DC conversion by performing just one DC-to-DC conversion directly from the battery. Application No. 3: Telecommunications power It is possible to make the power supply in a telecommunication radio a GaN design. Since the radio is typically set up outdoors with only natural cooling, high efficiency is important. Also, progressive generations of mobile networks (5G, 6G) call for higher networking speeds and data processing, thus requiring high-density designs with very low losses. The LMG2100 can help improve power density >40% for these types of designs. In a typical mid-voltage application, GaN converts power from a negative battery voltage level (typically –48V) to supply power for power amplifiers at +48V using inverting buck-boost or forward converter topologies, or to supply power for fieldprogrammable gate arrays and other DC loads using a buck converter topology. Application No. 4: Motor drives Yes, you can use GaN in motor-drive circuitry. The applications are diverse, and include robotics, power tool drives and two-wheeled traction inverter designs, with different load profiles. GaN’s zero reverse recovery (because there is no body diode) leads to no settling time for the current in reverse bias of the diode, which causes 7)5'$4*B0*34$94$*,%?4$*:-%(;*&).5$.<* %&'!()#*+! ,(-.#)+/!0'10'! ,2)+34+/5#)+!67(!8-29+3)+3!:,;'<! ! ! %!"#$% ! ! ! ! ! ! ! ! !!% ! ! 1) 0) ! ! 1) 0) ! ! ! ! ! ! ! 566! % ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! % ;#))+3=!6#8>7?!725)!:;;@<! ! *%&$1#-&$.'65'7-8'9-0:';#<.1$'.$/<,$' 7! 7! 89! 8:! &'!()*! (#++,-.! 8;! 8;! ' ' /01! /01! ! ! ! ! ! ! "#$!%&'()*! ! ! ! ! machine learning algorithms and enable the storage of larger and more complex data sets will increase exponentially. Highdensity designs with an efficiency requirement of each stage of >98% will typically converts the battery voltage (48V) to a bus voltage (48V). You can also use BBUs for battery power conversion when the mains line goes off and the power flow is bidirectional. lower dead-time losses and better efficiency. As a result of GaN’s higher switching frequencies, there is lower current ripple, which as I mentioned earlier enables a reduction in the size of passive
www.ti.com SEMICONDUCTOR MATERIALS 13 www.power-mag.com Issue 3 2024 Power Electronics Europe components, and can lead to sleeker motor-drive designs. Conclusion GaN has the potential to replace traditional silicon FETs in mid-voltage applications across the board. Other application areas for 100V to 200V GaN include generalpurpose DC/DC conversion, Class-D audio amplifiers, and battery test and formation equipment. GaN also offers higher switching frequencies and lower power losses, benefits that become more pronounced with integrated power stages that simplify power designs. A6#)! BC!D#.E!635/*+! "=! ">! %FG!C!H! !"#$%&'(&)*% "=! +,--%&'(&)*% ! ! ! ! ! "#$! %&'(()*+! ./**'(0%&'(&'% 12% "?! "! "@! "?! !"#$%&'#$()*+),'-).'/0)1&2(%$) 32"%/$)456)($728$) U(/7%$!Y!)$'(+*1!#-4!B&C!+&,!3(*!(,*-!2-*-%!)%(<$15! BIBA! JAK! 'L$! @LMN! O)D+3!'-44(I! Name: Company Name: Address: Post Code: Tel: Total Number of Copies @ £ p+p Total £ Drives S & S Hyd H/B Pne H/B Ind Mot Comp H/B H/B Air QUANTITY QUANTITY Hydraulics & Pneumatics There are now 6 of these handy reference books from the publishers of the Drives & Controls and Hydraulics & Pneumatics magazines. Published in an easily readable style and designed to help answer basic questions and everyday problems without the need to refer to weighty textbooks. We believe you’ll find them invaluable items to have within arms reach. From the publishers of QUANTITY QUANTITY QUANTITY 2-5 copies £4.30, 6-20 copies £4.10, 20+ copies £3.75. QUANTITY PRACTICAL ENGINEER’S HANDBOOKS HYDRAULICS INDUSTRIAL MOTORS SERVOS AND STEPPERS PNEUMATICS COMPRESSED AIR INDUSTRIAL ELECTRIC DRIVES PLEASE ALLOW UPTO 28 DAYS FOR DELIVERY $&! -!.5&!#452).' -%$)! ,4$ 4HE (IGH 3TREET 4ONBRIDGE +ENT 4. "% Postage and Packaging: 1-3 copies: £2.99 4-6 copies: £4.99 7 or more copies: £6.99 If you would like to obtain additional copies of the handbooks, please email info@dfamedia.co.uk or call us on 01732 370340. Alternatively you can return the completed form below to: Engineers Handbook, DFA MANUFACTURING MEDIA LTD, 192 The High Street, Tonbridge, Kent TN9 1BE #HEQUES SHOULD BE MADE PAYABLE TO $&! -ANUFACTURING -EDIA ,TD AND CROSSED ! # 0AYEE #OPIES OF THE HANDBOOKS ARE AVAILABLE AT a PER COPY $ISCOUNTS ARE AVAILABLE FOR MULTIPLE COPIES
14 ENERGY EFFICIENCY www.prbx.com Issue 3 2024 Power Electronics Europe www.power-mag.com Ecodesign, Reuse, Repair, Prolonging Lifetime and New Technology – Is it the new paradox? Patrick Le Fèvre, PRBX, Chief Marketing and Communication Officer The European Ecodesign is well known for energy related issues such as energy efficiency and standby energy consumption, and many detailed articles have been written on this topic. As one of the key elements of the European Green Deal strategy there is another, less wellknown aspect to Ecodesign that’s about reducing waste and granting consumers the ‘Right to Repair’ thus prolonging the lifetime of equipment. Clearly the time is right for ‘Right to Repair’ to be addressed, initially for consumer products that are the visible part of the iceberg, forming part of the much bigger problem of changing our way of working and dealing with the issue of prolonging the lifetime of equipment whilst developing a circular economy. Many business segments will be highly influenced by the new European Directives and will need to figure out new ways to deal with obsolescence. So how will the power supply industry embrace this change and how could it contribute to prolonging the lifetime of equipments and to reduce waste? New EU rules to make sustainable products the norm. As announced in the EU Circular Economy Action Plan, the Commission has proposed new rules to make almost all physical goods on the EU market more environmentally friendly, circular, and energy efficient throughout their whole lifecycle from the design phase through their daily use, repurposing, and end-of-life. As part of the Action Plan dated June 2023 the Environment Committee put forward a proposal to make products in the EU ready for those conditions by developing a strategy to prolong the lifetime of equipments and to protect consumers. An important part of this proposal is to set common rules promoting the repair of goods, advancing towards the objective of sustainable consumption under the European Green Deal (Figure 01). Developing a repair approach will reduce e-waste and reduce the environmental impact, resulting in significant savings for consumers and all of society. As part of that and similar to how it is for Ecodesign energy consumption labeling, France has proposed the use of a similar label bearing a reparability index to inform consumers about the possibility of repairing a product whilst consumers should have access to repair guidelines. As proposed in the scope of the project, on December 4 2023 the European Parliament and Council provisionally agreed an update to the ‘ecodesign’ rules, aiming to improve various aspects of products throughout their lifecycle to make them more durable, reliable, easier to reuse, upgrade, repair and recycle, use less resources and energy and water. The proposal covers consumer goods and concerns defects that may occur in them, whether or not still under legal guarantee. The producer will have an obligation to repair goods for five to ten years after they were purchased. Goods for which reparability requirements currently exist include household products such as washing machines, washer-dryers, dishwashers, refrigeration appliances, electronic displays, welding equipment, vacuum cleaners, and servers and data storage. Mobile phones, cordless phones and tablets are also listed in the recent draft, and EV chargers have been considered in the latest discussions. All of these products use power supplies and manufacturers need to keep future legislation and regulations in mind and monitor their evolution. Figure 01 Left - Green Deal policy framework around ESPR (green) and the ESPR’s relationship to the Ecodesign directive (blue). (Source:PRBX/Ecochain)
www.prbx.com ENERGY EFFICIENCY 15 www.power-mag.com Issue 3 2024 Power Electronics Europe Why the new Ecodesign rules will matter for the power industry. This introduction may appear to give the impression that it’s mostly the consumer segment that will be the subject of future legislation but in fact, inspired by the Ecodesign workgroup a lot of activities are taking place within industry to prolong lifetime and this is where it becomes an interesting area for the power supplies industry. Regarding consumer applications for power supplies, they are either built-in the equipment and part of the overall system, or external such as USB chargers, and the legislator is working on a classification of the level of reparability in making it environmentally and economically a good idea to repair instead of replace. This is part of the 2024 workgroup that is working in parallel with the industry to define reasonable classifications for the benefit of end users and the environment. Considering the high levels of integration and current building practices, e.g., the use of sealed plastic products such as external adapters, these may not be classified as repairable but the manufacturers might still have the obligation to guarantee support and service for ten years. Also, for embedded power supplies to listed equipments power supplies, manufacturers will be obliged to guarantee the availability of spare parts during the service period. At higher power levels, as for the energy consumption Ecodesign regulation, servers and data storage are already included in the proposition, and power supplies manufacturers are working in close cooperation with the European representatives to develop power solutions meeting the reparability needs, but also to guarantee longer life time in operation. When considering the circular economy, up to 80% of a product’s environmental impact can be determined at the design phase. When designing a power supply for a datacenter we always take into consideration energy efficiency, and power designers use the latest technologies such as Wide Bandgap Semiconductors in order to deliver the highest levels of performance. Regarding prolonging lifetime there is a lot of work going on to select components able to keep their original performance for more than ten years in operational conditions, but designers must also include reparability in the mechanical design, which could imply a modular concept easing maintenance, and when end of life arrives, recycling. For many designers it will be a new way of working but for those used to developing power solutions for refurbishing and system modernization it’s nothing really new and a lot of the best practices deployed in this industry are already meeting future Ecodesign regulations. Before Ecodesign regulation, Reuse, Repair and Prolong Lifetime was already the norm in the railway industry! Outside of what the Ecodesign is aiming for in consumer segments, many industrial applications require power supplies manufacturers to provide power solutions for refurbishing and systems modernization. Among many, the transport industry and especially the railway are the best examples to illustrate what might be applicable to other segments when it comes to Reuse, Repair and Prolonging Lifetime. One good example is the French railway state-owned operator, ‘Société National des Chemins de Fer (SNCF)’, which in September 2023 announced that as part of its commitment to sustainability, SNCF Voyageurs and its Rolling Stock Division are committed to optimizing the use and lifespan of their trains at every stage of their life cycle: mid-life and end-of-life refurbishment to extend their service life and combat obsolescence, and recycling and reuse of spare parts, etc. To achieve that goal, the SNCF has announced the commencement of a major refurbishing project to restore and upgrade 104 high speed trains, ‘Trains à Grande Vitesse (TGV)’ to “combat obsolescence” (Figure 02). Figure 02 –SNCF is renovating 104 TGVs with the aim of expanding the current fleet’s lifespan. (Source: PRBX/SNCF)
16 ENERGY EFFICIENCY www.prbx.com Issue 3 2024 Power Electronics Europe www.power-mag.com These 104 eligible trainsets have been assessed during the 4th quarter of 2023 and 1st quarter of 2024. A number of criteria will be taken into account when deciding the fate of each train set, including the condition of the structure of the train set, its metal components, the boiler, the bogies and the electrical installations including power supplies. Based on these criteria, the trainsets will be classified into three categories: 1. Those in perfect condition that will continue to be in service, but will undergo renovation to improve their comfort. 2. Those that require more extensive reliability and renovation work due to their advanced age. 3. Those that will be withdrawn from service due to obsolescence of parts (electronic components or state of the chassis). These written-off trainsets will be used as parts banks as they contain up to 3,000 potentially recoverable components that can be reused to repair other trainsets. illustrates within an industrial environment what Ecodesign Reuse, Repair and Prolong Lifetime is aiming for. Reusing parts to reduce waste and optimize resources has been part of the SNCF life cycle process for a long time as rather than buying new, checking and repairing 500,000 TGV spare parts every year represents a saving of half a billion euros a year. Designing power supplies for refurbishing – New technology paradox. The variety of power supplies required by railway companies when refurbishing trains is very wide and covers from low power modules to high power converters up to hundreds of kilowatts (Figure 03). In a train, many power supplies are embedded within sub-assemblies e.g., LED lighting with built-in power supplies and drivers, but a number of systems require standalone power solutions meeting the latest legislative requirements. In general, refurbishing contractors are using referenced part numbers approved by the train manufacturers, and about 80% of the need is available as Commercial off-the-shelf (COTS) from certified power supplies manufacturers, complying with railways standards. However, when refurbishing and modernizing trains that might have been manufactured decades ago, 20% of the power supplies will require extra features, higher power density, lower energy consumption and many more things, often with the need to fit into an existing box that’s specific to the application (Figure 04). When refurbishing or modernizing, the railway industry is following the same pattern as the others, and with the increased demand for higher power density and lower power consumption, power designers are now investigating the implementation of Wide Bandgap (WBG) switching semiconductors, Gallium Nitride (GaN) and Silicon Carbide (SiC). SiC diodes have been used in railway power supplies for decades, but power switching transistors are relatively new in railway applications. Considering that the lifetime of railway equipment could be greater than 20 years, reliability and supply chain sustainability are a must, and implementing a new technology requires a thorough technical evaluation and the need to ensure that the supply chain is able to guarantee product support for more than 20 years. In the process of validating a new technology for highly demanding railway Figure 03 Left – Power supplies required by railway companies when refurbishing trains is very large and going from low power modules to high power converters up to hundreds of kilowatts. (Source : PRBX/Shutterstock/E CO LENS) Figure 04 Left – PRBX 110VDC, 10kW NickelCadmium battery charger for refurbishing when replacing Lead-Acid batteries in railway applications. (Source: PRBX)
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