Salvatore Tomarchio

XXI Brain Storming Day

Unict – Catania

29 Ottobre 2010

Salvatore Tomarchio

Ph.D. student - XXV ciclo

Tutor Prof. Angelo Raciti

UNIVERSITA’ DI CATANIA

DIEES – Department of Electrical Electronic and

Systems Engineering

Salvatore Tomarchio

Subjects of Research

Power Switching Converters (Low and

Medium Power).

a. LED Lamps or Solid State Lighting (SSL)

b. Power Converters for Power Module IGBTs and

Short Circuit Failure Mode (SCFM)

Salvatore Tomarchio

The Research Activity is part of a European project, CSSL Project

(Consumerizing Solid State Lighting).

27 Partners, such us:

(Philips – lighting, Research; TNO; M2i; Boschman BV; Wittenburg;

STMicroelectronics; Università di Catania - DIEES; Archimede; Cambridge

University, Nat. Centre of Microelectronics, Leitat, Czech Technical University

and other… ).

LED Lamps or SSL (Solid State Lighting)

LED Lamps (SSL)

Salvatore Tomarchio

The workpackages and their objective are:

WP 1 – Specification and Architecture

WP 2 – LED Device

WP 3 – Electronics and Control

WP 4 – Reliability, Thermal and Safety

WP 5 – Prototype and Verification

WP 6 – Project and Management, Dissemination and

Exploration

Work Plane

Salvatore Tomarchio

WP 3 – Electronics and Control

WP3 will design, develop, validate and prototype a new generation

of integrated electronic driver for LED lighting including the

dimming control. It will focus on features that can be classified

into three levels: Low End (Basic features, very low cost), Mid End

(general purpose features) and High End (Advanced features). For

instance, features such as tuneable white colour, failure

diagnosis and detection, Power factor control, switch and

dimming control through wired or wireless protocols, etc.

WP 5 – Prototype and Verification

The objectives of WP5 are : integrate development and innovation

achievements and deliver physical demonstrators on both

component and system level; evaluate retrofit prototypes,

comparable retrofit products and the integrated system through

field assessments; promoting and developing market for the SSL

retrofit products by working with utility partners.

Work Plane

Salvatore Tomarchio

I. Study of the bright greatness and transmission of the heat.

II. Comparison between the more important LED Lamp manufactures.

III. Study and Analysis of the high light LED technology devices.

IV. Analysis of the Power Converter Architectures for Module LEDs driving.

V. Realization by a LED Lamp prototype.

VI. Thermal characterization in order to understanding the temperature limit of the

prototype.

VII. Electrical Characterization, Evaluation of the electrical stress in short circuit

condition, over voltage and voltage decrease, LED failure, and other.

Solid State Lighting – Outline

Salvatore Tomarchio

I. Study of the bright greatness and transmission of the heat.

II. Comparison between the more important LED Lamp manufactures.

III. Study and Analysis of the high light LED technology devices.

IV. Analysis of the Power Converter Architectures for Module LEDs driving.

V. Realization by a LED Lamp prototype.

VI. Thermal characterization in order to understanding the temperature limit of the

prototype.

VII. Electrical Characterization, Evaluation of the electrical stress in short circuit

condition, over voltage and voltage decrease, LED failure, and other.

Solid State Lighting – Outline

Salvatore Tomarchio

Light Feature Value

System flux 806 lm

System efficacy 67 lm/W

CCT 2700

CRI >85

Dimmable 10%-100%

Lifetime >25000 h

Maximum input power < 12 W

Operating temperature -20°C to 45°C

Electrical Feature Value

Input Voltage 230V +/- 10% AC 50 Hz

Dimming compatibility Leading and trailing edge

Dimming levels 10% - 100%

Low level startLamp start at lowest

dimmer setting

FlickeringNo flicker for

recommended dimmer list

Driver efficiency > 85%

Starting

light on within 0.5 s. At

nominal power: 30% flux

after 0.1s, 70% after 1.0s

under nominal operation

Output power 11 W

Early failures < 1% failures after 1000h

Light and Electrical System

Feature

Salvatore Tomarchio

The dimmer is a device that to allows reduce the power consumption by the load (LEDs) and it

can be controlled in remote. Furthermore, it’s causes harmonic distortion due to cut the

shape of the grid waveform and alike increases in frequency components.

Dimmer Compatibility

Digital Dimming:

When the device is supplied from a dimmer, the LED

current is decreased by a PWM. The duty cycle of the

PWM is set according to the AC mains RMS value.

Bleeder Circuit.

It allow the device to operate on low AC RMS input

Voltage, because this circuit pull the minimum current

that keep ON TRIAC in the dimmer

Salvatore Tomarchio

Feature

Requirements

1. High Efficiency

2. Low Cost

3. Low Output

4. Voltage

5. PFC > 0.7

Architecture Topology

Characteristics Power

Converter

1. Not isolated Power

Converter

2. Buck Converter

3. Active PFC

Salvatore Tomarchio

Options:

1. Power MOSFET N-Channel

2. Power MOSFET P- Channel

Experimental Analysis on Switch

Driving in Buck Converter

Power Switches

Vo

utD

C

COMPARISON

First. Topology: Second Topology:

Shift level (N – Ch) Current Mirror (P-Ch)

BleederPower Switches

Bleeder

Salvatore Tomarchio

VinAC

[V]VinDC

[V]D

[%]PON

[W]POFF

[W]PCOND

[W]PTOT

[W]Pload

[W]PIN

[W]η

[%]

15 21,2 94,3 28·10-3 5,8 ·10-3 0,292 0,326 4,1 5,9 69

150 212 9,4 0,389 0,148 0,110 0,656 7,27 10,6 68

220 311 6,3 1,280 0,400 59·10-3 1,739 7,27 10,8 67

Losses in Power MOSFET

and Global Efficiency

Power Switches

Vo

utD

C

Salvatore Tomarchio

VinAC

[V]VinDC

[V]D

[%]PON

[W]POFF

[W]PCOND

[W]PTOT

[W]IG

[A]ID

[A]

220 311,13 6,5 0,275 1,15 98·10-3 1,52 19 ·10-3 380·10-3

Power Loss on Current Mirror:

Plosses ~500 mW

Losses in Power MOSFET

and Global Efficiency

Power Switches

Salvatore Tomarchio

University of Catania , DIEES – ARIEL, Catania, Italy

ABB Corporate Research, Västerås, Sweden

Salvatore Tomarchio

Tutor:

Prof. Angelo Raciti

Ing. Filippo Chimento

Internship in ABB AB Corporate Research, Västerås (SW),

from. 1-09-2010 to. 28-02-2011

INTERNSHIP

Salvatore Tomarchio

Vlinea

400 V – 4 kV

+

-

High Power System > 1 MW

IGCT

Vblocco ~ 4.5 kV

IN ~ 1 kA

Operating Field of Research

IGBT

Salvatore Tomarchio

GDU

• Turn ON

Process

• Turn OFF

Process

• Monitoring

functions

• Protective

functions

Power Supply

DC-DC Converter

Logic Control

FPGA

Protection

Circuits

GDU

(Gate Drive Unit)

Interfaces

I/O

Operating Field of Research

Salvatore Tomarchio

Outline

1. Auxiliary Supply System in failure condition

2. Power Supply for IGBT and IGCT Gate Driving

(Scaling components System from 5 W to 100 W)

3. SCFM (Short Circuit Failure Mode) operation of

Power Module IGBTs

Typical HVDC-FACTS Topology

1.

2.

3.

Salvatore Tomarchio

1. Auxiliary Supply System in failure condition

a. Optical Power Supply

b. Systems fed by external circuits

Power Converters for Power

Module IGBTs

Salvatore Tomarchio

1. Auxiliary Supply System in failure condition

a. Optical Power Supply

Power Converters for Power

Module IGBTs

Primary

DC/DC

Secondary

DC/DC

Logic

DC/DC

DetectorOptical input

power

supervision

Logic

Driver

15 V

1.2 – 1.8 V

3-5 V

Salvatore Tomarchio

1. Auxiliary Supply System in failure condition

b. Systems fed by external circuits

Power Converters for Power

Module IGBTs

G.U.

G.U.

G.U.

Salvatore Tomarchio

Power Converters for Power

Module IGBTs

1. Auxiliary Supply System in failure condition

b. Systems fed by external circuits

G.U.

G.U.

G.U.

G.U.

Salvatore Tomarchio

2. Power Supply for IGBT and IGCT Gate Driving

(Scaling components System from 5 W to 100 W)

The GDU needs a external power supply

that gets energy by the external circuit

Power Converters for Power

Module IGBTs

Vline

400 V – 4 kV

Salvatore Tomarchio

Power Converters for Power

Module IGBTs

In order to obtain 300 V in output of the DC-DC 1, the

Buck Converter has been used as DC-DC Power

Converter topology.

Topics Discussed

1. The devices size choice

(Active and Passive)

a. MOSFET 3X 1500V/8A

b. Diode 4 X 1200V/5A

c. Inductor L = 53 mH

d. Capacitor C = ....

2.Voltage Sharing in Series

Connection Devices3.Series Connection Devices

Driving

Passive

solution

for

voltage

sharing

balance

Salvatore Tomarchio

3. SCFM of Power Module IGBTs

Short Circuit Failure

Mode (SCFM)

1. In HVDC application, to prevent shut down of the system due

to the defect arising in a IGBT Module, redundant modules are

included in the system, such that the surviving modules share

the voltage and the failed module is still able to carry the load

current .

3. When the chip fails, it dissipates, for a very short duration, a

sufficiently high energy to melt the platelet and forms a stable

alloy with silicon. Metals like silver and aluminum are preferred

as they form low melting eutectic alloys with silicon.

2. This “short circuit failure mode” has an important

consequence on the Module design. A single failed chip and its

contact system must conduct the whole load current. To reduce

the resistance of the failure path through the chip, a metal

platelet is used in contact with the silicon chip.

Salvatore Tomarchio

Publications

1. Convertitori di potenza nel campo del lighting: soluzioni innovative per

l’applicazione alle lampade a catodo freddo, F. Chimento, S. Musumeci, A.

Raciti, S. Tomarchio, R. Scollo, Proceedings of Congresso Nazionale AEIT,

AEIT'06, Capri (Italy), September, 16th-20th 2006.

2. Optimized Design of Power Semiconductor Devices for DC-AC Royer Converter

Topology in Case of CCFL Lighting Applications, F. Chimento, S. Musumeci, A.

Raciti, S. Tomarchio, R. Scollo, Proceedings of the 12th International Power

Electronics and Motion Control Conference, EPE-PEMC 2006, August 30th -

September 1st, 2006, Portoroz, Slovenia.

3. Dispositivi di potenza innovativi in convertitori DC-DC per la produzione di

energia da campi fotovoltaici, A. Raciti, S. Musumeci, S. Tomarchio, R. Scollo, S.

Buonomo, L. Abbatelli, AEIT 2009, Sostenibilità energetica: Tecnologie e

Infrastrutture - La ricerca incontra l'industria, Catania (Italy), September, 27th-

29th 2009.

Submitted:

1) Paper for publication on EPE Journal, “Experimental Investigation of a

Monolithic Cascode device in a Forward Converter for Industrial Application”.

2) “A High Input Voltage Power Supply for Gate Driving Application Based on Series

Connection of Power Switches”

3) “Parasitic Evaluation in IGBT Module with Physics Based and Behavioural

Model”

4) “Influence of the Temperature on the Parameters of Punch Through IGBTs in

Parallel Connection”

Salvatore Tomarchio

End