ENT
GEM
ANA
M
S A M D AV I S
POWER
SUPPLIES
SYSTEMS
APPLICATIONS
COMPONENTS
SEMICONDUCTORS
ID
VGS
VD
-3.0
-2.0
-1.0
0.0
1.0
2.0
3.0
MANAGEMENT
0V
-1V
-1.5V
-2V
-2.5V
-3.3V
BY SAM DAVIS
VIN 100.0
Linear VGS
Regulators HSFET 80.0
Driver 5V
Control 60.0 4V
Anti-Cross- SW 3V
BP6
20.0
Conduction
RT 2V
Oscillator Pre-Bias LSFET 40.0 1V
SYNC/RESET_B ID 00.0 0V
Ramp
PWM
S Q GND
OC Event -20.0
RESET_VOUT + Current
R Q Average IOUT Sense, -40.0
COMP
OC
Error Amplifier Detection CLK -60.0
FB Fault
+ VREF for -80.0
Soft-Start and OC Threshold DATA
Reference VOUT_COMMAND -100.0
DAC -3.0 -2.0 -1.0 0.0 1.0 2.0 3.0
SMBALERT
PMBus Engine VD
VSET Courtesy of Efficient Power Conversion
ADC, PMBus Commands, CNTL
VOUT Sense
IC Interface, EEPROM
OV/UV Detection
ADDR0
CHAPTER 12:
WIRELESS POWER
TRANSFER
Y
ou can employ wireless power transfer at to the load, wirelessly. Wireless power transfer is usually
different power levels. At the low power level, controlled by two ICs: one transmits and another receives
wireless power transfer is intended for smart- the transferred power, as shown in Fig. 12-1.
phones and other portable battery-powered
systems. Higher-power wireless transfer is How do the receiver and transmitter ICs provide the
used to recharge the battery in an electric wireless transfer?
vehicle. First, we will describe the lower power technolo- The power-transfer receiver IC provides efficient ac/dc
gy in an FAQ format. Next, we will describe work done at power conversion as required to comply with WPC 1.1 com-
the Oak Ridge National Laboratory for wireless charging munication protocol. Control algorithms provide an effective
batteries in an electric vehicle. and safe Li-Ion and Li-Pol battery chargereliminating the
need for a separate battery charger circuit.
Is there a wireless power transfer standard for portable By utilizing near-field inductive power transfer, a sec-
phones? ondary coil embedded in the portable device can pick up
Wireless power transfer is based on the Wireless Power the power transmitted by the primary coil. The ac signal
Consortiums WPC 1.1 Standard (July 2012) that facilitates from the secondary coil is then rectified and conditioned
cross-compatibility of compliant transmitters and receivers. to apply power directly to the battery. Global feedback is
The Standard defines the physical parameters and the established from the secondary to the primary in order to
communication protocol used in wireless power transfer. stabilize the power transfer process. This feedback utilizes
The Wireless Power Consortiums global standard for the WPC 1.1 power communication protocol.
compatible wireless charging is called Qi (pronounced What determines the power transfer?
chee). The Qi standard guarantees that any device car- Power transfer depends on coil coupling, which
rying the Qi logo will work with any charging surface that depends on the distance between coils, alignment,
carries the Qi logo, regardless of manufactur-
er or brand. Qi allows design freedom, prod- Transmitter Receiver
uct differentiation, and guaranteed wireless Power
charging interoperability.
Power Voltage
AC-DC Rectification Load
Stage Conditioning
How does wireless power technology
work? Communication
Wireless power transfer relies on mag-
BQ500410A
netic induction between planar receiver and Feedback Controller
transmitter coils. Positioning the receiver coil bq51k
over the transmitter coil causes magnetic
coupling when the transmitter coil is driven. 12-1. Qi-compliant wireless power transfer receivers and transmitter
Flux couples into the secondary coil, which circuits. The bq500410a is a Texas Instruments transmitter IC.
induces a voltage and current flows. The Companion receiver ICs include the bq51050B, bq51051B, bq51011,
secondary voltage is rectified and transferred bq5013, bq51013A, and bq51013B.
B
High Frequency Inverter
Load conditions; i.e., state-of-charge of the battery and
coupling coefficient; i.e., vehicle coil to primary pad gap
and any misalignment between transmit and receive coils
r R 4U d0
determine the # %
frequency $
response of the WPT system. The
U (t) ' sin &d %costo! the (2)
t " secondary
&
&
amount of power transferred
1
( 2) % coil is gov-
erned by the switching frequency, duty cycle, and the input
voltage of the inverter. This relationship can be expressed
as:
(2)
a
y'
Id1l Where:
Ud0 = HF power inverter rail voltage
x d = pulse duty ratio
= angular frequency
Although the primary coil voltage can be controlled by
12-6. Vector field analysis diagram (analytical the active front-end converter to vary the dc rail voltage
construction) for coupling coil design. Ud0, the ultimate objective is to dynamically change the
switching frequency and the duty cycle in order to achieve
current total harmonic distortions (THDI) of <5%. In addi- the best operating conditions in terms of efficiency and
tion, because the AFER regulates the primary side DC link power transfer. In the ORNL laboratory setting, the HF pow-
voltage, the battery current ripple is reduced to <10 A. er inverter voltage was adjusted using a power supply. In a
commercialized version of this WPT technology, a dedicat-
Coupling Coil Design ed short-range communication (DSRC) link as shown in Fig.
Electromagnetic design of WPT coupling coils provides 12-4 would be needed. The transmitter side of the DSRC
the most fundamental investigation into their performance. collects the measurement data such as battery voltage,
At ORNL, the WPT team developed couplers based on the battery current, and battery management system (BMS)
magnetic vector potential at a field point due to current messages needed for regulation. The grid-side receiver
flowing in an ideal primary coil conductor. The potential at side of the DSRC channel receives this information for
this field point is defined to lie at the location of the second- control purposes along with supporting primary side mea-
ary coil. For a coil pair of radius a, assuming infinitesimal surements. Then, a DSP-based embedded control system
conductor radius, and having a coil to coil spacing z, then determines the switching frequency and the appropriate
the radius vector from the primary coil origin to the field duty cycle according to the control law being used. The
point becomes switching signals for the inverter IGBTs are generated by
the DSP control algorithm and applied to the HF power in-
r= a 2 + z2 verter gate drives. The control system can also regulate the
inverter power based on the reference power commands
(Fig. 12-6). The corresponding vector potential, A, for the that can be received through the V2I communications from
case of N1 primary turns and I1 A yield a primary excitation a smart grid compliant utility.
of N1I1 amp-turns. Portions of this article were prepared by the Oak Ridge
At the field point P, the magnetic vector potential is National Laboratory, operated by the UT-Battelle for the
strongly dependenton primary
2 coil radius,
0 Ntotal
2 current, U.S. Department of Energy under contract DE-AC05-
0 N1I1a1 1I1a1
B(r, ) =
r cos +
the co-elevation angle , and inverse with the square sin of the(1) 00OR22725. Accordingly, the U.S. Government retains a
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CHAPTER 13:
ENERGY
HARVESTING
E
nergy harvesting is the process by which mechanical work, however they provide small amounts of
ambient energy is captured and converted power to support low-energy electronics. In most cases,
into electricity for small autonomous devices, the fuel for energy harvesters is naturally present and
such as satellites, laptops and nodes in sensor may be considered free. Using natural sources in remote
networks without the need for battery power. areas for energy harvesting is an attractive alternative to
Energy harvesting applications reach from inconvenient utility and battery power. These natural energy
vehicles to the smart grid. sources may be available maintenance-free for a lifetime.
With electronic circuits now capable of operating at Energy harvesting can also be an alternative energy source
microwatt levels, it is feasible to power them from non-tra- that supplements the primary power source and enhances
ditional sources. This has led to energy harvesting, which its reliability.
provides the power to charge, supplement or replace Energy harvesters are intended for applications requir-
batteries in systems where battery use is inconvenient, im- ing very low average power, but require periodic pulses of
practical, expensive or dangerous. It can also eliminate the higher load current. For example, in many wireless sensor
need for wires to carry power or to transmit data. Energy applications the circuitry is only powered to make measure-
harvesting can power smart wireless sensor networks to ments and transmit data periodically at a low duty cycle.
monitor and optimize complex industrial processes, remote Energy harvesting is becoming more feasible today
field installations and building HVAC. In addition, otherwise because of the increased efficiency of devices capable
wasted energy from industrial processes, solar panels, or of capturing, storing, and producing electrical energy.
internal combustion engines, can be harvested for useful This can be accomplished with the help of very efficient,
purposes. A key component in energy harvesting is a pow- very low-voltage input step-up converters. Also, improved
er converter that can operate with ultralow voltage inputs. low-voltage, high-efficiency microprocessors may allow
Now that we have described why it is feasible and what them to become participants in energy harvesting systems.
it can do, how does energy harvesting ac- 1nF
tually work? Put simply, it is a process that: 1:100
C1 VSTORE
5V
+ +
Captures minute amounts of energy + 0.1F
THERMOELECTRIC LTC3108 6.3V
Accumulates that energy 220F 330pF
GENERATOR
Stores the energy C2 V OUT2
PGOOD
Maintains the stored energy as a power PGD P
20mV TO 500mV 2.2V
SW VLDO
source
Typical energy harvesting inputs include: 2.2F SENSORS
Energy Harvesting IC itors value will be dictated by the load current, duration of
Linear Technologys LTC3108, a highly integrated dc-dc the load pulse, and the voltage droop the circuit can toler-
converter is intended for energy harvesting. It can harvest ate. The capacitor must be rated for whatever voltage has
and manage surplus energy from extremely low-input been selected for VOUT by VS1 and VS2 (Table 13-1).
voltage sources such as TEG (thermoelectric generators),
thermopiles. and small solar cells. TABLE 13-1. SETTINGS FOR OUTPUT VOLTAGE
The circuit in Fig. 13-1 uses a small step-up transformer VS2 VS1 VOUT
to boost the input voltage to an LTC3108 that provides a GND GND 2.35
complete power-management solution for wireless sens- GND VAUX 3.3
ing and data acquisition. It can harvest small temperature VAUX GND 4.1
differences and generate system power instead of using
VAUX VAUX 5
traditional battery power. The LTC3108 is available in a
small, thermally enhanced12-lead (4mm 3mm) DFN and There must be enough energy available from the input
a 16-lead SSOP packages. voltage source for VOUT to recharge the capacitor during
The LTC3108 utilizes a MOSFET switch to form a reso- the interval between load pulses. Reducing the duty cycle
nant step-up oscillator using an external step-up transform- of the load pulse allows operation with less input energy.
er and a small coupling capacitor. This allows it to boost The VSTORE capacitor may be a very large value (thou-
input voltages as low as 20mV, high enough to provide mul- sands of microfarads or even Farads) to provide holdup
tiple regulated output voltages for powering other circuits. at times when the input power may be lost. Note that this
The frequency of oscillation is determined by the induc- capacitor can charge all the way to 5.25V (regardless of the
tance of the transformer secondary winding and is typically settings for VOUT), so ensure that the holdup capacitor has
in the range of 20kHz to 200kHz. For input voltages as low a working voltage rating of at least 5.5V at the temperature
as 20mV, a primary-secondary turns ratio of about 1:100 is for which it will be used. Fig. 13-2 plots the time for voltage
recommended. For higher input voltages, this ratio can be to build up to its final value for a given input voltage and the
lower. input transformer turns ratio. The LTC3108s extremely low
The ac voltage produced on the secondary winding quiescent current (<6A) and high-efficiency design ensure
of the transformer is boosted and rectified using an exter- the fastest possible charge times for the output reservoir
nal-charge pump capacitor (from the secondary winding capacitor.
to pin C1) and the rectifiers internal to the LTC3108. The As listed in Table 13-1 above, the main output is pin-se-
rectifier circuit feeds current into the VAUX pin, providing lectable via VS1 and VS2 for one of four fixed voltages
charge to the external VAUX capacitor and the other out- (2.35V, 3.3V, 4.1V, or 5V) to power a wireless transmitter
puts. or sensors. A second switched output can be enabled by
the host to power devices that do not have a micropower
LDO Output shutdown capability. The addition of a storage capacitor
A 2.2V LDO can support a low-power processor or other provides continuous power even when the input energy
low-power ICs. The LDO is powered by source is unavailable.
the higher value of either VAUX or VOUT. A power-good comparator monitors
This enables it to become active as soon VOUT. The PGD pin is an open-drain out-
as VAUX has charged to 2.3V, while the put with a weak pull-up (1M) to the LDO
VOUT storage capacitor is still charging. voltage. Once VOUT charges to within 7%
In the event of a step load on the LDO of its regulated voltage, the PGOOD out-
output, current can come from the main put goes high. If VOUT drops more than
VOUT capacitor if VAUX drops below 9% from its regulated voltage, PGD goes
VOUT. The LDO requires a 1F ceramic low. The PGD output is designed to drive
capacitor for stability. Larger capacitor a microprocessor or other chip I/O and
values can be used without limitation, but is not intended to drive a higher current
will increase the time it takes for all the load such as an LED. Pulling PGOOD up
outputs to charge up. The LDO output is externally to a voltage greater than VLDO
current limited to 4mA typical. will cause a small current to be sourced
For pulsed-load applications, size the 13-2. Plot of time for voltage to into VLDO. PGOOD can be pulled low
VOUT capacitor to provide the necessary build up to its final value using the in a wire-OR configuration with other
current for a pulse on load. The capac- LTC3108. circuitry.
300
PZ1 PZ2 lower threshold approximately
IR05H4OCSPTR 300mV above the selected reg-
VIN PGOOD PGOOD ulated output voltage to prevent
1F short cycling during buck pow-
+ 5V TO 16V 6V
LTC3588-1 10H
VOUT er-up. When the input capacitor
SOLAR PANEL 100F CAP SW 2.5V
9V 25V VIN2 VOUT voltage is depleted below the
BATTERY
+ 3F
D0 UVLO falling threshold, the buck
4.7F 2.7V
6V D1 GND
10F converter is disabled. Extremely
6V NESS SUPER CAPACITOR
ESHSR-0003CO-002R7 low quiescent current (450nA
35881 F11 typical) in UVLO allows energy to
accumulate on the input capacitor
13-3. The LTC3588-1 employs a high efficiency buck converter to harvest solar in situations where energy must
energy and then convert it to a well-regulated output. be harvested from low power
sources.
VOUT2 is an output that can be turned on and off by the You can configure the LTC3588-1 for use with dc sourc-
host, using the VOUT2_EN pin. When enabled, VOUT2 is con- es such as a solar panel as shown in Fig. 13-3 by con-
nected to VOUT through a 1.3 P-channel MOSFET switch. necting them to one of the PZ1/PZ2 inputs. Connecting the
This output, controlled by a host processor, can be used source in this way prevents reverse current from flowing in
to power external circuits such as sensors and amplifiers, each element. Current limiting resistors should be used to
that do not have a low power sleep or shutdown capability. protect the PZ1 or PZ2 pins. This can be combined with a
VOUT2 can be used to power these circuits only when they battery backup connected to VIN with a blocking diode.
are needed. Analog Devices ADP5091/92 is an intelligent integrated
energy harvesting nano-powered management solution that
Piezoelectric Energy Harvesting converts dc power from PV cells or thermoelectric gener-
Linear Technologys LTC3588-1 is an ultralow quiescent ators (Fig. 13-4).The IC charges storage elements such as
current power supply for energy harvesting and/or low rechargeable Li-Ion batteries, thin film batteries, super ca-
current step-down applications (Fig. 13-3). The IC inter- pacitors, or conventional capacitors, and powers up small
faces directly to a piezoelectric or alternative ac power electronic devices and battery-free systems.
source, to rectify a voltage waveform and store harvested The ADP5091/92 provides efficient conversion of the
energy on an external capacitor, bleed off any
excess power via an internal shunt regulator, and VID LLD To MCU
maintain a regulated output voltage by means of 100k 2.5V
REG_OUT
a nanopower high-efficiency synchronous buck 1F
REG_D0 REG_FB
regulator. Thermo electric From MCU
REG_D1 PGOOD
The LTC3588-1 has an internal full-wave generator 4.7F
SYS
bridge rectifier accessible via the differential PZ1 22H
SW
and PZ2 inputs that rectifies ac inputs such as VIN ADP5091
BAT PAS5409HR
those from a piezoelectric element. The rectified 4.7F 0.03F
output is stored on a capacitor at the VIN pin and MPPT 3.3V 12 Ah
can be used as an energy reservoir for the buck 10nF
250k CBP REF
converter. The low-loss bridge rectifier has a total
drop of about 400mV with typical piezo gener- SETSD
ated currents (~10A). The bridge is capable of BACK_UP SETPG
CR2032
carrying up to 50mA. One side of the bridge can 3V DIS_SW
SETHYST
be operated as a single-ended DC input. PZ1 225mAh MNOP
SETBK
1M
and PZ2 should never be shorted together when TERM
the bridge is in use. AGND PGND
When the voltage on VIN rises above the
UVLO rising threshold the buck converter is
enabled and charge is transferred from the input 13-4. The ADP5091/92 provides efficient conversion of the harvested
capacitor to the output capacitor. A wide (~1V) limited power from a 16 W to 600 mW range with sub-W operation
UVLO hysteresis window is employed with a losses.
harvested limited power from a 16 W to 600 mW range The ADP5091/92 is available in a 24-lead LFCSP and is
with sub-W operation losses. With the internal cold-start rated for a 40C to +125C junction temperature range.
circuit, the regulator can start operating at an input volt-
age as low as 380 mV. After a cold startup, the regulator is
functional at an input voltage range of 80 mV to 3.3 V. You Related Articles
can program an additional 150mA regulated output with an 1. Sam Davis, Energy Harvesting on the Move, powerelectronics.
external resistor divider or VID pin. com, March 2015.
By sensing the input voltage, the control loop keeps the 2. Sam Davis, Researchers Observe Piezoelectricity and the
input voltage ripple in a fixed range to maintain stable dc- Piezotronic Effect in Atomically Thin Molybdenum Disulfide
to-dc boost conversion. The OCV dynamic sensing mode (MoS2), powerelectronics.com, November 2014.
and none-sensing mode both programming regulation 3. Sam Davis, Energy Harvesting Poised to Replace Pacemaker
points of the input voltage allow extraction of the highest Batteries, powerelectronics.com, September 2014.
possible energy from the harvester. A programmable mini- 4. Sam Davis, Thermogalvanic Process Converts Low Temp Waste
mum operation threshold (MINOP) enables boost shutdown Heat Into Electricity, powerelectronics.com, June 2014.
during a low light condition. As a low light indicator for 5. Frank Schmidt, Power Leap for Energy Harvesting,
microprocessor, the LLD is the MIONP comparator output. powerelectronics.com, May 2014.
In addition, the DIS_SW pin can temporarily shut down the 6. Sam Davis, SolePower: Generate Power When You Walk,
boost regulator and is RF transmission friendly. powerelectronics.com, June 2013.
The charging control function of ADP5091/92 protects 7. Sam Davis, Waste Heat-to-Power Update, powerelectronics.com,
rechargeable energy storage, which is achieved by mon- June 2013.
itoring the battery voltage with programmable charging 8. Roger Allan, Energy Harvesting Powers Wireless Sensor
termination voltage and shutdown discharging voltage. In Networks In Industrial Apps , electronicdesign.com, September
addition, a programmable PGOOD flag with programmable 2012.
hysteresis monitors the SYS voltage. 9. Roger Allan, Energy Harvesting Efforts Are Picking Up Steam,
An optional primary cell battery can be connected and powerelectronics.com, April 2012.
managed by an integrated power path management con- 10. Sam Davis, Effective Energy-Harvesting Requires Appropriate
trol block that is programmable to switch the power source Components, powerelectronics.com, August, 2011.
from the energy harvester, rechargeable battery, and prima-
ry cell battery. BACK TO TABLE OF CONTENTS
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CHAPTER 14:
CIRCUIT PROTECTION
DEVICES
S
everal types of devices are employed in successfully limiting a very large surge from an event like a
electronic systems to protect against voltage lightning strike, where the energy involved is many orders
transients, power surges, and excessive of magnitude greater than the varistor can handle. Fol-
voltage or current. Varistors is one of those low-through current resulting from a strike may melt, burn,
devices that protect against excessive or even vaporize the varistor. This thermal runaway leads to
transient voltages by shunting the current the failure of dominant current paths under thermal stress
created by the excessive voltage away from sensitive when the energy in a transient pulse exceeds the manufac-
components. tures Absolute Maximum Ratings. You can reduce the
A varistors resistance varies with the applied voltage. It probability of catastrophic failure by increasing the rating,
has a nonlinear, non-ohmic currentvoltage characteristic either by using a single varistor of higher rating or by con-
similar to a diode, except that it has the same characteris- necting more devices in parallel.
tic for both directions of traversing current. At low voltage
it has a high electrical resistance that decreases as the MOV
voltage is raised. The most common type of varistor is the The most common type of varistor is the metal-ox-
metal-oxide varistor (MOV). It is electrically equivalent to a ide varistor (MOV) that contains a ceramic mass of zinc
network of back-to-back diode pairs, each pair in parallel oxide grains, in a matrix of other metal oxides sandwiched
with many other pairs. between two electrodes). The boundary between each
When a small or moderate voltage is applied across grain and its neighbor forms a diode-like junction, which
an MOVs electrodes, only a tiny cur-
rent flows, caused by reverse leakage Fixed Resistor 14-1. Voltage vs.
through the diode junctions. When Forward Linear I-V Curve current for a typical
1mA
Current
a large voltage is applied, the diode MOV.
6 Varistor
junction breaks down due to a combina- II
5 I-V Curve
tion of thermionic emission and electron
Symbol 4
tunneling, and a large current flows.
3
The result of this behavior is a highly Forward Varistor
nonlinear current-voltage characteristic, 2 Voltage
Region
in which the MOV has a high resistance 1mA
at low voltages and a low resistance at -V +V (volts)
Reverse 50 100 150 200 250 300 Forward
high voltages. Voltage Reverse Voltage
A varistor remains non-conductive Region Breakdown
Voltage
as a shunt-mode device during normal
operation when the voltage across it re-
mains well below its clamping voltage, III IV
thus varistors are typically used for
suppressing line voltage surges. Reverse Current
-I
Varistors will eventually fail from not
zero potential, making it more difficult to suppress the arc in the device datasheet
the melting elements gap. Fuses are insensitive to voltage Ktemp = the temperature derating factor determined from
changes within their ratings so selecting the proper voltage the derating factor (Fig. 14-2)
rating is strictly a safety issue. Fuses can operate at any The lowest suitable fuse rating is obtained by rounding
voltage below or equal to their rated voltage. up the calculated value to the next higher current rating
Current rating is determined by the maximum input cur- shown in the fuse datasheet.
rent of a device. Typically, the maximum current consump- Melting integral, termed melting I2t, is the thermal energy
tion occurs at the maximum output load and the minimum required to melt a specific fuse element. The fuse element
input voltage. Although some devices are designed for construction, materials and cross sectional area determine
constant current output regulation, most are designed as this value.
constant power devices. This means that as the input volt- Peak inrush current is usually greater than the steady
age drops, the input current must increase to uphold the state current. Also, periodic inrush currents can be suffi-
constant output power. The magnitude of the input current ciently powerful to warm the fuse element. Though not large
can be determined from: enough to melt the element, it can still cause thermal stress
to the element. Cyclical expansions and contractions of the
fuse element can lead to mechanical fatigue and premature
Pout _ max
I input _ max = failure.
Vin _ min E Calculate the melting I2t values of the fuse for the con-
(1) dition where the product of the peak current squared and
Where: the time when the peak occurs is maximum. For example,
Pout_max = Maximum output power of the dc-dc convert- the steady state current is maximum at low line so a tran-
er I input _ max sient load surge needs to be added to the low line current
Vin_min =I rated = input voltage on the input pins of the
Minimum to establish the maximum peak current for an operating
dc-dc converter K temp condition. But the inrush current is usually maximum at
E = Efficiency of the device at Pout_max and Vin_min the highest input voltage. The fuses melting I2t must be
To prevent damage to device components, select a evaluated at the condition with the highest calculated I2t
fuse current rating with a large enough current capability to ensure that the fuse will not open during these normal
so that the fuse will not open under steady state conditions, operating conditions.
yet will open during an abnormal (excessive) overload or Select a fuse with the minimum I2t greater than the ener-
short-circuit condition. Therefore, select a fuse to be 150% gy of the inrush current pulse. This ensures that the fuse will
to 200% percent of the maximum steady state input current not cause a nuisance opening during transient conditions.
at maximum load and minimum line input voltage. For reliable system operation for the required number of
Interrupting rating is the maximum current at rated volt- turn-on cycles, meet the following condition:
age the fuse can safely interrupt. This rating must exceed I2t Fuse I2t Pulse FP (3)
the maximum fault (short-circuit) current the circuit can Where:
produce. Interrupting ratings for ac and DC currents are dif- I2t Pulse = Energy of a current pulse
ferent and the fuse data sheet should be consulted before I2t Fuse = Melting integral of a fuse
selection. FP = Pulse factor (dependent on fuse element construc-
Temperature derating is the ambient temperature ex- tion)
ceeding the standard 23C. The fuse current rating should I2t Fuse can be found in fuse datasheets. Do not use
be derated (a higher current rating with higher tempera- the fuses maximum melting integral in Equation 3, and use
Pout _ maxat an ambient temperature
tures). Conversely, operating either the minimum or nominal melting integral of the fuse.
lowerIthan
input _the = standard
max23C allows use of a lower current Other selection considerations include start-up (inrush)
rating.
Vin _ min E currents and transient load conditions. When a device is ini-
Fuse rating is determined by: tially powered, the input bulk capacitors must be charged.
For example, current flowing into the input terminals of a
dc-dc converter is approximately I = V/R for typical power
I input _ max
I rated = supplies with charge times less than 10 mS. When V is
K temp the input voltage change, and R is a combination of wiring
(2) resistance, your sources resistance under start-up, and the
Where: Equivalent Series Resistance (ESR) of the converters input
I input_max = the current determined from Equation 1 or bulk capacitors.
Larger devices often use a large 14-4. FLAT GDT has a flat package
capacitor with very low ESR inside the and horizontal circuitry design that
converter. This inrush current can have meets the need for more sensitive
a significant effect on the fuses life. overvoltage protection requirements
Size the fuse properly to allow these in high-density and space-restricted
inrush current pulses to pass without applications.
nuisance openings or degrading the
fuse element as discussed in melting
integral.
To calculate current pulse energy,
first determine the magnitude and tion, the Clamp3321ZA extends the battery life of end-user
duration of the current pulse. The most accurate way to applications by providing low reverse leakage current of
determine parameters of a current pulse is to measure this <1nA (typical).
current in the application under minimum and maximum These TVS diodes protect sensitive electronics from
voltage conditions. damage or latch-up due to ESD. They replace 0201 size
multilayer varistors (MLVs) in portable applications such
TVS as cell phones, notebook computers, and other portable
A transient voltage suppressor (TVS) reacts to sudden electronics. They feature large cross-sectional area junc-
or momentary overvoltage conditions. One such common tions for conducting high transient currents. This device
device used for this purpose is known as the transient offers desir-able characteristics for board level protection
voltage suppression diode that is simply a Zener diode including fast response time, low operating and clamping
designed to protect electronics device against overvoltage. voltage, and no device degradation.
The characteristic of a TVS requires that it respond to It features extremely good ESD protection charac-
overvoltages faster than other common overvoltage protec- teristics highlighted by low typical dynamic resistance of
tion components such as varistors or gas discharge tubes. 0.33 , low peak ESD clamping voltage, and high ESD
This makes TVS devices or components useful for protec- withstand voltage (15kV contact per IEC 61000-4-2). Low
tion against very fast and often damaging voltage spikes. maximum capacitance (5pF at VR=0V) minimizes loading
These fast overvoltage spikes are present on all distribution on sensitive circuits. Each device will protect one data line
networks and can be caused by either internal or external operating at 3.3 V.
events, such as lightning or motor arcing. Clamp3321ZA is in a 2-pin SLP0603P2X3F package.
Applications of transient voltage suppression diodes are It measures 0.6 0.3 mm with a nominal height of only
used for unidirectional or bidirectional electrostatic dis- 0.25mm. Leads are finished with NiAu. The small package
charge protection of transmission or data lines in electronic provides flexibility to protect single lines in applications
circuits. The level of energy in a transient overvoltage can where arrays are not practical. The combination of small
be equated to energy measured in joules or related to elec- size and high ESD surge capability makes them ideal for
tric current when devices are rated for various applications. use in portable applications such as cellular phones, digital
These bursts of overvoltage can be measured with special- cameras, and tablet PCs. Fig. 14-3 shows clamping voltage
ized electronic meters that can show power disturbances vs. peak pulse current (tp = 8/20S).
of thousands of volts amplitude that last for a few microsec-
onds or less. Among its features:
Semtechs Clamp 3321ZA is a high-performance tran- Transient protection for high-speed signal lines: IEC
sient voltage suppression (TVS) for protecting low voltage 61000-4-2 (ESD) 17kV (air), 15kV (contact)
interfaces (Fig. 14-3). The single-line Clamp3321ZA offers 3.3V working-voltage protection for low-voltage interfaces
a unique combination of features that protect increasingly Low ESD clamping voltage of 10.5V at 8kV
sensitive interfaces. Ultra-small package size: 0.6mm 0.3mm with nominal
The Clamp3321ZA delivers optimal transient protection height of only 0.25mm
for safeguarding devices operating at 3.3V. It features low Low typical dynamic resistance: 0.33 W
dynamic resistance, which provides fast response to tran- Pb Free and RoHS/WEEE compliant
sients, as well as low-clamping voltage to protect devices
from damage. It is housed in an ultra-small, fully encapsu- GDT
lated package, which provides a more robust solution than A new gas discharge tube (GDT) from Bourns provides
conventional CSP (Chip Scale Package) solutions. In addi- a breakthrough flat package design with a volume and
May 2012.
5. Sam Davis, Surge Stopper IC Protects
Loads From >500V Power Supply Input,
powerelectronics.com, March 2012.
6. Deepak Divan, Filling the Gaps in Surge
Protection, powerelectronics.com, May
2006.
Arc Voltage 7. Bruno van Beneden, Varistors:
Ideal Solution to Surge Protection,
Time powerelectronics.com, May 2003.
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CHAPTER 15:
PHOTOVOLTAIC
SYSTEMS
A
photovoltaic cell converts light energy increasingly popular. These cells offer less efficiency than
directly into electricity by the photovoltaic ef- their mono-silicon (mono) counterparts, but they are
fect, which is a physical and chemical phe- grown in large vats that reduce cost. By the mid-2000s,
nomenon. It is defined as a device whose poly was dominant in the low-cost panel market, but more
electrical characteristics, such as current, recently the mono returned to widespread use.
voltage, or resistance, vary when exposed Manufacturers of wafer-based cells responded to high
to light. Solar cells are the building blocks of photovoltaic silicon prices in 2004-08 with rapid reductions in silicon
modules, known as solar panels. consumption. Current cells use 8-9 grams (0.28-0.32 oz) of
Multiple solar cells in an integrated group, all oriented silicon per watt of power generation, with wafer thicknesses
in one plane, constitute a solar photovoltaic panel or solar in the neighborhood of 200 microns.
photovoltaic module. Photovoltaic modules often have a The overall efficiency is the product of these individual
sheet of glass on the sun-facing side, allowing light to pass metrics, which are:
while protecting the semiconductor wafers. Solar cells are Charge carrier separation efficiency
usually connected in series in modules, creating an addi- Reflectance efficiency
tive voltage. Connecting cells in parallel yields a higher cur- Thermodynamic efficiency
rent; however, problems such as shadow effects can shut Conductive efficiency
down the weaker (less illuminated) parallel string (a number A solar cell has a voltage-dependent efficiency curve,
of series-connected cells) causing substantial power loss temperature coefficients, and allowable shadow angles.
and possible damage because of the reverse bias applied Due to the difficulty in measuring these parameters
to the shadowed cells by their illuminated partners. Strings directly, other parameters are substituted:
of series cells are usually handled independently and Thermodynamic efficiency
not connected in parallel, though (as of 2014) individual Quantum efficiency
power boxes are often supplied for each module, and are Integrated quantum efficiency
connected in parallel. Although modules can be intercon- VOC ratio
nected to create an array with the desired peak dc voltage Fill factor
and loading current capacity, using independent MPPTs Reflectance losses are a portion of quantum efficiency
(maximum power point trackers) is preferable. Otherwise, under external quantum efficiency. Recombination losses
shunt diodes can reduce shadowing power loss in arrays make up another portion of quantum efficiency, VOC ratio,
with series/parallel connected cells. and fill factor. Resistive losses are predominantly catego-
Adjusting for inflation, it cost $96 per watt for a solar rized under fill factor, but also make up minor portions of
module in the mid-1970s. Process improvements and a quantum efficiency, VOC ratio, OC is open circuit.
very large boost in production have brought that figure The Fill Factor is the ratio of the actual maximum obtain-
down 99%, to 68 cents per watt in 2016, according to data able power to the product of the open circuit voltage and
from Bloomberg New Energy Finance. Swansons Law is an short circuit current. This is a key parameter in evaluating
observation similar to Moores Law that states that solar cell performance. In 2009, typical commercial solar cells had a
prices fall 20% for every doubling of industry capacity. Fill Factor > 0.70. Grade B cells were usually between 0.4
During the 1990s, polysilicon (poly) cells became to 0.7. Cells with a high Fill Factor have a low equivalent
series resistance and a high equivalent shunt resistance, substituted for wafer cells cut from monocrystalline sili-
so less of the current produced by the cell is dissipated in con ingots. Solar cells made with this technique can have
internal losses. efficiencies approaching those of wafer-cut cells, but at
Single pn junction crystalline silicon devices are now appreciably lower cost.
approaching the theoretical limiting power efficiency of Polycrystalline silicon, or multi-crystalline silicon (multi-
33.7%, noted as the ShockleyQueisser limit in 1961. In the Si) cells are made from cast square ingotslarge blocks of
extreme, with an infinite number of layers, the correspond- molten silicon carefully cooled and solidified. They consist
ing limit is 86% using concentrated sunlight. of small crystals giving the material its typical metal flake
For triple-junction thin-film solar cells, the world record is effect. Polysilicon cells are the most common type used in
13.6%, set in June 2015. photovoltaics and are less expensive, but also less effi-
Solar cells can be classified into first-, second-, and cient, than those made from monocrystalline silicon.
third-generation cells. Ribbon silicon is a type of polycrystalline siliconit is
First-generation cellsalso called conventional, tradition- formed by drawing flat thin films from molten silicon and
al, or wafer-based cellsare made of crystalline silicon, results in a polycrystalline structure. These cells are cheap-
the commercially predominant PV technology that in- er to make than multi-Si, due to a great reduction in silicon
cludes materials such as polysilicon and monocrystalline waste, as this approach does not require sawing from
silicon. ingots. However, they are also less efficient.
Second-generation cells are thin-film solar cells that Thin-film solar-cell technologies reduce the amount of
include amorphous silicon, CdTe, and CIGS cells and are active material in a cell. Most designs sandwich active
commercially significant in utility-scale photovoltaic power material between two panes of glass. Since silicon solar
stations, building integrated photovoltaics or in small panels only use one pane of glass, thin film panels are
stand-alone power system. approximately twice as heavy as crystalline silicon panels,
Third-generation solar cells include a number of thin-film although they have a smaller ecological impact (deter-
technologies often described as emerging photovol- mined from life-cycle analysis). The majority of film panels
taicsmost of them have not yet been commercially have 2-3 percentage points lower conversion efficiencies
applied and are still in the research or development than crystalline silicon. Cadmium telluride (CdTe), copper
phase. Many use organic materials, often organometallic indium gallium selenide (CIGS), and amorphous silicon
compounds as well as inorganic substances. Despite the (a-Si) are three thin-film technologies often used for outdoor
fact that their efficiencies had been low and the stability applications. Thin-film solar cells are increasing due to it
of the absorber material was often too short for commer- being silent, renewable, and solar energy being the most
cial applications, there is a lot of research invested into abundant energy source on Earth.
these technologies as they promise to achieve the goal of Cadmium telluride is the only thin-film material so far to
producing low-cost, high-efficiency solar cells. rival crystalline silicon in cost/watt. However, cadmium is
By far, the most prevalent bulk material for solar cells is highly toxic and tellurium (anion: telluride) supplies are
crystalline silicon (c-Si), also known as solar grade silicon. limited. The cadmium present in the cells would be toxic
Bulk silicon is separated into multiple categories according if released. However, release is impossible during normal
to crystallinity and crystal size in the resulting ingot, ribbon, operation of the cells and is unlikely during res in residen-
or wafer. These cells are entirely based around the concept tial roofs. A square meter of CdTe contains approximately
of a p-n junction. Solar cells made of c-Si are made from the same amount of Cd as a single C cell nickel-cadmium
wafers between 160 to 240 micrometers thick. battery, in a more stable and less soluble form.
Monocrystalline silicon (mono-Si) solar cells are more Copper indium gallium selenide (CIGS) is a direct band
efficient and more expensive than most other types of gap material. It has the highest efficiency (~20%) among
cells. The corners of the cells look clipped, like an octagon, all commercially significant thin film materials. Traditional
because the wafer material is cut from cylindrical ingots methods of fabrication involve vacuum processes includ-
that are typically grown by the Czochralski process. Solar ing co-evaporation and sputtering. Recent developments
panels using mono-Si cells display a distinctive pattern of attempt to lower the cost by using non-vacuum solution
small white diamonds. processes.
Epitaxial wafers can be grown on a monocrystalline Silicon thin-film cells are mainly deposited by chemical
silicon seed wafer by atmospheric-pressure CVD in a vapor deposition (typically plasma-enhanced, PE-CVD)
high-throughput inline process, and then detached as from silane gas and hydrogen gas. Depending on the
self-supporting wafers of some standard thickness (e.g., deposition parameters, this can yield amorphous silicon (a-
250 m) that can be manipulated by hand, and directly Si or a-Si:H), protocrystalline silicon, or nanocrystalline sili-
con (nc-Si or nc-Si:H), also called microcrystalline silicon. cal circuit. A special electrical property of the PV cellwhat
Amorphous silicon is the most well-developed thin is called a built-in electric fieldprovides the force, or
film technology to-date. An amorphous silicon (a-Si) solar voltage, needed to drive the current through an external
cell is made of non-crystalline or microcrystalline silicon. load, such as a light bulb.
Amorphous silicon has a higher bandgap (1.7 eV) than
crystalline silicon (c-Si) (1.1 eV), which means it absorbs Solar Modules
the visible part of the solar spectrum more strongly than The heart of a photovoltaic system is the solar module.
the higher-power density infrared portion of the spectrum. Many photovoltaic cells are wired together by the manufac-
The production of a-Si thin-film solar cells uses glass as a turer to produce a solar module. When installed at a site,
substrate and deposits a very thin layer of silicon by plas- solar modules are wired together in series to form strings.
ma-enhanced chemical vapor deposition (PECVD). Strings of modules are connected in parallel to form an
Protocrystalline silicon with a low-volume fraction of array.
nanocrystalline silicon is optimal for high open-circuit volt- Module TypesRigid flat-framed modules are currently
age. Nc-Si has about the same bandgap as c-Si and nc-Si most common and most of these are composed of silicon.
and a-Si can advantageously be combined in thin layers, Silicon cells have atomic structures that are single-crystal-
creating a layered cell called a tandem cell. The top cell in line (mono-crystalline), poly-crystalline (multi-crystalline),
a-Si absorbs the visible light and leaves the infrared part of or amorphous (thin film silicon). Other cell materials used
the spectrum for the bottom cell in nc-Si. in solar modules are cadmium telluride (CdTe, commonly
Gallium arsenide (GaAs) is also used for single-crys- pronounced CadTel) and copper indium diselenide (CIS).
talline thin film solar cells. Although GaAs cells are very Some modules are manufactured using combinations of
expensive, they hold the worlds record in efficiency for a these materials. An example is a thin film of amorphous sili-
single-junction solar cell at 28.8%. GaAs is more commonly con deposited onto a substrate of single-crystalline silicon.
used in multi-junction photovoltaic cells for concentrated In 2005, approximately 90% of modules sold in the
photovoltaics (CPV, HCPV) and for solar panels on space- United States were composed of crystalline silicon, either
crafts, as the industry favors efficiency over cost for space- single-crystalline or poly-crystalline. The market share of
based solar power. crystalline silicon is down from previous years, however,
PV cells come in many sizes and shapes, from smaller and continues to drop as sales of amorphous silicon, CdTe
than a postage stamp to several inches across. They are and CIS modules are growing.
often connected together to form PV modules that may be Rated PowerGrid-connected residential PV systems
up to several feet long and a few feet wide. use modules with rated power output ranging from 100 to
Modules, in turn, can be combined and connected to 300 watts. Modules as small as 10 watts are used for other
form PV arrays of different sizes and power output. The applications. Rated power is the maximum power the
modules of the array make up the major part of a PV sys- panel can produce with 1,000 watts of sunlight per square
tem, which can also include electrical connections, mount- meter at a module temperature of 25C or 77F in still air.
ing hardware, power-conditioning equipment, and batteries Actual conditions will rarely match rated conditions and so
that store solar energy for use when the sun is not shining. actual power output will almost always be less.
PV Arrays are made up of PV modules, which are PV System VoltageModern systems without batter-
environmentally sealed collections of PV Cells. The most ies are typically wired to provide from 235V to 600V. In
common PV module is 5 to 25 square feet in size and battery-based systems, the trend is also toward use of
weighing about 3 to 4 lb/sq. ft. Often sets of four or more higher array voltages, although many charge controllers
smaller modules are framed or attached together by struts still require lower voltages of 12V, 24V, or 48V to match the
in what is called a panel. This panel is typically around 19 voltage of the battery string.
to 35 square feet in area for ease of handling on a roof. This Using Manufacturers Product Information to Compare
allows some assembly and wiring functions to be done on ModulesSince module costs and efficiencies continue
the ground if called for by the installation instructions. to change as technology and manufacturing methods
When light shines on a PV cell, it may be reflected, ab- improve, it is difficult to provide general recommenda-
sorbed, or pass right through. But only the absorbed light tions that will be true into the future regarding, for exam-
generates electricity. The energy of the absorbed light is ple, which type of module is cheapest or the best overall
transferred to electrons in the atoms of the PV cell semicon- choice. It is best to make comparisons based on current
ductor material. With their newfound energy, these elec- information provided by manufacturers, combined with the
trons escape from their normal positions in the atoms and specific requirements of your application.
become part of the electrical flow, or current, in an electri- Two figures that are useful in comparing modules are:
PV WATTS
improvements in size, weight, and cost
3 60
reductions, they require further advances
PV AMPS
0.01F
0.01F
0.01F
0.1F
0.1F
0.1F
optimum power by
10F
10F
10F
VDD_EXT ADSP-CM41xF VDD_ANA0 performing maximum
VDD_ANA1 power-point tracking for
VREG CIRCUIT
0.1F
Inverter manufacturer datasheets generally include the and ac sides of the inverter, ground-fault protection, and
following information: overcurrent protection for the solar modules. Most systems
Rated output power in watts or kilowatts: some inverters include a combiner board of some kind since most mod-
may provide an output rating for different output voltages. ules require fusing for each module source circuit. Some
Output voltage(s): indicates to which utility voltages the inverters include this fusing and combining function within
inverter can connect and may also produce three phase the inverter enclosure.
power.
Peak efficiency: represents the highest efficiency that the Related Articles
inverter can achieve. 1. Sam Davis, World Energy Resources, powerelectronics.com,
CEC weighted efficiency: this efficiency is published by January 2016.
the California Energy Commission on its GoSolar website. 2. Sam Davis, Solar System Efficiency: Maximum Power Point
This is an average efficiency and is a better representa- Tracking Is Key, powerelectronics.com, December 2015.
tion of the inverters operating profile. 3. Sam Davis, IBM Research Solar Camera Watches for and
Maximum input current: maximum dc the inverter can use. Predicts Solar Energy, powerelectronics.com, November 2015.
Maximum output current: The maximum continuous ac 4. Sam Davis, CWRU Researchers Efficiently Charge a Lithium-Ion
that the inverter will supply. Battery with Solar Cell, powerelectronics.com, October 2015.
Peak power tracking voltage: dc voltage range in which 5. Spencer Chin, Solar Fuel a Step Closer To Reality,
the inverters maximum point power tracker will operate. powerelectronics.com, March 2015.
Start voltage: indicates the minimum dc voltage that is 6. Spencer Chin, Solar Energy System Generates Electricity On
required in order for the inverter to turn on and begin Demand, powerelectronics.com, January 2015.
operation. 7. Sam Davis, Revolutionary Solar-friendly Form of Silicon Shines,
IPxx rating: the Ingress Protection rating or IP Code clas- powerelectronics.com, December 2014.
sifies and rates the level of protection provided against 8. Arpita Agarwal, Direct Duty Cycle Control for MPPT Digital
the ingress of solid foreign objects (first digit) or water Implementation, powerelectronics.com, August 2014.
(second digit), a higher digit means greater protection. 9. Richard J. Bravo, Solar Inverters Can Improve Power Quality,
In the United States, the NEMA enclosure type is used powerelectronics.com, April 2014.
similarly to the international rating. 10. Guerra, Alberto, Inverter/Modules Aid Energy, Appliance, PV
Balance of system equipment (BOS) includes mounting and Motor Sectors, powerelectronics.com, April 2011.
systems and wiring systems used to integrate the solar
modules into the structural and electrical systems of the BACK TO TABLE OF CONTENTS
home. The wiring systems include disconnects for the dc
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CHAPTER 16:
WIND POWER
W
ind power, as an alternative to burn- land, and offshore farms have less visual impact, but con-
ing fossil fuels, is plentiful, renewable, struction and maintenance costs are considerably higher.
widely distributed, clean, produces Small onshore wind farms can feed some energy into the
no greenhouse gas emissions during grid or provide electricity to isolated off-grid locations.
operation, and uses little land. The Wind turbines (Fig. 16-2) operate on a simple principle.
net effects on the environment are The energy in the wind turns two or three propeller-like
far less problematic than those of nonrenewable power blades around a rotor. The rotor is connected to the main
sources. shaft, which spins a generator to create electricity. The
Wind power is very consistent from year to year, but has wind turns the blades, which spin a shaft, which connects
significant variation over shorter time scales. It is therefore to a generator and makes electricity.
used in conjunction with other electric power sources to A typical electrical circuit for a wind-turbine installation
give a reliable supply. As the proportion of wind power in includes generator, storage batteries, and charge con-
a region increases, a need to upgrade the grid, and a low- troller. The ac output normally goes to a local transformer
ered ability to supplant conventional production can occur. station (that collects all the turbines outputs), it is then
Wind farms consist of many individual wind turbines transformed to a higher voltage and transmitted via a cable
connected to the electric power transmission network (Fig. or overhead line to an infeed point (another transformer
16-1). Onshore wind is an inexpensive source of electricity, station), where the connection to the normal power grid is
competitive with or in many places cheaper than coal or made. When being connected to the grid, this voltage must
gas plants. Offshore wind is steadier and stronger than on be synchronized with the utility grid.
Power-management techniques
such as having excess capacity, geo-
graphically distributed turbines, dis-
patchable backing sources, sufficient
hydroelectric power, exporting and
importing power to neighboring areas,
using vehicle-to-grid strategies or re-
ducing demand when wind production
is low, can in many cases overcome
these problems. In addition, weather
forecasting permits the electricity net-
work to be readied for the predictable
variations in production that occur.
In a wind farm, individual turbines
are interconnected with a medium volt-
age (often 34.5 kV), power-collection
16-2. Typical wind turbine. system, and communications network.
At a substation, this medium-voltage
Wind is actually a form of solar energy and is a result of electric current is increased in voltage with a transformer
the uneven heating of the atmosphere by the sun, the irreg- for connection to the high-voltage electric power transmis-
ularities of the earths surface, and the rotation of the earth. sion system.
Wind flow patterns and speeds vary greatly across the One of the biggest current challenges to wind-pow-
United States and are modified by bodies of water, vegeta- er-grid integration in the United States is the necessity of
tion, and differences in terrain. Humans use this wind flow, developing new transmission lines to carry power from
or motion energy, for many purposes: sailing, flying a kite, wind farms, usually in remote, lowly populated states in the
and even generating electricity. middle of the country due to availability of wind, to high-
Horizontal-axis wind turbines typically either have two or load locations, usually on the coasts where population
three blades. These three-bladed wind turbines are operat- density is higher. The current transmission lines in remote
ed upwind, with the blades facing into the wind. locations were not designed for the transport of large
Utility-scale turbines range in size from 100 kilowatts to amounts of energy. As transmission lines become longer,
as large as several megawatts. Larger wind turbines are the losses associated with power transmission increase,
more cost-effective and are grouped together into wind as modes of losses at lower lengths are exacerbated and
farms, which provide bulk power to the electrical grid. In new modes of losses are no longer negligible as the length
recent years, there has been an increase in large offshore is increased, making it harder to transport large loads over
wind installations in order to harness the huge potential that large distances.
wind energy offers off the coasts of the U.S. However, resistance from state and local governments
Single small turbines, below 100 kilowatts, are used makes it difficult to construct new transmission lines.
for homes, telecommunications dishes, or water pumping. Multi-state power-transmission projects are discouraged
Small turbines are sometimes used in connection with die- by states with cheap electricity rates for fear that export-
sel generators, batteries, and photovoltaic systems. These ing their cheap power will lead to increased rates. A 2005
systems are called hybrid wind systems and are typically energy law gave the Energy Department authority to
used in remote, off-grid locations, where a connection to approve transmission projects states refused to act on, but
the utility grid is not available. after an attempt to use this authority, the Senate declared
Today, most turbines use variable speed generators the department was being overly aggressive in doing so.
combined with partial- or full-scale power converter be- Another problem is that wind companies find out after the
tween the turbine generator and the collector system, fact that the transmission capacity of a new farm is below
which generally have more desirable properties for grid the generation capacity, largely because federal utility rules
interconnection and have low-voltage ride-through capabili- to encourage renewable energy installation allow feeder
ties. Modern concepts use either doubly fed machines with lines to meet only minimum standards. These are important
partial-scale converters or squirrel-cage induction gener- issues that need to be solved, as when the transmission ca-
ators or synchronous generators (both permanently and pacity does not meet the generation capacity, wind farms
electrically excited) with full-scale converters. are forced to produce below their full potential or stop run-
cheaper and achieve a higher capacity factor but would to incorporating large amounts of wind power into a grid
produce less electricity (and thus less profit) in high winds. system. Intermittency and the non-dispatchable nature
Conversely, a large generator would cost more but gener- of wind energy production can raise costs for regulation,
ate little extra power and, depending on the type, may stall incremental operating reserve, and (at high penetration lev-
out at low wind speed. Thus an optimum capacity factor of els) could require an increase in the already existing energy
around 40% to 50% would be aimed for. demand management, load shedding, storage solutions or
system interconnection with HVDC cables.
Penetration Wind power is variable, and during low wind periods it
Wind energy penetration refers to the fraction of ener- must be replaced by other power sources. Transmission
gy produced by wind compared with the total generation. networks presently cope with outages of other generation
There is no generally accepted maximum level of wind plants and daily changes in electrical demand, but the vari-
penetration. The limit for a particular grid will depend on the ability of intermittent power sources such as wind power,
existing generating plants, pricing mechanisms, capacity are unlike those of conventional power generation plants,
for energy storage, demand management, and other fac- which, when scheduled to be operating, may be able to
tors. An interconnected electricity grid will already include deliver their nameplate capacity around 95% of the time.
reserve generating and transmission capacity to allow for Presently, grid systems with large wind penetration re-
equipment failures. This reserve capacity can also serve quire a small increase in the frequency of usage of natural
to compensate for the varying power generation produced gas spinning reserve power plants to prevent a loss of
by wind stations. Studies have indicated that 20% of the electricity in the event that conditions are not favorable for
total annual electrical energy consumption may be incor- power production from the wind. At lower wind-power-grid
porated with minimal difficulty. These studies have been for penetration, this is less of an issue. Conversely, on par-
locations with geographically dispersed wind farms, some ticularly windy days, even with penetration levels of 16%,
degree of dispatchable energy or hydropower with stor- wind-power generation can surpass all other electricity
age capacity, demand management, and interconnected sources in a country.
to a large grid area enabling the export of electricity when The combination of diversifying variable renewables by
needed. Beyond the 20% level, there are few technical type and location, forecasting their variation, and integrat-
limits, but the economic implications become more signifi- ing them with dispatchable renewables, flexible fueled gen-
cant. Electrical utilities continue to study the effects of large erators, and demand response can create a power system
scale penetration of wind generation on system stability that has the potential to meet power supply needs reliably.
and economics. Integrating ever-higher levels of renewables is being suc-
A wind energy penetration figure can be specified for cessfully demonstrated in the real world.
different durations of time, but is often quoted annually.
To obtain 100% from wind annually requires substantial High-Altitude Wind Power
long-term storage or substantial interconnection to other Considering all costs, airborne wind energy could be
systems which may already have substantial storage. On a the worlds cheapest energy source. (Possible exceptions
monthly, weekly, daily, or hourly basisor lesswind might are limited hydro sources and limited situations where
supply as much as or more than 100% of current use, with surface-based wind turbines may be the most economic for
the rest stored or exported. Seasonal industry might then supplying relatively local needs.)
take advantage of high wind and low usage times such as High-energy winds are at altitudes high above us, not
at night when wind output can exceed normal demand. just at a few hundred feet where they can be tapped by
Such industry might include production of silicon, alumi- tower-based turbine rotors. Airborne Wind Energy technolo-
num, steel, or of natural gas, and hydrogen, and using gies will employ tethered wind energy capture devices that
future long term storage to facilitate 100% energy from fly to these altitudes where wind power is much greater
variable renewable energy. than it is at ground level.
There are several groups developing Airborne Wind
Variability Energy (AWE) technologies intended for use up to 2,000
Electricity generated from wind power can be high- ft. above ground level (AGL) and others intended for use
ly variable at several different timescales: hourly, daily, at altitudes greater than 2,000 ft. AGL. Some technologies
or seasonally. Annual variation also exists, but is not as might be able to bridge this segmentation, but not always
significant. Because instantaneous electrical generation in the exact incarnations for above and below that altitude.
and consumption must remain in balance to maintain grid The 2,000 ft. was chosen because that is the altitude above
stability, this variability can present substantial challenges which the FAA is not currently interested in approving what
it considers to be obstructions. AWE technologies can be 4. Sam Davis, Efficiency, Reliability Issues Dictate Wind Farm
flown higher outside the 12 nautical mile limit off the coast Performance and Profit, powerelectronics.com, November 2014.
into international airspace, but still in the U.S. economic 5. Sam Davis, Hybrid Solar-Wind Energy Technology Produces 435
zone. to 1250 Megawatt-Hours/Hour, powerelectronics.com, June 2014.
Still to be demonstrated is an efficient approach for 6. Davis, Sam, The Skys the Limit for Airborne Wind Energy Power
transmitting power from a high-altitude wind source to the Conversion, powerelectronics.com, August 2011.
ground where it can be used. The voltage across the 7. Paul Schimel, Wind Turbine of the Future, electronicdesign.com,
connecting cable would be too high using conventional September 2013.
methods. 8. Sam Davis, Technology Solutions Key to Achieving Offshore
Wind Power Benefits, powerelectronics.com, April 2011.
Related Articles 9. Lou Pechi, Answers to Energy Crisis Are Blowin in the Wind,
1. Sam Davis, World Energy Resources, powerelectronics.com, powerelectronics.com, September 2007.
January 2016. 10. PET, Wind Will Power Component Development Too,
2. Sam Davis, A Wind Turbine Without Blades, powerelectronics. powerelectronics.com, July 2006.
com, June 2015.
3. Sam Davis, American Wind Energy Association Touts Wind BACK TO TABLE OF CONTENTS
Energy Advantages, powerelectronics.com, March 2015.
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CHAPTER 17:
ENERGY
STORAGE
T
he book Solar Energy Storage by Brent reduces the cost of electricity by 40% to 50% over diesel
Sorensen notes that electricity generated generation alone.
from intermittent sources requires efficient
advanced electricity storage systems (ESSs). Flow-Battery Energy-Storage System
Electrical energy storage refers to the process ViZn Energy Systems Inc. (ViZn) has bolstered its
of converting electrical energy from a power proprietary flow-battery technology to enhance the capabil-
network into a form that can be stored and then converted ities, reliability, and lifetime of all next-generation flow-bat-
to electrical energy when needed. Such a process enables tery systems for multi-megawatt energy storage applica-
electricity to be produced at times of either low demand or tions. Designated Vanguard II, the battery stack further
low generation cost, or from intermittent renewable energy expands the operating range of ViZns systems by enhanc-
sources, and to be used at times of high demand, high ing the fast switching and high power cycling capabilities
generation cost, or when no other generation means is required for many applications, further maximizing ROI and
available. providing industry-leading payback periods.
Sorensen notes that energy storage is crucial for in- The Vanguard II battery stack has demonstrated 20%
creasing the share of energy from renewable energy source greater capacity and is immune to cycle-life degradation,
(RES) generators. This especially applies to energy from providing more headroom to handle spikes in power re-
the sun and wind, which is characterized by intermittence. quirements for demanding and unpredictable applications
However, the problem with some of the present energy stor- on both sides of the meter. All ViZn flow batteries incorpo-
age technologies is that they can be stored for a relatively rate the new Vanguard II stack control technology, which
small amount of energy, and in that sense a relatively short eliminates life-limiting issues such as dendrite growth, sim-
period of time to balance intermittent energy from RES gen- plifies cell balancing, and removes thermal and electrolyte
erators (i.e., hourly, daily up to a
maximum weekly value). 17-1. Simplified Charging
Energy storage materially flow-battery system
improves the stability and pre- employed by ViZn.
dictability of renewable energy. Pumps on the right
It allows higher penetration and left bottom
of renewables for distributed keep the zinc-iron
(commercial and industrial), electrolyte flowing.
micro-grid, and utility-scale appli-
Catholyte Anolyte
cations where higher electricity
prices, unstable grids, and lower
regulatory hurdles provide a
needed storage environment.
Combining batteries with re-
Ion-
newable energy can reduce Selective
diesel consumption by 75% and Membrane
5. Sam Davis, Flow-Battery Energy-Storage System Expands Utility Grid, powerelectronics.com, August 2014.
Capabilities, powerelectronics.com, January 2016. 9. Spencer Chin, Solar Energy System Generates Electricity On
6. Sam Davis, NASA Selects Proposals for Advanced Energy Demand, powerelectronics.com, January 2015.
Storage Systems, powerelectronics.com, August 2014. 10. Sam Davis, Revolutionary Solar-friendly Form of Silicon Shines,
7. Sam Davis, Enhanced Sodium-Beta Batteries Boost powerelectronics.com, December 2014.
Performance, Cut Cost for Large-Scale Energy Storage,
powerelectronics.com, August 2014. BACK TO TABLE OF CONTENTS
8. Sam Davis, Unique Battery Stores Wind or Solar Power for the
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CHAPTER 18:
ELECTRONIC
LIGHTING
E
lectronic lighting using LEDs is one of todays the capacitors cost while selecting a capacitor with a long
most rapidly evolving technologies. The major lifespan.
reason for this growth is the development of Heating is an important design issue for LEDs and other
white LEDs whose efficiency keeps increas- lighting devices. An incandescent bulb gives off 90% of its
ing. By 2020, the U.S. Department of Energy energy as heat, and a compact fluorescent bulb wastes
(DoE) estimates that commercial LED lighting 80% as heat. LEDs dont heat as much as other light sourc-
efficiency will be as high as 258 lumens es, but it is an issue that has required
per watt, or two and a half times as various heat-control techniques whose
efficient as todays fluorescent lamps, cost doesnt have a major impact on
resulting in 90% energy savings. By overall cost.
then, the DoE predicts the cost of LEDs
will fall by 80% and global penetration White LEDs
will be 60%. AlGaInP is one of the two types of
With an average lifespan of over LED materials now used for lighting sys-
100,000 hours, LEDs last more than 10 tems. The other is indium gallium nitride
times longer than any other light source. (InGaN). Slight changes in the composi-
However, LED lifetimes are rated differ- tion of these alloys changes the color of
ently than incandescent lights that fail the emitted light. AlGaInP produces red,
when the filament breaks. One definition orange, and yellow LEDs. InGaN produc-
for an LEDs typical lifetime is the aver- es green, blue, and white LEDs.
age number of hours until light falls to Emergence of AlGaInP and InGaN
70% of initial brightness. materials for LEDs made commercial
The commercial LED marketplace LED lighting feasible. These two materi-
calls for low-cost lighting, which requires als allowed white light to be produced by
minimal cost components. LEDs oper- mixing LEDs from different parts of the
ate with a dc voltage so the incoming 18-1. A new LED bulb from lighting spectrum.
ac must be rectified and reduced to a Cree is rated at 460 lumens for Now, there are two approaches to cre-
low voltage for the LED driver. The LED the 40-watt replacement and ating white light. One is to mix the light
power circuit can be non-isolated so 815 lumens for the 60-watt from several colored LEDs to create a
it may not need an input transformer. replacement. Its two versions spectral power distribution that appears
However, there is one component that have a soft white (2700K) white. By locating red, green, and blue
must be chosen carefully, the electro- and daylight (5000K) color LEDs adjacent to one another, and prop-
lytic or tantalum capacitor used in the temperature. erly mixing the amount of their output, the
rectifier circuit. Although the LED may resulting light appears white.
have a long lifespan, the capacitors lifetime will probably Another approach to generating white light is to use
be shorter. Electrolytic capacitor have a tendency of drying phosphors for a short-wavelength LED. When illuminated
out and failing. Therefore, the manufacturer must minimize by a blue LED light, one phosphor emits yellow light with
a broad spectral power distribution. The remaining blue to 85 percent less energy during its lifetime. The new Cree
light, when mixed with the yellow light, results in white light. LED bulb has achieved the ENERGY STAR certification by
Additional phosphors are being developed to produce soft meeting all the high-performance requirements.
white and bright white lighting.
LED Drivers
Improved LED Bulb Todays drivers operate in either constant current and
Cree Inc. has introduced what it considers a better constant voltage modes, with a number of variations.
LED bulb, delivering an even better light with better per- Constant current drivers usually tend to be used when
formance, a longer life, and more energy savings (Fig. one driver is required per light. The current will remain the
18-1). The new Cree LED bulb is built to deliver true LED same, regardless of the number of LEDs. Constant voltage
performance in color quality, light output, and dimming. It drivers are best for applications where the user requires
has an improved longer lifetime of over 27 years (30,000 flexibility with the number of LEDs connected to one power
hours), lasting as much as six times longer than some LED supply. As lamps are added, the current will increase to the
bulbs. Its proven 4Flow Filament Design, which ensures maximum limit.
that it looks and lights like a traditional incandescent. The The LT3744 from Linear Technology is a synchronous
new bulb also provides consumers with a higher color step-down dc/dc converter that delivers constant current to
rendering index of 83 to better display colors, true ENERGY drive high-current LEDs (Fig. 18-2). The LT3744 uses two
STAR-compliant omnidirectional distribution for all-around external switching MOSFETs, delivering up to 20A (80W) of
light, and is fully dimmable with most standard dimmers continuous LED current from a nominal 12V input. In pulsed
and suitable for enclosed fixtures. LED applications, it can deliver up to 40A of LED current or
The new LED Bulb delivers 460 lumens for the 40-watt 160 watts from a 12V input. Delivering efficiencies as high
replacement and 815 lumens for the 60-watt replacement in as 95%, it can eliminate the need for external heat sinking.
soft white (2700K) and daylight (5000K) color temperatures The LT3744s peak current mode controller maintains
inside a durable, shatterproof housing, and consumes up 3% LED current regulation over a wide voltage range from
VIN VEE to VIN. By allowing VEE
9V TO 16V 1F to float to negative voltages,
26.5V
25V
VIN SGND 3A LED several LEDs can be driven
200k M1
from a single Li-Ion battery with
TG
EN/UVLO EN/UVLO 220nF a simple, single step-down
2
BOOST output stage. Additionally,
30.9k 10F
D1 25V this enables a unique invert-
INTVCC
L1 ing step-down topology that
CTRLT 10F 4.7H
2V 5m allows a single common anode
VREF
VEE 4 heat sink to be used for RGB
2.2nF LT3744 SW
100k 10F
10k BG M2 50V
LEDs. A frequency-adjust pin
FAULT
CTRL1 VEE
allows the user to program the
CTRL2 VFNEG frequency between 100 kHz
30.1k VEE 1M
CTRL3 and 1 MHz, optimizing efficien-
ISP
2V
ISN cy while minimizing external
PWM1
0V
PWM2
FB component size. Combined
PWM3 43.2k with its 5mm 6mm QFN
SYNC PWM_OUT2 package, the LT3744 offers
PWM_OUT3 VEE
SS PWM_OUT1 M3 a very compact 80-watt LED
10nF VC1 LED_ISP driver solution.
VC2
VEE The LT3744 provides both
20k VC3 20m
VEE PWM dimming and CTRL
RT LED_ISN
680pF dimming, which offer 3,000:1
102k dimming capability for four
M1, M2: INFINEON BSC067N06LS3 VEE D2
VEE VEE
M3: INFINEON BSC010N04LS LED current levels, ideal for
D1: PMEG4002EB
D2: PMEG4010 3744 TA04 color mixing applications,
L1: WRTH 7443551470 4.7H such as those required in DLP
18-2. The LT3744 is burst-mode 3A LED driver with 98% efficiency. projectors. Similarly, its unique
Voltage axis
40
0
Triac -40
-80
Neon Lamp -120
R2 -160
-200
0 30 60 90 120 150 180 210 240 270 300 330 360
L2 Angle in Degrees
C1 C2
18-4. For the triac-based incandescent trimmer, the blue
line indicates the switching of the triac.
Boost Flyback
Converter Converter
AC Input
VOUT
1 14 6 7
BVSENSE VCB ASU VCC
4 BDRV FDRV 10 RTN
2 VIN FVSENSE 12
AGND PGND CFG VT
9 8 5 13
NTC
18-5. iW3616 control circuit converts a dimmer from an incandescent to an LED lamp.
VIN dimming, but it can also save significant energy. Plus, dim-
BOOST LED DRIVER
ming lights to half power will save overall significant energy
and actually extend LED lifespan.
LED+ The MAX16834 from Maxim Integrated is a cur-
rent-mode, high-brightness LED (HB LED) driver designed
IN NDRV to control a single-string LED current regulator with two
LEDs external n-channel MOSFETs (Fig. 18-6). The MAX16834
MAX16834 integrates all the building blocks necessary to implement
ON
OFF PWMDIM CS LED- a fixed-frequency HB LED driver with wide-range dimming
ANALOG DIMOUT control. The MAX16834 allows implementation of different
REFI
DIM converter topologies such as SEPIC, boost, boost-buck, or
PGND SENSE+ high-side buck current regulator.
The MAX16834 features a constant-frequency, peak-
current-mode control with programmable slope compen-
sation to control the duty cycle of the PWM controller. A
dimming driver offers a wide-range dimming control for the
external n-channel MOSFET in series with the LED string. In
18-6. Maxims MAX16834 current-mode, high-brightness addition to PWM dimming, the MAX16834 allows for analog
LED (HB LED) driver. dimming of LED current.
The MAX16834 switching frequency (100kHz to 1MHz)
An incandescent lamp is resistive so the voltage and is adjustable using a single resistor from RT/SYNC. The
current through the lamp have a linear relationship. Due to MAX16834 disables the internal oscillator and synchronizes
the thermal inertia of the incandescent lamps filament, the if an external clock is applied to RT/SYNC. The switching
pulsed input voltage of Fig. 18-4 does not cause the light MOSFET driver sinks and sources up to 3A, making it suit-
output to flicker. In contrast, the LED is a nonlinear load in able for high-power MOSFETs driving in HB LED applica-
which lamp current and voltage depend on the diode-like tions, and the dimming control allows for wide PWM dim-
performance of an LED. Furthermore, the LED responds ming at frequencies up to 20kHz.The MAX16834 is suitable
much faster than an incandescent lamp to changes in for boost and boost-buck LED drivers.
applied voltage. Thus, the 120 Hz triac drive voltage can The MAX16834 alone operates over a 4.75V to 28V in-
appear as flicker using an LED, unless a smart LED driver put supply range. With a voltage clamp that limits the IN pin
modifies the triac output to eliminate flicker. voltage to less than 28V, it can operate in boost configura-
Among the new smart LED drivers intended for use tion for input voltages greater than 28V. Additional features
with existing triac dimmers are iWatts iW3616 and iW3617 include external enable/disable input, an on-chip oscillator,
from iWatt (Fig. 18-5), now part of Dialog Semiconductor. fault indicator output (FLT) for LED open/short or overtem-
They are two-stage ac/dc power-supply controllers opti- perature conditions, and an overvoltage protection circuit
mized for dimmable LED luminaires. The iW3616 C
FLY1 C FLY2
1 F
tomatically detects the dimmer type and phase,
providing compatibility with analog and digital SCL RGB LED 0...25.5 mA/LED
dimmers. SDA R
Most LEDs can be dimmed using pulse width EN LP5521
MCU G
modulation (PWM). Incandescent lamps have CLK_32K
thermal inertia that allows a relatively low PWM INT B
TRIG
frequency to avoid visual flicker during dimming.
In contrast, LEDs light up very quickly and require ADDR_SEL0 GPO
ADDR_SEL1
a higher frequency PWM to avoid flicker. There GNDs
has been some concern that dimming light caus-
es a loss of energy. However, the opposite is true. 18-7. Texas Instruments LP5521 is a three-channel LED driver
Driver efficiency may be reduced slightly during designed to produce a variety of lighting effects.
for true differential overvoltage protection. pins for other devices. The LP5521 requires only four small
Texas Instruments LP5521 is a three-channel LED driver and low-cost ceramic capacitors.
designed to produce variety of lighting effects for mobile Comprehensive application tools are available, including
devices (Fig. 18-7). A high-efficiency charge pump enables command compiler for easy LED sequence programming.
LED driving over full Li-Ion battery voltage range. The de- Texas instruments LP5521 is a three-channel LED driver
vice has a program memory for creating variety of lighting designed to produce variety of lighting effects for mobile
sequences. When program memory has been loaded, the devices. A high-efficiency charge pump enables LED driv-
LP5521 can operate autonomously without processor con- ing over full Li-Ion battery voltage range. The device has a
trol allowing power savings. program memory for creating variety of lighting sequences.
The device maintains excellent efficiency over a wide When program memory has been loaded, the LP5521 can
operating range by automatically selecting proper charge operate autonomously without processor control allowing
pump gain based on LED forward voltage requirements. power savings.
The LP5521 is able to automatically enter power-save The IC maintains excellent efficiency over a wide oper-
mode, when LED outputs are not active and thus lowering ating range by automatically selecting proper charge pump
current consumption. gain based on LED forward voltage requirements. The
Three independent LED channels have accurate LP5521 is able to automatically enter power-save mode,
programmable current sources and PWM control. Each when LED outputs are not active and thus lowering current
channel has program memory for creating desired lighting consumption.
sequences with PWM control. Three independent LED channels have accurate
The LP5521 has a flexible digital interface. A trigger programmable current sources and PWM control. Each
I/O and 32-kHz clock input allow synchronization between channel has program memory for creating desired lighting
multiple devices. Interrupt output can be used to notify the sequences with PWM control. The LP5521 has a flexible
processor when LED sequence has ended. LP5521 has digital interface. A trigger I/O and 32-kHz clock input allow
four pin-selectable I2C-compatible addresses. This allows synchronization between multiple devices. Interrupt output
connecting up to four parallel devices in one I2Ccompati- can be used to notify processor, when LED sequence has
ble bus. GPO and INT pins can be used as digital control ended. LP5521 has four pin-selectable I2C-compatible ad-
750
Q2
Q1 1k
1k M1
D4
VIN 0.5 SKYHOOK
40V 1F
100V
D2 D3 LED+ VCC
DRN8 VIN VDD
20k 5V
VIN ISP ISN SRC8 0.1F 10k 10k 10k
EN/UVLO INTVCC DRN7
0.1F SDA SDA
PWM PWMOUT 100V SRC7
2.2nF SYNC 1F DRN6 SCL SCL
SRC6 LT3965 ALERT ALERT
VMODE
DRN5
VREF LT3955 FB 500mA SRC5 EN/UVLO EN/UVLO
CTRL GND DRN4
1F VLED RTCLK
GNDK 26V SRC4 28k
50V
PGND SW DRN3 500Hz DIMMING FREQUENCY
RT DIM/SS VC SRC3 ADDR1
DRN2 ADDR2
28.7k 0.1F 0.01F
375kHz SRC2
ADDR3
L1 DRN1
D1 33H ADDR4
SRC1 GND LEDREF
IN4148 28k LED
D5
turnkey test system based on the companys CAS 140CT 2. Sam Davis, Intelligent LED Driver Employs Ledotron Digital
CCD Array Spectrometer, Keithley Series 2400/2600 Dimming, powerelectronics.com, February 2014.
Sourcemeter, and a control PC combined with tester soft- 3. Koenraad Rutgers, Overcoming Reliability Challenges in LED
ware developed in-house. The interplay between all the Streetlight Applications, powerelectronics.com, August 2013.
components has been optimized for the tough conditions of 4. Sam Davis, LED Driver Micro-Module Needs No External
continuous application in production environments. Sensors, powerelectronics.com, July 2012.
This LED Tester can measure critical measuring param- 5. Georgia Salis, LEDs Are Making Inroads on Automotive Lighting
eters, e.g., color coordinates of white LEDs, extremely pre- Systems, powerelectronics.com, July 2012.
cisely and reproducibly. All calibrations are based on the 6. Hector F. Arroyo, How to Add Analog Dimming to Virtually Any
PTB and NIST national reference standards. The Keithley LED Driver, powerelectronics.com, January 2012.
2600 delivers fast current supply to the LEDs and in this 7. Cathal Sheehan, Design Efficient Thermal Management for
way permits short measurement times. Added Reliability in LED Apps, powerelectronics.com, June 2011.
The tester software comprises a user-friendly interface 8. Kelvin Shih, Is the Thermal Resistance of LEDs Constant?,
with a multitude of functions. You can select different results powerelectronics.com, April 2010.
and structure their display on the monitor to suit the appli- 9. Irene Signorino, Next-Generation Solid-State Lighting Fixtures
cation. The hardware setup is provided with an entering Need Optimized LED Drivers, powerelectronics.com, September
page in order to configure parameters and settings for 2009.
each application. 10. Tsing Hsu, Simple, Constant-Current Drive Controls 16 LEDs,
powerelectronics.com, February 2008.
Related Articles
1. Ed Rodriguez, Cooling LED Arrays and Power Converters BACK TO TABLE OF CONTENTS
Impacts Performance and Reliability, powerelectronics.com, April
2014.
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CHAPTER 19:
MOTION-SYSTEM
POWER
MANAGEMENT
T
he key component in a motion system is the
motor because it determines the design of the Motion Motor Mechanical
Input Motor
associated motion controller as well as the Controller Drive load
motor drive. From a power-management view-
point, the important motion-system design Feedback
considerations are providing the appropriate Device
control signals as well as the required drive power for
the specific motor. Each motion controller is unique for a 19-1.Typical motion system.
specific motor. Fig. 19-1 shows the typical
motion system that includes a motion 24 V
M
controller and a motor drive.
An electric motor is an electrical
machine that converts electrical energy VDD M1 M2
3.3 V 3.3 V
into mechanical energy. In normal motor-
MAX14871
ing mode, most electric motors operate
through the interaction between an electric FAULT
IRQ
DIR VDD VDD
motors magnetic field and winding cur- C GPO
PWM
rents to generate force within the motor. PWM
EN DRIVER
Electric motors are used to produce
linear or rotary force (torque). That is, 3.3 V DRIVER
the motion controller controls the motors
rotary speed or its linear position. You can VREF
convert rotating motion to linear motion TCOFF
using mechanical components or use a CURRENT
COFF REGULATION
linear motor to provide linear motion by MODE
itself.
The motors moving part is the rotor SNS COM GND
that turns the shaft to deliver mechanical
power. The stator is the stationary part of R SENSE
the motors electromagnetic circuit and 19-2. Maxims MAX14871 dc motor driver provides a low-power and
usually consists of either windings or per- simple solution for driving and controlling brushed motors with voltages
manent magnets. Windings are wires that between 4.5V and 36V.
are laid in coils, usually wrapped around a laminated soft reduced external components and low supply current. Inte-
iron magnetic core to form magnetic poles when energized grated current regulation allows user-defined peak startup
by current. motor currents and requires minimal external components.
In a brushed motor, a commutator switches the input The MAX14871 includes three modes of current regula-
of most dc machines and certain ac machines consisting tion: fast decay, slow decay, and 25% current ripple modes.
of slip-ring segments insulated from each other and from Current regulation based on 25% ripple simplifies the
the electric motors shaft. The motors armature current isdesign and enables regulation independent of motor char-
supplied through the stationary brushes in contact with theacteristics. A separate voltage sense input (SNS) reduces
revolving commutator, which causes a current reversal and current-sensing errors due to parasitic trace resistance.
applies power to the machine in an optimal manner as the The term electronic commutator is usually associated
rotor rotates from pole to pole. In absence of such currentwith self-commutated brushless dc motor and switched
reversal, the motor would brake to a stop. reluctance motor applications. Some problems with the
The MAX14871 dc motor driver provides a low-power brushed dc motor are eliminated in the brushless dc
and simple solution for driving and controlling brushed mo-(BLDC) design. In this motor, the mechanical rotating
tors with voltages between 4.5V and 36V. Very low driver onswitch or commutator is replaced by an external electronic
resistance reduces power during dissipation (Fig. 19-2). switch synchronized to the rotors position. BLDC motors
The MAX14871 features a charge- pump-less design for are typically 85% to 90% efficient or more.
BLDC motors
19-3. ON Semiconductor MC33035 brushless dc motor controller. are commonly used
where precise speed
control is necessary.
They have several
VM
advantages over
Fault conventional motors:
N
4
14 Without a commu-
S S
N
tator to wear out, the
5 2 life of a BLDC motor
Rotor
6
Position can be significantly
Decoder
1 longer compared
Fwd/Rev
3 to a dc motor using
brushes and a
60/120 22 24
Motor commutator. Com-
Enable Output mutation also tends
7 Undervoltage
Vin
Lockout
Buffers to generate electrical
17
and RF noise. Without a commutator
18
or brushes, a BLDC motor may be
Reference
Regulator used in electrically sensitive devices
8 like audio equipment or computers.
21
Speed
Hall effect sensors provide the
Set 11 Error Amp commutation and can also provide
Thermal a convenient tachometer signal
Faster 12 Shutdown 20
PWM for closed-loop control (servo-con-
RT
R
trolled) applications.
13
Q They are also acoustically quiet
S 19
motors, which is an advantage if
Oscillator
10 S being used in equipment affected
CT Q
R 9 by vibrations.
The BLDC motion controller must
15 provide the proper electronic com-
16 23 Current Sense mutation interface.
Reference
Brake ON Semiconductors MC33035 is
one of a series of high performance
Host
communication
Galvanic
isolation
Passive
Motor
EMI 6
7 (PMSM)
Filter IRS2630D
IRMCF143
Power
3.3 V
Supply Encoder
Optional
2
EEPROM
opto isolation
17
Digital I/O
6 opto isolation
Analog Input
19-6. Texas Instruments DRV8811 is a motor microstepping motor driver with two H-bridge drivers, as well as
microstepping indexer logic to control a stepper motor.
squirrel cage is nearly at line frequency and tends to be in with position or speed feedback on the motor. As dynamic
the outer parts of the rotor cage. As the motor accelerates, response requirements increase, more specialized motor
the slip frequency becomes lower, and more current is in designs such as coreless motors are used. AC motors
the interior of the winding. By shaping the bars to change superior power density and acceleration characteristics
the resistance of the winding portions in the interior and compared to that of dc motors tends to favor PM synchro-
outer parts of the cage, effectively a variable resistance is nous, BLDC, induction, and SRM drive applications.
inserted in the rotor circuit. However, the majority of such A servo system differs from some stepper motor appli-
motors have uniform bars. cations in that the position feedback is continuous while the
motor is running; a stepper system relies on the motor not
Servo Motor to miss steps for short-term accuracy, although a stepper
A servomotor is a motor, very often sold as a complete system may include a home switch or other element to
module, used within a position-control or speed-control provide long-term stability of control. For instance, when a
feedback control system mainly to control valves, such as typical dot matrix computer printer starts up, its controller
motor-operated control valves (Fig. 19-5). Servomotors are makes the print-head stepper motor drive to its left-hand
used in applications such as machine tools, pen plotters, limit, where a position sensor defines home position and
and other process systems. Motors intended for use in a stops stepping. As long as power is on, a bidirectional
servomechanism must have well-documented character- counter in the printers microprocessor keeps track of print-
istics for speed, torque, and head position.
power. The speed vs. torque 8 to 38 V
cross between a dc electric motor and a rotary solenoid. As one mechanism, the elongation in a single plane is used to
each coil is energized in turn, the rotor aligns itself with the make a series stretches and position holds, similar to the
magnetic field produced by the energized field winding. way a caterpillar moves.
Unlike a synchronous motor, in its application, the stepper
motor may not rotate continuously; instead, it steps Related Articles
starts and then quickly stops againfrom one position to 1. Ryan Scott, Motor Control System Efficiency with IGBTs,
the next as field windings are energized and de-energized powerelectronics.com, September 2012.
in sequence. Depending on the sequence, the rotor may 2. Alberto Guerra, Multichip QFN IPM Provides Efficient Drive for
turn forward or backward, and it may change direction, Low Power Motors, powerelectronics.com, September 2012.
stop, speed up, or slow down arbitrarily at any time. 3. Randy Frank, Motion Controls Move Vehicles in a New Direction,
Simple stepper motor drivers entirely energize or entirely electronicdesign.com, January 2012.
de-energize the field windings, leading the rotor to cog to 4. Ali Husain, Run a Single-Phase Induction Motor with a Three
a limited number of positions; more sophisticated drivers Phase Inverter, powerelectronics.com, May, 2011.
can proportionally control the power to the field windings, 5. Roger Allan, Smart Motor Controllers Take Charge of Expanding
allowing the rotors to position between the cog points and Applications,, powerelectronics.com, March 2011.
thereby rotate extremely smoothly. This mode of operation 6. Kaushik Rajashekara, Cryogenic Power For Transportation Heats
is often called microstepping (Fig. 19-6). Computer con- Up, powerelectronics.com, June 2014.
trolled stepper motors are one of the most versatile forms 7. White Paper, Power Analysis of PWM Motor Drives,
of positioning systems, particularly when part of a digital powerelectronics.com, April 2014.
servo-controlled system. 8. Alberto Guerra, Optimized IPM Spawns Energy-Efficient Motors,
electronicdesign.com, May 2012.
Piezoelectric motor 9. Tom Rowan, Versatile Microstepper Driver ICs Provide Next
A piezoelectric motor or piezo motor is a type of electric Generation Stepper, powerelectronics.com, September 2010.
motor based upon the change in shape of a piezoelectric 10. Sam Davis, Monolithic 500-V, 1-A Three-Phase Motor Drive IC
material when an electric field is applied. Piezoelectric Fits SMT SOP, powerelectronics.com, July 2009.
motors make use of the converse piezoelectric effect
whereby the material produces acoustic or ultrasonic BACK TO TABLE OF CONTENTS
vibrations in order to produce a linear or rotary motion. In
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CHAPTER 20:
C
components are exposed to the line voltage, whereas the
urrent sensing is used to perform two indirect method provides isolation that may be necessary for
essential circuit functions. First, it is used design safety.
to measure how much current is flowing
in a circuit, which may be used to make Current Sense Resistor
decisions about turning off peripheral loads The resistor is a direct method of current measurement
to conserve power or to return operation to that has the benefit of simplicity and linearity. The current
normal limits. A second function is to determine when it is sense resistor is placed in line with the current being mea-
a too much or a fault condition. If current exceeds safe sured and the resultant current flow causes a small amount
limits, a software or hardware interlock condition is met and of power to be converted into heat. This power conversion
provides a signal to turn off the application, perhaps a motor is what provides the voltage signal. Other than the favorable
in a stalled condition or short circuit. It is essential to choose characteristics of simplicity and linearity, the current sense
the appropriate technology with the necessary robustness resistor is a cost-effective solution with stable Temperature
to properly withstand the extreme conditions that can exist Coefficient of Resistance (TCR) of < 100 ppm/C or 0.01%
during a fault. /C and does not suffer the potential of avalanche multipli-
A signal to indicate the how much condition and the cation or thermal runaway. Additionally, the existence of low
too much condition is available in a variety of measure- resistance (< 1 m is available) metal alloy current sense
ment methods: products offer superior surge performance for reliable pro-
1. Resistive (Direct) tection during short circuit and overcurrent events.
a. Current Sense Resistors
b. Inductor dc resistance Inductor DC Resistance
2. Magnetic (Indirect) The dc resistance of an inductor can also be used to
a. Current Transformer provide a resistive current measurement. This method is
b. Rogowski Coil considered lossless because of the low resistance value
c. Hall Effect Device of the copper, typically < 1 m and because it is providing
3. Transistor (Direct) a secondary use of an existing component. In higher current
a. RDS(ON) applications; a 30 amp current would provide a 30 mV sig-
b. Ratio-metric nal for a 1 m resistance value. This method has two draw-
Thermal Isolation
20-6a. Shows a four-terminal The OARS (Open Air Resistor Surface Mount)
resistor for current sense is a unique design that elevates the hot spot of the
applications. resistive material well above the circuit-board mate-
rial. This places the hottest region of the part into the
20-6b. Two pad designs, (1) available airstream, which dissipates the maximum
with isolated pad regions, and amount of heat energy to the air instead of the PCB.
(a) (2) with a plated through-hole. This provides two key advantages for thermal
design, which affects the PCB material and the other
neighboring power or semiconductor components.
Typical FR4 PCB material is only rated to 130C; a
power resistor that is traditionally against the board
could cause damage to the material during power
excursions or reduces the upper temperature perfor-
mance limits of the circuit. An elevated current sense
Pad Design 1 Pad Design 2 prevents damage to the circuit material and permits
(b)
the solder joint to run cooler. The second benefit by
dissipating the heat to the air instead of the PCB is
can benefit from a four-terminal pad design. These parts the improved performance of nearby heat-affected devices.
offer physically separated connection points for current and These effects may include lifetime rating, power handling,
voltage, which reduces contact related measurement error. luminous output, accuracy, and reliability.
In the case of the CSL, the current will flow through the inner The thermal images shown in Fig. 20-7 help illustrate
pins and voltage is sensed on the outer pins and is recom- the isolation performance of the OAR and OARS products.
mended for best accuracy with the LRF3W to be configured These tests were conducted on FR4 board material with
as a cross flow arrangement with current on diametrically no ambient airflow; airflow would improve system thermal
opposing corners (e.g., pin 2 to pin 3). performance. Observe the temperature of the solder joint
The pad layout (Fig. 20-6b) creates separate regions for with respect to the hot spot. These temperatures are based
measuring signal voltage from the current carrying portion, on reaching thermal equilibrium, however in the application
which reduces error. Pad Design 1 illustrates one method these results may be extended to be considered as the ther-
that creates an isolated pad region within the pad layout, but mal performance characteristics for an overcurrent protec-
this design may reduce the pad area below necessary limits tion condition. The FR4 will not exceed its temperature rating,
to carry high currents through the copper trace. Pad De- though extreme circuit conditions exist.
sign 2 uses a plated through-hole to connect under the pad
and connects to an Solder Joint Stress
internal or outer trace The OARS resistive product familys elevated and curved
for measurement; construction permits the resistor to flex. This construction
this maximizes the reduces the stress generated by differences in thermal
pad space to carry expansion coefficients between the heat producing metal
current to the resistor. and the dissipating circuit board material. Surface-mount
The contact point components that are flat and parallel to the circuit board will
places the signal apply shear forces to the solder joint that can lead to failure
line as close to the
current channel as
possible; minimizing
(a)
measurement error.
20-7. Thermal
images illustrating
the isolation Figure 20-8. Differences in the thermal expansion
performance of coefficient between the metal materials of the current
(b) OAR5 OAR5 OAR5 the OARand OARS sense resistor and the circuit board materials dissipate
(2.94 Watts) (5.15 Watts) (5.15 Watts)
Side View Side View Side View product. forces on each part.
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CHAPTER 21:
THERMOELECTRIC
GENERATORS
A
thermoelectric generator, TEG, is a sol- Although these materials still remain the cornerstone
id-state device that converts heat directly for commercial and practical applications in thermoelectric
into electrical energy through a phenom- power generation, significant advances have been made
enon called the Seebeck effect. Thermo- in synthesizing new materials and fabricating material
electric generators consist of three major structures with improved thermoelectric performance.
components: thermoelectric materials, Recent research has focused on improving the materials
thermoelectric modules, and thermoelectric systems that figure-of-merit (zT), and hence the conversion efficiency, by
interface with the heat source. reducing the lattice thermal conductivity.
Thermoelectric materials generate power directly from Researchers are trying to develop new thermoelec-
heat by converting temperature differences into a dc volt- tric materials for power generation by improving the
age. To be good thermoelectric materials these materials figure-of-merit zT. One example of these materials is the
must have both high electrical conductivity and low ther- semiconductor compound -Zn4Sb3, which possesses
mal conductivity. Having low thermal conductivity ensures an exceptionally low thermal conductivity and exhibits a
that when one side is made hot, the other side stays cold, maximum zT of 1.3 at a temperature of 670K. This material
which helps to generate a large voltage while in a tempera- is also relatively inexpensive and stable up to this tem-
ture gradient. perature in a vacuum, and can be a good alternative in the
The typical efficiency of TEGs is around 5% to 8%. Old- temperature range between materials based on Bi2Te3 and
er devices used bimetallic junctions and were bulky. More PbTe.
recent devices use highly doped semiconductors made Besides improving the figure-of-merit, there is increasing
from bismuth telluride(Bi2Te3), lead telluride (PbTe), calcium focus to develop new materials by increasing the electrical
manganese oxide (Ca2Mn3O8), or combinations thereof, power output, decreasing cost and developing environ-
depending on temperature. Maximizing the efficiency (or, mentally friendly materials. For example, when the fuel cost
conversely, the total power output) of requires trade-offs is low or almost free, such as in waste-heat recovery, then
between total heat flow through the thermoelectric modules the cost per watt is only determined by the power per unit
and maximizing the temperature gradient across them. The area and the operating period. As a result, it has initiated a
design of heat-exchanger technologies to accomplish this search for materials with high power output rather than con-
is one of the most important aspects of engineering of a version efficiency. For example, the rare earth compound
thermoelectric generator. YbAl3 has a low figure-of-merit, but it has a power output of
Three semiconductors are known to have both low ther- at least double that of any other material, and can operate
mal conductivity and high power factor: over the temperature range of a waste-heat source.
Low temperature materials (up to around 450K): alloys Many challenges are confronted when designing a
based on Bismuth (Bi) in combinations with Antimony reliable TEG system that operates at high temperatures.
(Sb), Tellurium (Te), or Selenium (Se). Achieving high efficiency in the system requires extensive
Intermediate temperature (up to 850K): such as materials engineering design in order to balance between the heat
based on alloys of Lead (Pb). flow through the modules and maximizing the temperature
Highest-temperatures material (up to 1300K): materials gradient across them. To do this, designing heat-exchanger
fabricated from silicon germanium (SiGe) alloys. technologies in the system is one of the most important as-
pects of TEG engineering. In addition, the system amounts of power (a few watts) are needed.
must minimize the thermal losses due to the in- Most thermoelectric generator
terfaces between materials at several places. module manufacturing companies use
Another challenging constraint is avoiding many thermoelectric couples that are
large pressure drops between the heating sandwiched between two pieces of
and cooling sources. non-electrically conductive materials.
When selecting materials for thermo- It is also necessary for this material to be
electric generation, a number of other thermally conductive to ensure a good heat
factors need to be considered. During transfer; usually two thin ceramic wafers are
operation, ideally the thermoelectric used to form what is called a thermoelectric
generator has a large temperature module.
gradient across it. Thermal expansion Each module can contain dozens of pairs
will then introduce stress in the de- 21-1. TG8-1.0 Thermoelectric of thermoelectric couples called thermoelec-
vice, which may cause fracture of the Module from GMZ. tric generator modules, TEC modules, and
thermoelectric legs, or separation from sometimes Peltier or Seebeck modules, which
the coupling material. The mechanical properties of the simply denotes whether they are being used to generate
materials must be considered and the coefficient of thermal electricity (Seebeck) or produce heat or cold (Peltier).
expansion of the n- and p-type material must be matched Functionally there is no difference between the two. They
reasonably well. both are capable of producing heat and cold or generat-
Thermoelectric generators can be applied in a variety ing electricity, depending on whether heat is applied or an
of applications. Frequently, thermoelectric generators are electrical current.
used for low-power remote applications or where bulkier There are differences in performance between various
but more efficient heat engines such as Stirling engines modules depending on what they were manufactured for.
would not be possible. Unlike heat engines, the solid-state For example, if a module is being manufactured for use in
electrical components typically used to perform thermal to a 12-volt dc automotive cooler, the thermoelectric couples
electric energy conversion have no moving parts. The ther- will be of a thicker gauge and so will the wire connecting
mal to electric energy conversion can be performed using the modules to the 12-volt dc power source. In most cases,
components that require no maintenance, have inherently the module itself is quite large. This is simply because the
high reliability, and can be used to construct generators module will be conducting a heavy load of current and will
with long service-free lifetimes. This makes thermoelectric need to be able to handle the load. Although these type
generators well suited for equipment with low to modest modules can be used to produce electricity, they are not
power needs in remote uninhabited or inaccessible loca- well suited for the task because they have a high internal
tions such as mountaintops, the vacuum of space, or the resistance (lowering output) and lower temperature solder
deep ocean. that may melt if used for Seebeck purposes. This means
Besides low efficiency and high cost, two general the electrical connection may fail when the higher heat
problems exist in such devices: high output resistance and needed to produce significant amounts of electricity is
adverse thermal characteristics. applied to the module.
High output resistance. In order to get a significant output
voltage, a very high Seebeck coefficient is needed (high GMZ-Energy
V/C). A common approach is to place many thermo-el- GMZ-Energys TG16-1.0 thermoelectric module is ca-
ements in series, causing the effective output resistance pable of producing twice the power of the companys first
of a generator to be very high (>10). Thus, power is product, the TG8 (Fig. 21-1). The highly efficient TG16-1.0
only efficiently transferred to loads with high resistance; directly converts waste heat into usable electricity and is
power is otherwise lost across the output resistance. This well suited for extremely high-temperature environments,
problem is solved in some commercial devices by putting such as those in boilers and furnaces.
more elements in parallel and fewer in series. By doubling the power density, GMZs new module sub-
Adverse thermal characteristics. Because low thermal stantially increases performance while maintaining a mini-
conductivity is required for a good thermoelectric gen- mal footprint. The TG16-1.0 will augment the TG8, enabling
erator, this can severely dampen the heat dissipation of dramatic efficiency improvements and new functionalities
such a device (i.e., thermoelectric generators serve as in products requiring high power density. Now, with two
poor heat sinks). They are only economical when a high product offerings, GMZ is capable of providing a solution to
temperature (>200 C) can be used and when only small even more OEM partners around the world.
Power (Watts)
by 30% to 60% across multiple classes of thermoelectric
4
materials, including bismuth telluride, lead telluride, skutter- 500C
udites, silicon germanium, and half-Heusler materials. 3
The company has recently applied its nano-structuring 2 450C
process to half-Heusler materials, yielding a unique com-
1
bination of high performance, high strength and low cost.
0 400C
GMZs proprietary method of bulk manufacturing TE mate-
0 2 4 6 8 10
rials of less than 1 micron in size is more cost-effective than Current (Amps)
known nanowire or thin-film manufacturing methods for
temperatures of 550C to 650C on the hot side and 100C 21-2. TG8-1.0 power output as a function of temperature
on the cold side. and output current.
A demonstration of the TEGs ability to convert a ve-
hicles waste heat into electricity was performed for the costs ranging from $40 to $800 per gallon, the U.S. military
Armys TARDEC (Tank Automotive Research, Development is especially interested in thermoelectric technologies,
and Engineering Center) program. For that program, GMZ which are physically robust, have long service lives, and
Energy successfully demonstrated a 1,000W TEG designed require no maintenance due to their solid-state design.
for diesel engine exhaust heat recapture. The company GMZs patented half-Heusler material is uniquely well
integrated five 200W TEGs into a single 1,000W diesel suited for military applications. The 1000W TEG features
engine solution that directly converts exhaust waste heat enhanced mechanical integrity and high-temperature
into electrical energy, which increases fuel efficiency and stability thanks to a patented nano-structuring approach.
lowers overall costs. GMZs TEG also enables silent generation, muffles engine
The GMZ TEGs demonstrated continuous output power noise, and reduces thermal structure. Half-Heusler is envi-
with no degradation in performance over the test period. ronmentally friendly and mechanically and thermally robust,
To simulate vehicle performance, the unit was tested by although cost may be an eventual issue.
connecting directly to the exhaust of a 15-liter V8 diesel The TARDEC TEG incorporates GMZs TG8-1.0 mod-
engine inside an engine test cell. At approximately 80 liters ules, which are the first commercially available modules
(2.8 ft3), GMZs TEG was less than one-third of the TARDEC capable of delivering power densities greater than one
programs specified size requirement. Watt/cm while operating at 600C. Fig. 21-2 shows the
The operating temperature range of a TEG depends on power output of a TG8-1.0 module as a function of current
the materials employed. For example, a bismuth-tellurium and temperature. The TARDEC 1000W TEG consists of 400
system is suitable for relatively low temperature operation TG8-1.0 modules with associated cold-side and hot-side
(room temperature to 200 C), whereas silicon-germa- heat exchangers and manifolds. GMZ did the engineering
nium alloys work best for high-temperature applications and CFD simulation to project performance. The technolo-
(>800C). For moderate temperature (T = 500C to 800C) gys uniqueness is its ability to operate at high-temperature
heat sources such as a vehicles exhaust and industrial gradients (high T), which allows the extraction of more
waste heat, half-Heusler types are the material of choice. power per unit area of the TEG modules.
The GMZ TEGs demonstrated continuous output power The next phase of this program will be testing in a Brad-
with no degradation in performance over the test period. ley Fighting Vehicle. Besides saving money and adding
To simulate vehicle performance, the unit was tested by silent-power functionality for the U.S. military, this TEG can
connecting directly to the exhaust of a 15-liter V8 diesel increase fuel efficiency for most gasoline and diesel en-
engine inside an engine test cell. At approximately 80 liters gines. This low-cost TEG technology fits into a broad array
(2.8 ft3), GMZs TEG was less than one-third of the TARDEC of commercial markets, including long-haul trucking, heavy
programs specified size requirement. equipment, and light automotive.
With this demonstration, GMZ successfully reached an Due to the high currents involved, GMZ usually employs
important milestone in the $1.5 million vehicle-efficiency series connections to maximize voltage and minimize cur-
program sponsored by TARDEC and administered by the rent as much as possible as well as to minimize I2R losses.
U.S. Department of Energy (DOE). With battlefield fuel Because diesel exhaust is less than 600C and the module
hot-side temperature is even lower than the flow tempera- minimize current) as much as possible in order to minimize
ture, the modules do not give their full power output the I2R losses due to the high currents involved. Because
way they do in other applications. However, even with the diesel exhaust is less than 600C and the module hot-side
derating to account for the lower hot-side temperature, the temperature is even lower than the flow temperature, the
economics of incorporating these systems is very compel- modules do not give their full power output the way they
ling with payback times typically less than 12 to 24 months. do in applications like self-powered boilers. However, even
A high T capability can result in higher efficiency in with the derating to account for the lower hot-side tempera-
some cases. However, what really matters is the $/Watt. ture, the economics of incorporating these systems is very
When the input energy is free, the cost of the output energy compelling with payback times typically less than 12 to 24
is driven entirely by the cost of the generator. GMZ de- months.
signed the system to minimize the $/W in order to maximize High T capability of the TG8-1.0 can result in higher ef-
their utility to the largest possible set of prospective users. ficiency in some cases. However, what really matters is the
Because any thermoelectric material generates more pow- $/Watt. When the input energy is free, the cost of the output
er with higher T, GMZ focused on half-Heusler material energy is driven entirely by the cost of the generator. The
systems, which have very high temperature capability. GMZ system is designed to minimize the $/W in order to maxi-
modules are rated for 600C continuous hot-side capability mize the largest possible set of prospective users. Because
with 700C intermittent. This maximizes power per device, any thermoelectric material generates more power with
which minimizes the $/W. higher T, GMZ has focused
Ceramic Substrate
In volume production, GMZ on half-Heusler material sys-
expects its TEG systems to be tems that have very high tem-
below $1/W. perature capability. Modules
GMZ Energys proprietary are rated for 600C continuous
Thermally Conductive
platform technology enables Layer hot-side capability with 700C
low-cost manufacturing of intermittent. This maximizes the
bulk thermoelectric materials. TE Material power per device and minimiz-
The companys nano-structur- es $/W. In volume production,
ing process reduces thermal GMZ expects to sell its TEG
conductivity while maintaining 21-3. Lairds PCS series of thermoelectric modules are systems at or below $1/W.
electrical conductivity, enhanc- intended for thermal cycling applications.
ing the performance (figure Test and Measurement
of merit, zT) by 30% to 60% across multiple classes of In certain applications, thermoelectric modules (TEMs)
thermoelectric materials, including bismuth telluride, lead are typically used to achieve the rapid temperature chang-
telluride, skutterudites, silicon germanium, and half-Heusler es. The advantages of thermoelectric modules over other
materials. types of thermal cycling devices are precise temperature
Compared to thin-film and nanowire materials, GMZs control, compactness, faster temperature ramp rates, and
nano-structured bulk materials have superior mechanical efficiency.
integrity and high-temperature (20C-800C) thermal sta- The PC Series TEMs from Laird are proven to perform
bility. GMZs TEG materials and processes also allow direct for more than 800,000 temperature cycles and can operate
bonding to interconnect without the need for metallization, in temperatures up to 120C. This exceeds the require-
which lowers costs and increases module durability and ments for certain applications and provides a lower total
life cycle. This enables the module to provide consistent cost of ownership.
energy over long-term cycling, even in the most challeng- These TEMs are constructed with multiple layers
ing environments. between the ceramic substrates, copper buss bars, and
The 1000W TEG is composed of 400 TG8 modules with semiconductor couples (Fig. 21-3). To reduce thermally
associated cold-side and hot-side heat exchangers and induced stress, a flexible and thermally conductive soft
manifolds. GMZ did the engineering and CFD simulation layer is inserted between the cold-side ceramic substrate
to project the performance. GMZs uniqueness is its ability and copper buss bars. The integration of the polymer into
to operate at high-temperature gradients (high T), which the thermoelectric modules absorbs the mechanically
allows the extraction of more power unit area of its TE mod- induced stresses caused by rapid temperature cycling. As
ules. a result, the stress induced on the semiconductor couples
The 1000W test unit included 400 modules. In general, and solder joints is significantly reduced, extending the
GMZ tries to do series connections (maximize voltage and overall operational life of TEM.
Thermal cycling exposes TEMs to mechanical stress- 3. PET, Outdoor Thermoelectric Cooler Series, powerelectronics.
es as the module contracts and expands from repeated com, March 2013.
cooling and heating cycles. The high-temperature diffusion 4. PET, Thin-Film Thermoelectric Modules, powerelectronics.com,
of impurities and mechanical stresses over time signifi- February 2013.
cantly reduces the operational life of a standard TEM. The 5. PET, Thermoelectric Power Generators for Energy Harvesting,
PC Series is designed to handle hundreds of thousands of powerelectronics.com, February 2013.
thermal cycles with minimal degradation. 6. PET, Thin Film Thermoelectric Module Product Line,
Among its features: powerelectronics.com, February 2013.
Designed to pass rigorous testing 7. PET, High Performance Air-To-Air Thermoelectric Assembly,
Robust construction developed for thermal cycling appli- powerelectronics.com, June 2012.
cations 8. PET, Thermoelectric Tester, powerelectronics.com, January 2013.
800K+ thermal-cycle operating life 9. PET, Mismatched alloys could lead to better thermoelectric
Superior temperature control stability generators, PV, powerelectronics.com, September, 2010
RoHS compliant 10. PET, Thermoelectrics Target Hot CPUs: Are Power Semis Next?,
powerelectronics.com, December 2002.
Related Articles
1. PET, High-Power-Thermoelectric-Module, powerelectronics.com, BACK TO TABLE OF CONTENTS
December 2014.
2. PET, Harvesting Unused Energy with Flat Thermoelectrics,
powerelectronics.com, January 2013.
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CHAPTER 22:
FUEL CELLS
F
uel cells convert the chemical energy from a been introduced for commercial lease and sale in limited
fuel into electricity through a chemical reaction quantities: the Toyota Mirai and the Hyundai ix35 FCEV.
of positively charged hydrogen ions with oxy- Additional demonstration models include the Honda FCX
gen or another oxidizing agent. They differ from Clarity and Mercedes-Benz F-Cell. General Motors and its
batteries because they require a continuous partners estimated that per mile traveled, a fuel-cell electric
source of fuel and oxygen or air to sustain the vehicle running on compressed gaseous hydrogen pro-
chemical reaction. Fuel cells produce electricity continu- duced from natural gas could use about 40% less energy
ously as long as these inputs are supplied. In a battery, the and emit 45% less greenhouse gases than an internal
chemicals present in the battery react with each other to combustion vehicle. A lead engineer from the Department
generate a voltage. They are used for primary and backup of Energy whose team is testing fuel-cell cars said in 2011
power for commercial, industrial, and residential buildings that the potential appeal is that these are full-function ve-
and in remote or inaccessible areas. They can also be hicles with no limitations on range or refueling rate so they
used to power vehicles, including forklifts, automobiles, are a direct replacement for any vehicle.
buses, boats, motorcycles, and submarines. ForkliftsFuel-cell forklifts lift and transport materials. In
All fuel cells consist of an anode, cathode, and elec- 2013, there were over 4,000 fuel-cell forklifts used in materi-
trolyte that allows positively charged hydrogen ions (or al handling in the United States. Most companies in Europe
protons) to move between the two sides of the fuel cell. and the U.S. do not use petroleum-powered forklifts, as
The anode and cathode contain catalysts that cause the these vehicles work indoors where emissions must be con-
fuel to undergo oxidation reactions that generate positively trolled and instead use electric forklifts. Fuel-cell-powered
charged hydrogen ions and electrons. The hydrogen ions forklifts can provide benefits over battery-powered forklifts
are drawn through the electrolyte after the reaction. At the as they can work for a full eight-hour shift on a single tank
same time, electrons are drawn from the anode to the cath- of hydrogen and can be refueled in three minutes. Fu-
ode through an external circuit, producing direct current el-cell-powered forklifts can be used in refrigerated ware-
electricity. At the cathode, hydrogen ions, electrons, and houses, because lower temperatures do not degrade their
oxygen react to form water. performance.
Individual fuel cells produce relatively small electrical Motorcycles and bicyclesIn 2005, a British manufac-
potentials, about 0.7 V, so cells are stacked, or placed turer of hydrogen-powered fuel cells, Intelligent Energy (IE),
in series, to create sufficient voltage to meet an applica- produced the first working hydrogen-run motorcycle called
tions requirements. Besides electricity, fuel cells produce the ENV (Emission Neutral Vehicle). The motorcycle holds
water, heat, and, depending on the fuel source, very small enough fuel to run for four hours, and to travel 160 km (100
amounts of nitrogen dioxide and other emissions. The mi) in an urban area, at a top speed of 80 km/h (50 mph).
energy efficiency of a fuel cell is generally between 40% to AirplanesBoeing researchers and industry partners
60%, or up to 85% efficient in cogeneration if waste heat is throughout Europe conducted experimental flight tests in
captured for use. The most widely used types are: February 2008 of a manned airplane powered only by a
Proton Exchange Membrane Fuel Cells (PEMFC) fuel cell and lightweight batteries. The fuel-cell demon-
Solid Oxide Fuel Cells (SOFC) strator airplane, as it was called, used a (PEM) fuel-cell/
lithium-ion battery hybrid system to power an electric motor,
Fuel-Cell Applications which was coupled to a conventional propeller. In 2003, the
AutomobilesAs of 2015, two fuel-cell vehicles have worlds first propeller-driven airplane to be powered entirely
by a fuel cell was flown. The fuel cell was a stack design A typical fuel cell produces a voltage from 0.6 V to 0.7 V at
that allowed it to be integrated with the planes aerodynam- full-rated load. Voltage decreases as current increases, due
ic surfaces. to several factors:
UAVsA Horizon fuel-cell UAV set the record distance Activation loss.
flown for a small UAV in 2007. The military is interested Ohmic loss (voltage drop due to resistance of the cell
in this application because of its low noise, low thermal components and interconnections).
signature, and ability to attain high altitude. In 2009, the Mass transport loss (depletion of reactants at catalyst
Naval Research Laboratorys (NRLs) Ion Tiger utilized a sites under high loads, causing rapid loss of voltage).
hydrogen-powered fuel cell and flew for 23 hours and 17 To deliver the desired amount of energy, the fuel cells
minutes. Fuel cells are also in use to provide auxiliary pow- can be combined in series to yield higher voltage, and in
er in aircraft, replacing fossil-fuel genera- parallel to allow a higher current to be
tors that were previously used to start the PEM Fuel Cell supplied. Such a design is called a fu-
engines and power on-board electrical Electrical Current el-cell stack. The cell surface area can
needs. Excess e- e- Water and also be increased, to allow higher current
BoatsThe HYDRA fuel-cell boat used Fuel Heat Out from each cell. Within the stack, reactant
an AFC system with 6.5 kW net output. e- gases must be distributed uniformly over
Iceland committed to converting its vast e- each of the cells to maximize the power
H+
fishing fleet to use fuel cells to provide H2O output.
auxiliary power and, eventually, to provide H+
primary power in its boats. Amsterdam H2 H+ Proton Exchange Membrane Fuel
recently introduced its first fuel-cell-pow- O2 Cells (PEMFCs)
H+
ered boat that ferries people around the In the archetypical hydrogen-oxide
citys canals. proton-exchange membrane fuel-cell de-
SubmarinesGerman and Italian sign, a proton-conducting polymer mem-
submarines use fuel cells to remain brane contains the electrolyte solution
Fuel In Air In
submerged for weeks without the need that separates the anode and cathode
Anode Cathode
to surface. The U212A is a non-nuclear Electrolyte
sides (Fig. 22-1).
submarine developed by German naval On the anode side, hydrogen diffus-
shipyard Howaldtswerke Deutsche Werft. 22-1. Proton exchange es to the anode catalyst where it later
The system consists of nine PEM fuel cells, membrane fuel cell dissociates into protons and electrons.
providing between 30 kW and 50 kW each. These protons often react with oxidants,
The ship is silent, giving it an advantage in the detection of causing them to become what are commonly referred to
other submarines. as multi-facilitated proton membranes. The protons are
Portable Power SystemsFuel cells can be used in conducted through the membrane to the cathode, but the
the leisure sector (i.e., RVs, cabins, marine), the industrial electrons are forced to travel in an external circuit (supply-
sector (i.e., power for remote locations including gas/oil ing power) because the membrane is electrically insulating.
wellsites, communication towers, security, weather sta- On the cathode catalyst, oxygen molecules react with the
tions), and in the military sector. SFC Energy is a German electrons (which have traveled through the external circuit)
manufacturer of direct methanol fuel cells for a variety of and protons to form water.
portable power systems. Ensol Systems Inc. is an integrator The materials used for different parts of the fuel cells
of portable power systems, using the SFC Energy DMFC. differ by type. The bipolar plates may be made of different
The most important design features in a fuel cell are types of materials, such as, metal, coated metal, graphite,
The electrolyte substance. The electrolyte substance flexible graphite, CC composite, carbonpolymer com-
usually defines the type of fuel cell. posites, etc. The membrane electrode assembly (MEA) is
The fuel that is used. The most common fuel is hydrogen. referred as the heart of the PEMFC and is usually made of a
The anode catalyst breaks down the fuel into electrons proton exchange membrane sandwiched between two cat-
and ions. The anode catalyst is usually made up of very alyst-coated carbon papers. Platinum and/or similar type of
fine platinum powder. noble metals are usually used as the catalyst for PEMFC.
The cathode catalyst turns the ions into waste chemicals The electrolyte could be a polymer membrane.
like water or carbon dioxide. The cathode catalyst is
often made up of nickel, but it can also be a nanomateri- Phosphoric Acid Fuel Cell (PAFC)
al-based catalyst. In these cells, phosphoric acid is used as a non-con-
ductive electrolyte to pass positive hydrogen ions from Hydrogen Fuel Oxygen
Solid Oxide
the anode to the cathode. These cells commonly work in Electrolyte
temperatures of 150C o 200C. This high temperature will Porous Anode Porous Cathode
Fuel Oxidation at Anode Oxygen Reduction
cause heat and energy loss if the heat is not removed and H2 + O2 2e g H2O
4 O2 Ions
O + 2e g O2
used properly. This heat can be used to produce steam for
air-conditioning systems or any other thermal energy-con- 500-1500C
suming system. Using this heat in cogeneration can en- Interconnect
Wires
hance the efficiency of phosphoric acid fuel cells from 40%
to 50% up to about 80%. Phosphoric acid, the electrolyte Electrons Electrons
used in PAFCs, is a non-conductive liquid acid that forces 22-2. Solid oxide fuel cell.
electrons to travel from anode to cathode through an ex-
ternal electrical circuit. Since the hydrogen ion production this carbon coking issue at the University of Pennsylvania
rate on the anode is small, platinum is used as a catalyst to has shown that the use of copper-based cermet (heat-re-
increase this ionization rate. A key disadvantage of these sistant materials made of ceramic and metal) can reduce
cells is the use of an acidic electrolyte. This increases the coking and the loss of performance. Another disadvantage
corrosion or oxidation of components exposed to phos- of SOFC systems is slow startup time, making SOFCs less
phoric acid. useful for mobile applications. Despite these disadvantag-
es, a high operating temperature provides an advantage by
Solid Oxide Fuel Cells removing the need for a precious metal catalyst like plati-
Solid oxide fuel cells (SOFCs) use a solid material, most num, thereby reducing cost. Additionally, waste heat from
commonly a ceramic material called yttria-stabilized zirco- SOFC systems may be captured and reused, increasing
nia (YSZ), as the electrolyte (Fig. 22-2). Because SOFCs the theoretical overall efficiency to as high as 80% to 85%.
are made entirely of solid materials, they are not limited The high operating temperature is largely due to the
to the flat-plane configuration of other types of fuel cells physical properties of the YSZ electrolyte. As temperature
and are often designed as rolled tubes. They require high decreases, so does the ionic conductivity of YSZ. There-
operating temperatures (800C-1,000C) and can be run on fore, to obtain optimum performance of the fuel cell, a high
a variety of fuels including natural gas. operating temperature is required. According to its website,
SOFCs are unique in that negatively charged oxygen Ceres Power, a UK-based SOFC fuel-cell manufacturer, has
ions travel from the cathode (positive side of the fuel cell) to developed a method of reducing the operating temperature
the anode (negative side of the fuel cell) instead of posi- of their SOFC system to 500C to 600C. They replaced the
tively charged hydrogen ions traveling from the anode to commonly used YSZ electrolyte with a CGO (cerium gado-
the cathode, as is the case in all other types of fuel cells. linium oxide) electrolyte. The lower operating temperature
Oxygen gas is fed through the cathode, where it absorbs allows Ceres Power to use stainless steel instead of ceram-
electrons to create oxygen ions. The oxygen ions then ic as the cell substrate, which reduces cost and startup
travel through the electrolyte to react with hydrogen gas at time of the system.
the anode. The reaction at the anode produces electricity
and water as byproducts. Carbon dioxide may also be a Theoretical Maximum Efficiency
byproduct depending on the fuel, but the carbon emissions The energy efficiency of a system or device that con-
from an SOFC system are less than those from a fossil-fuel verts energy is measured by the ratio of the amount of
combustion plant. useful energy put out by the system (output energy) to
SOFC systems can run on fuels other than pure hy- the total amount of energy that is put in (input energy) or
drogen gas. However, since hydrogen is necessary for by useful output energy as a percentage of the total input
the reactions listed above, the fuel selected must contain energy. In the case of fuel cells, useful output energy is
hydrogen atoms. For the fuel cell to operate, the fuel must measured in electrical energy produced by the system.
be converted into pure hydrogen gas. SOFCs are capable Input energy is the energy stored in the fuel. According
of internally reforming light hydrocarbons such as methane to the U.S. Department of Energy, fuel cells are generally
(natural gas), propane, and butane. These fuel cells are at between 40% to 60% energy-efficient. This is higher than
an early stage of development. some other systems for energy generation. For example,
Challenges exist in SOFC systems due to their high the typical internal combustion engine of a car is about
operating temperatures. One such challenge is the poten- 25% energy-efficient. In combined heat and power (CHP)
tial for carbon dust to build up on the anode, which slows systems, the heat produced by the fuel cell is captured and
down the internal reforming process. Research to address put to use, increasing the efficiency of the system to up to
FCgen-1020ACS
Ballard Power Systems offers an air-cooled, scalable
proton exchange membrane fuel-cell stack suitable for
a wide range of light-duty applications where durability, 22-5. Delphis two stack sizes can be implemented into
reliability, and a simplified balance of plant are key require- a stationary or transportation application. Compared
ments. to conventional technology, they provide increased
The FCgen-1020ACS fuel cell (Fig. 22-4) has been engi- efficiency and reliability while decreasing emissions.
the fuel cell can achieve higher efficiency than internal Related Articles
combustion engines and other conventional power sourc- 1. Sam Davis, Book Review: High Temperature Solid Oxide Fuel
es. Additional benefits to the fuel-cell technology are the Cells for the 21st Century (2nd Edition), powerelectronics.com,
reduction in operating noise and a low level of emissions. January 2016.
Among other benefits: 2. Peter Podesser, Fuel-Cell/Battery Hybrid is a Leaner Portable
High quality, reliable power: Power Solution, powerelectronics.com, October 2009.
Delphi Gen 4 Stack produces up to 9 kW 3. Sam Davis, Getting Fuel-Cells from Concept Cars to
Delphi Gen 3 Stack produces 1.5 kW Showrooms, powerelectronics.com, March 2014.
Optimum cell sizes (active area) for a range of packaging 4. Sam Davis, Potential Future of Electricity Generation,
requirements powerelectronics.com, September 2013.
403}cm3 with the Delphi Gen 4 Stack 5. Mark Valentine, PEM Fuel Cells Emerge from Niche Markets,
105cm3 with the Delphi Gen 3 Stack powerelectronics.com, May 2006.
Power density at 500mW/cm2 6. Jonathan W. Kimball, Power Converters for Micro Fuel Cells,
Stable cell performance powerelectronics.com, October 2004.
Equivalent of 40,000 hours of operation 7. Gregg Makuch, Micro Fuel Cells Strive for Commercialization,
Delphi has produced more than 30,000 fuel cells powerelectronics.com, February 2004.
Thermal Cycle Capability is >200 8. Ashok Bindra, Can Micro Fuel Cells Supplant Batteries?,
High mechanical robustness, achieving the equivalent of powerelectronics.com, October 2003.
3 million miles in a vibration test schedule.
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CHAPTER 23:
POWER MANAGEMENT OF
TRANSPORTATION
SYSTEMS
P
ower management plays a vital role in transpor- devices, although GaN has the additional penalty of higher
tation systems that travel on land, air, and sea. cost. For low voltage, below 200V, obviously a MOSFET is
Regardless of the particular application or tech- straightforward to use. For high voltage, there is a choice:
nology, power management regulates, controls, MOSFETs, IGBTs, bipolar transistors, or a combination
and distributes power throughout that system. thereof.
Land transportation includes the automotive During the last 15 years the EMI requirements for elec-
industry, whose requirements are specific and different tronic units for automotive applications has become more
from most industrial and commercial applications. Some of stringent, from CISPR25 class 2 to class 4. The main reason
these power-management requirements are similar to the is the demand for compatibility. A contemporary vehicle
general requirements for power supplies, whereas some has many electronics units on board and the tendency
are exclusive to the automotive industry: reverse polarity is for these numbers to grow. Each unit needs to operate
protection, load dump, alternator overvoltage, peak current, without interfering with other units on the vehicle. The next
water resistance, and vibration. The main issues for elec- point about EMI is the slew rate of voltage. This slew rate
tronic equipment in the automotive industry are: shouldnt be higher than 2500V/S, and its better when it is
Cost 1500V/S or less. In this case, EMI will be reduced, reliabil-
Reliability ity will be increased, and the cost of the EMI filter itself and
Electromagnetic compatibility (EMC). shielding will be reduced.
The requirements for the automotive industry are much Troubleshooting is included in the cost of the product.
closer to military requirements, but the cost must be signifi- If the product is more reliable, it results in a cost reduction
cantly lower. List 23-1 lists the main requirement and condi- of the product for the customer. In the automotive industry,
tions of electronic equipment for the automotive industry. this requirement is much stronger because of the price of
troubleshooting is much higher than in the industrial and
Semiconductors commercial markets. Thats why more reliable design is
At the heart of an automotive power converter are the preferable.
power semiconductors. Clearly, the main types of pow- List 23-1. Requirements and Conditions for Automotive
er semiconductors used in the automotive industry are Electronic Equipment
MOSFETs, IGBTs, and bipolar transistors. For automotive 1. Sources: battery and alternator
applications, it is preferable to use semiconductors with a 2. Load dump overvoltage from alternator
gate threshold voltage of 2-4V or higher. With a lower gate 3. Reverse polarity protection
threshold, semiconductor reliability will be reduced or the 4. Jump-start stresses
cost of the gate drive will increase significantly. Consider 5. High efficiency under light load and low consumption at
semiconductors with logic level threshold or GaN type idle and key off
are needed for the HB-SIB. motors, each of which is powered by 21 kWh (300 V)
A thin fluorine copolymer film protects the solar cells. lithium-polymer batteries, providing 7.5kW (10 HP) for
These cells are brittle and have no mechanical resistance, twin-bladed propellers. Batteries associated with each of
but when covered with this film, they can be molded into the four motors are housed in gondolas under the wing. The
the wing curvature without breaking. The resin is UV-resis- gondola also includes a power-management subsystem
tant, waterproof, and only 17 microns thin. that controls charge/discharge and temperature. Thermal
insulation conserves the heat radiated by the batteries to
Batteries keep them functioning at very low temperatures encoun-
Solar panels charge the batteries many times during a tered at high altitudes. Each motor is fitted with a reducer
typical long flight. Because they are part of the airframe, that limits propeller rotation to a 3.5 meter diameter within
their weight is critical. Plus, their efficiency and lifespan the range of 200 to 4,000 rpm.
impact the success of the mission. A set of unique batter- Over an ideal 24-hour cycle, HB-SIA motors delivered a
ies will be employed in the HB-SIB. Made by the Korean combined average of about 8 HP (6 kW). Thats roughly the
producer Kokam, they required extensive research to push power used by the Wright Brothers aircraft in 1903. The HB-
their performance limits. The key lies in the complex chemi- SIB will employ more powerful motors and batteries.
cal formula that has improved that batterys oxidation issue,
because they age faster and lose efficiency when oxidized. Flight Instruments
This technology is two years ahead of the industry, but it is The cockpits electronic instruments have three main
the most that can be disclosed at this time. Ameliorating functions:
this usual aging process allows Solar Impulse to have bat- Monitor the power supplied by solar panels to the motors
teries able to guarantee 2,000 flight hours for the HB-SIB, and batteries.
compared with only 500 for the HB-SIA. Energy density of Communicate to the pilot the necessary information for
the HB-SIA batteries is 260kW/kg (348 HP). controlling the airplane.
Each of the battery cells is a little different from the other. Provide real-time information to the mission team that is
These cells do not like stress, and extremely hot or cold monitoring the aircrafts flight path and behavior from the
temperatures impact their performance. Some days a cell ground.
is more efficient than others because of certain parameters A revolutionary new instrument was developed for the
that were applied the day before. Lithium-polymer can be HB-SIA with collaboration from Omega and Claude Nicol-
charged up to 4.35V, but that doesnt necessarily mean that lier, who heads the Solar Impulse test flight team. Its prima-
on Friday it will exploit its full potential as it did on Thursday. ry function is to inform the pilot within an accuracy of one
Battery output voltage depends on the temperature condi- degree, the bank angle of the aircraft (the turn or change of
tions as well as the type of charge and discharge. direction when it banks or inclines) must be below five de-
To ensure that lithium-polymer cells are fit for the aircraft, grees. For this reason, the Omega instrument is connected
they must undergo numerous tests. These tests check the to gyroscopes that are used to provide stability or maintain
cells behavior in extreme temperatures, how much energy a fixed orientation.
they can store, and for how long. Tests are also done for a Another key function of the Omega instrument is to
better understanding of their reaction to different situations. inform the pilot of his real flight direction. This is important
The challenge is to find the optimum balance between us- because the HB-SIAs huge wingspan, combined with light-
able lifespan and energy, which depends on temperature, ness, makes it very sensitive to air movements, especially
cell voltage, and current. For example, it was found that crosswinds, which can cause it to drift. LEDs on the front
keeping a constant temperature of 25C inside the motor panel indicate the flight direction to one degree. This also
gondolas provides the ideal environment for optimized helps align the aircraft in the axis of the runway for landing.
battery efficiency. On-board electronics have been optimized to combine
Solar Impulse uses Etel torque motors. Torque motor lightness and maximum efficiency. In flight, the electronic
quality operating in extreme environmental conditions is an systems undergo significant temperature variations be-
important characteristic. Performance must be maintained tween low and high altitudes; this must not affect their per-
optimal and constant during non-stop flights for many formance. Therefore, prototype circuits and devices have
hours. In addition, motor efficiency must be high to max- been destruction-tested with the test results used directly in
imize use of precious solar/battery energy. These motors the manufacturing process of the final systems.
can reach efficiencies of 96%, and they weigh less than Due to the repair work to the aircrafts main spar, Solar
other types of motors. Impulse 2s circumnavigation of the earth was delayed from
The power plant for the HB-SIA consists of four torque 2012 to 2015. The aircraft was delivered to Masdar in Abu
flight from Japan to Hawaii on June 28, 2015 (June 29, Ja-
pan local time). With Borschberg in the cockpit, it reached
Hawaii on July 3, setting new records for the worlds longest
solar-powered flight both by time (117 hours, 52 minutes)
and distance (7,212 km; 4,481 mi). The flights duration was
also a record for longest solo flight, by time, for any aircraft.
During that leg, however, the planes batteries were dam-
aged by overheating caused by being packed in too much
insulation. New parts had to be ordered, and as it was late
in the season, the plane was grounded in Hawaii, and the
U.S. Department of Transportation is storing the aircraft in a
hangar at Kalaeloa Airport on Oahu.
New batteries have been made and were installed in
the plane in the early weeks of 2016. Test flights began in
23-4. Elektra One has a maximum power of16-20 kW, February, and the circumnavigation resumed in April 2016,
and range is more than 400 km (249 miles) with a flight when northern hemisphere days lengthen enough to permit
time of up to more than three hours. multi-day solar-powered flights.
Dhabi for the World Future Energy Summit in late January Electric Aircraft
2015, and it began the journey on March 9, 2015. It was For several years, all-electric power assisted gliders and
scheduled to return to the same location in August 2016. A hang gliders have been available. Advantages of elec-
mission-control center for the circumnavigation was estab- tric aircraft include improved maneuverability due to the
lished in Monaco, utilizing satellite links to gather real-time greater torque from electric motors, increased safety due to
flight telemetry and remain in constant contact with the decreased chance of mechanical failure, less risk of explo-
aircraft and the support team. sion or fire in the event of a collision, and less noise. There
The route being followed by Solar Impulse 2 is entirely will be environmental and cost benefits associated with
in the northern hemisphere; its closest approach to the the elimination of consumption of fossil fuels and resultant
equator was expected to be a flyby of Honolulu at 21.3 N. emissions.
Twelve stops were originally planned to allow the alternation Electric aircraft are available from several sources
and rest periods of pilots Borschberg and Piccard, and to worldwide. As with on-road vehicles, the major problem
ensure good weather conditions for each take-off and land- with electric aircraft is rangethe best of both being 160
ing site along the route. For most of its time airborne, Solar to 400 km (about 100 to 250 miles) in a practical manned
Impulse 2 has been cruising at a ground speed of between configuration. Following are descriptions of these aircraft.
50 and 100 kilometers per hourusually at the slower end The battery and solar-panel powered Elektra One (Fig.
of that range at night to save 23-4) is built of lightweight fiber
power. The legs of the flight composite structures. Maximum
crossing the Pacific and Atlantic power is 16-20 kW, and range
oceans are the longest stages of is more than 400 km (249 miles)
the circumnavigation, and were with a flight time of up to more
each expected to take about five than three hours. Its wingspan
days. On multi-day flights, the is 8.6m, and it can carry up to a
pilots take 20-minute naps and 90kg payload.
use Yoga or other exercises to Cri-Cri (Fig. 23-5) uses
promote blood flow and maintain composite materials instead of
alertness. metal to reduce overall weight
By the end of May 2015, and make room for the high-en-
the plane had traversed Asia. 23-5. Cri-Cri uses composite materials instead of ergy-density lithium batteries that
It made an unscheduled stop in metal to reduce overall weight and make room provide power to four brushless
Japan to await favorable weather for the high-energy-density lithium batteries that electric motorstwo mounted
over the Pacific, increasing the ex- provide power to four brushless electric motors back-to-back on nose pods on
pected number of legs of the jour- two mounted back-to-back on nose pods on each sidewith counter-rotating
ney to 13. The aircraft began the each sidewith counter-rotating propellers. propellers. Projected perfor-
autonomous navigation.
significant is the application of these concepts in a fully decreasing lifecycle operations and support costs.
electrically integrated (no mechanical takeoffs for power) DDG 1000 will employ active and passive sensors and
power system on a surface combatant. These ships have a Multi-Function Radar (MFR) capable of conducting area
higher speed and lower noise requirements than any of the air surveillance, including over-land, throughout the ex-
other ships, as well as large combat systems to support. tremely difficult and cluttered sea-land interface.
Commercial cruise ships would be too big and too noisy for
a surface combatant, and do not have a power-system ar- Related Articles
chitecture to let them survive damage and continue to fight. 1. Peter Harrop, 21st Century Technology Propels Electric Aircraft
into the Blue Yonder, powerelectronics.com, October 2010.
Training Required 2. Don Tuite, Understanding U.S. and European Standards for
The new crew trained on components including main Electric-Vehicle Charging, electronicdesign.com, March 2012.
and auxiliary turbine generators, propulsion motors and 3. Solar-Powered Ship Travels the World, powerelectronics.com,
drives, dynamic braking resistors, auxiliary control pan- May 2013.
els, and high-voltage switchboards. They also spent time 4. Sam Davis, Powered by the Sun, Solar Impulse Takes Flight,
working with harmonic filters, neutral ground resistors, the powerelectronics.com, August 2013.
Integrated Fight-Through Power System (IFTP), power con- 5. Sam Davis, Volvo Car Group Embeds Batteries, Supercaps in
version modules, and an emergency diesel generator. Carbon Fiber Body, powerelectronics.com, October 2013.
Equipment operation was conducted at the local control 6. Sam Davis, Getting Fuel-Cells from Concept Cars to
level, as well as the remote supervisory Engineering Control Showrooms, machinedesign.com, March 2014.
System (ECS). The ECS system provides a significant ad- 7. Alexander Isurin, Philosophy of Topology and Components
vancement in machinery control with automation for system Selection for Cost and Performance in Automotive Converters.,
transitions and power management to support the reduced powerelectronics.com, September 2014.
manning concept for the DDG 1000. 8. Sam Davis, Tesla Updates its Roadster to Achieve 400 Mile
DDG 1000s power allocation flexibility allows for poten- Range on a Single Charge, powerelectronics.com, January 2015.
tially significant energy savings and is well-suited to enable 9. Sam Davis, U.S. Navys DDG 1000, Incorporating an Integrated
future high-energy weapons and sensors. Power System, Will Make Waves, powerelectronics.com, December
Its wave-piercing Tumblehome ship design has provid- 2015.
ed a wide array of advancements. The composite super- 10. Sam Davis, Sit Back and Enjoy the Ride . . . to Work,
structure significantly reduces cross-section and acoustic powerelectronics.com, January 2016.
output, making the ship harder to detect by enemies at sea.
The design also allows for optimal manning with a standard BACK TO TABLE OF CONTENTS
crew size of 158 sailors (including air detachment), thereby
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CHAPTER 24:
POWER-MANAGEMENT
TEST AND
MEASUREMENT
P
ower management involves test and measure- can multiply the RMS voltage and RMS current to get real
ment in three different levels: power.
System Apparent Power equals the product of the RMS voltage
Subsystem and RMS current.
Component Apparent Power= VRMS Y= IRMS
At the system level, there are ac and dc pow- Reactive Power is the vector difference between Appar-
er analyzers. At the subsystem level, a considerable amount ent Power and Real Power and is measured in Volt-Amperes
of test and measurement systems can ensure a power (VA). This is correct for sinusoidal waveforms.
supply is working properly. Testing at the component level Power Factor for sinusoidal voltage and current wave-
mostly involves the power semiconductors employed in the forms is the cosine of the phase angle () between the
system. voltage and current waveforms.
Power Factor = Real Power/Apparent Power
AC Power Glossary Harmonic Distortion on an ac powerline is a non-sinusoi-
RMS (Root mean squared value) is the most commonly dal current waveform that consists of a fundamental com-
used and useful means of specifying the value of both ac ponent at the supply frequency plus a series of harmonic
voltage and current. The RMS value of an ac waveform frequencies that are integral multiples of the fundamental
indicates the level of power that is available from that wave- frequency (Fourier Analysis).
form, which is one of the most important attributes of any ac Total Harmonic Distortion (THD) is a figure of merit that
source. quantifies the level of harmonics in non-sinusoidal ac volt-
RMS value = Peak Value/2 age or current waveforms.
Crest Factor is the relationship between peak and RMS.
Crest Factor = Peak Value/RMS Value System: AC and DC Power Analyzers
For a sinusoid: Crest factor = 2 Power analyzers accurately measure electrical power
Because the output current of a switch-mode power sup- characteristics of devices that generate, convert, or con-
ply is not sinusoidal, the crest factor of the current waveform sume electricity. There are now two types of power ana-
can be much greater than 2 lyzers: ac and dc. A dc power analyzer allows engineers
Average Value can only have real meaning over one half to gather and configure multiple instruments to complete
cycle of a symmetrical waveform. dc sourcing and measurement tasks. AC power analyzers
Average Value= Area enclosed by one half cycle/ provide precise measurements of true power (watts), power
Length of base over one half cycle factor, harmonics and efficiency in power-conversion equip-
Real Power is the power available to the load to do real ment. Reliable ac power analyzers enable engineers to
work and is given in Watts. With a pure resistive load, you minimize energy loss due to distorted, transient waveforms
junction MOSFET.
1.5 QG also provides other useful information to help with
switching operation analysis. For example, when a circuit
does not meeting performance expectations, examining the
1.0
QG curve can offer valuable insights that identify the source
of the problem.
0.5 Because QG varies with the output voltage and current,
60 40 20 0 20 40 60 80 100 120 140 160 180 it should be evaluated under in-circuit bias conditions.
TJ, Junction Temperature (C) The QG characteristics shown on a device data sheet only
24-9. Variation of on-resistance (RDS(ON)) vs. temperature provides an approximation of the value of QG during actual
presented on a Keysight B1506A. circuit operation. Therefore, a designer must be able to ac-
24-10. VGS (gate-source voltage) of a super junction 24-11. CISS, COSS, and CRSS vs. drain voltage presented
MOSFET that indicates QG presented on a Keysight on a Keysight B1506A.
B1506A.
curately evaluate QG for both low voltage and high voltage capacitances at the moment it turns on. Therefore, under-
power devices. standing how device capacitance changes with applied
Besides driving loss, the designer may want to calcu- voltage is very important for designers. Knowing the true
late conduction loss and switching loss. The QG curve value of device capacitance at a specific voltage and the
can also be interpreted as a representation of the non-lin- calculated voltage the device will experience in a circuit
earity of a power devices stray capacitances. This makes allows selection of a power MOSFET with the lowest loss.
it possible to calculate switching parameters and switch- To produce reliable capacitance measurements, the power
ing loss using known equations that combine the gate MOSFET capacitance measurement needs to be performed
resistance, the resistance in series to the gate, and the at relatively high frequencies.
switching frequency. The test instrument should have the Gate resistance is an important parameter for circuit
ability to accurately measure on-resistance, RDS(ON), and designers because it influences device operation speed
peak current, and also calculate conduction loss. These and switching loss. The tester should be able to measure
calculations should be performed automatically by the test the device gate resis-tance (RG) when it performs a capaci-
instrument for a given frequency. tance measurement, which eliminates the need for addition-
Understanding the input, output, and reverse return al complicated data analysis.
capacitances of three terminal devices (such as MOSFETs Circuit simulators such as SPICE are an essential tool
or IGBTs) is important, because these parameters dictate for designers. Accurately simulating the performance of a
the switching speed and the switching loss when operating circuit can result in significant cost savings through reduced
at high frequency. However, accurately measuring these development cycles and prototyping. Therefore, it would be
parameters is not easy or straightforward. To make an accu- helpful if the test instrument can precisely model CRSS, CISS
rate measurement, the capacitance between two terminals and RG. These device parameters are essential for accurate
of a three terminal device, the other terminal needs to be power circuit simulations.
appropriately configured. Tektronix/Keithleys 2600-PCT-xB is intended for charac-
It would be helpful if the test instrument automatically terization of MOSFETS, IGBTs, diodes, and other high-power
and accurately measures FET capacitance values (CISS, devices (Fig. 24-12). This instrument provides device-level
COSS, CRSS). This involves using all the resistors, capacitors, characterization that includes breakdown voltage, on-state
and protection circuits necessary to make high-voltage current, and capacitance measurements. This high-power
capacitance measurements. Fig. 24-11 shows a typical Parametric Curve Trace supports the full spectrum of device
presentation of these capacitance values. types and test parameters. This Parametric Curve Trace
An applied dc voltage causes a power MOSFETs de- configurations include everything necessary for the char-
pletion region to modulate, which in turn causes the junction acterization engineer to develop a complete test system
capacitance to vary with voltage. The drain or collector quickly. ACS Basic Edition software provides complete
terminal of a power MOSFET is often exposed to high volt- device characterization, including both real-time trace mode
ages when it is off, which determines the value of its junction for quickly checking fundamental device parameters like
breakdown voltage and full parametric mode for extracting and a full suite of other devices such as BJTs and diodes.
precise device parameters. ACS Basic Edition goes beyond Users have complete control to develop their own test algo-
traditional curve tracer interfaces by offering a broad array rithms in ACS Basic Edition.
of sample libraries. Users have complete control of all test
resources, allowing the creation of more advanced tests Testing Wide-Bandgap Devices
than previously possible on a curve tracer. Among the new characterizing challenges for these new
The measurement channels consist of Tektronix/ power devices is testing at both low and high current levels.
Keithleys SourceMeter Source Measure Unit (SMU) Instru- It may be necessary to use special test cables to provide
ments and an optional Multi-frequency capacitance-voltage sufficient noise immunity at the low currents. In addition,
(C-V) meter. The dynamic range and accuracy of these the existing gallium nitride (GaN) and silicon carbide (SiC)
instruments is orders of magnitude beyond what a tradition-semiconductors will require unique test fixtures because
al curve tracer could offer. they are housed in different packages. Another complica-
To achieve this performance, there is a complete set oftion is that some GaN are depletion-mode devices that are
precision cables to connect the instrumentation to either normally on so they include an integrated driver circuit to
Tektronix/Keithleys Model 8010 High Power Device Test Fix-keep the device off. In contrast, EPCs GaN is enhancement
ture for package part testing, or the Model 8020 High Powermode that is normally off so it doesnt need an integrated
Interface Panel for wafer-level testing. For the high-voltage
driver. Crees SiC devices would need an entirely different
channel, custom triax cables provide a guarded pathway type of test fixture.
that enables fast settling and very low currents, even at GaN and SiC power semiconductors need unique test
the full 3kV. For the high-current channel, special low-in-equipment to accommodate them. SiC and GaN have
ductance cables provide fast rise-time pulses to minimize higher power density, smaller size, better high-tempera-
self-heating effects. ture performance, higher frequency response, and lower
High-voltage capacitance-voltage (C-V) testing device ON resistance than their silicon counterparts. Plus, these
capacitance versus dc voltage is becoming more and more devices have lower leakage than silicon, so there is a need
important. For these tests, there is the Model PCT-CVU for sourcing higher test voltages, as well as appropriate low
Multi-frequency capacitance-voltage meter. When com- current-measurement sensitivity. For example, SiC leakages
bined with the optional 200V or 3kV bias tees, capacitance are more than two orders of magnitude lower than similarly
vs. voltage can be measured on two-, three-, or four-terminal
rated silicon devices, so they require current measurements
devices. Capacitances from pF to 100nF can be measured, in the single microamps range.
with test frequencies from 10kHz to 2MHz. ACS Dynamic testing of devices switching kilowatts in micro-
Basic Edition software provides over 60 canned tests for
seconds requires advanced driver circuits and very well de-
C-V including MOSFET Ciss, Coss, Crss, Cgd, Cgs, Cds, signed interconnect and layout of tester electronics as well
as device-under-test sockets and contactors.
Safe and reliable results requires tight design
for creepage and clearances. Also, very fast,
high power transition times requires attention
to ground noise and EMI.
Voltage and current requirements for
GaN and SiC devices require the handling
of breakdown voltages up to 3000 V or
even higher, more than 100 A, and junction
capacitances for dc biases up to 3000 V.
The tester must be able to withstand high
SiC and GaN voltages and fast switching
speeds. For best results, it is crucial to test
these devices at their specified voltage,
current and power rating.
One test equipment for use with GaN and
SiC transistors is Tektronix/Keithleys Para-
metric Curve Tracer, specifically designed
24-12. Tektronix/Keithleys 2600-PCT-xB is intended for characterization for high voltage and current characterization
of MOSFETS, IGBTs, diodes, and other high-power devices. of high-power semiconductors. To meet the
ments will have significant error because devices at any current level. By contain-
the voltage used to calculate them will ing all of this capability in one instrument,
be higher than the value at the DUT. This DUT precision-measurement power supplies
drop in voltage can also cause prob- Power + greatly decrease test system complexity
lems when testing the device at voltages Supply as well as cost.
near the minimum operating voltage. If Precision-measurement power sup-
the loading of the DMM is too great, the A DMM plies reduce the amount of equipment
voltage seen at the device may be below necessary to make a current measure-
the minimum operating voltage and the ment on a device. In this example, the
device will fail to operate correctly, result- 24-15. Measuring low current on a following equipment is used as illustrated
ing in incorrect measurements. DUT using a power supply with a in Fig 24-16 and 24-17. Test connections
This drop in voltage could be com- precision DMM in series with the are extremely simple as only two test
pensated for by outputting a higher volt- DUT. leads, HI and LO, are required for making
age at the power supply so the desired connections to the DUT. Remote voltage
voltage appears at the DUT. However, the loading of the sensing is not required for accurate voltage measurements
DMM varies with the amount of current flowing, so compen- because the currents are very low, so they wont produce
sation is difficult. A second DMM could be used to measure significant voltage drop in the test leads. Shielded cabling is
the voltage at the device directly, but this not only adds recommended to reduce noise. If the test circuit is ground-
cost and complexity to the test system by introducing yet ed, grounding should be at a single point to avoid measure-
another piece of equipment, it can also create a significant ment error due to ground current loops.
error source for low-current measurements. The DMM adds You can configure a Series 2280S Precision Mea-
additional load to the test circuit, resulting in currents higher surement DC Power Supply to measure the current con-
than those actually flowing through the device. sumption of a precision voltage reference when nothing is
connected to the references output. This quiescent supply
Using a Precision-Measurement Power Supply current of the voltage reference device being measured is
A better way to measure the current is to use a pre- specified in its datasheet at a typical current level of only
cision-measurement power supply. The current through 31A and a 35A maximum level. To make this measure-
a device can be measured with the same precision as a ment, the instrument will be configured for maximum preci-
high-quality 6-digit DMM, but it can be done more simply sion and accuracy.
and more accurately as well. Testing is simplified because To make highly accurate current measurements in the
only a single instrument is required to test the device. low micro-amps range, the Series 2280S Precision Mea-
With only a single instrument, testing can begin sooner surement DC Power Supply must be configured for maxi-
because there is less equipment to set up. Automating the mum precision.
measurement is simpler as well with only one instrument to For accurate current measurements in the low micro-
program. This eliminates the need to synchronize multiple amps range, the Series 2280S Precision Measurement DC
instruments and allows the test engineer to focus on making Power Supply should be configured for maximum precision.
the measurement.
Precision-measurement power supplies are capable of Precision
Measurement
measuring both the current and voltage applied to the de- Power Supply Precision Voltage
vice. Current is measured internally, so it places no loading Reference
on the test circuit like a series DMM would. This results in
the voltage at the device being equal to the programmed A IN
voltage. GND
For even greater accuracy, voltage can be sensed + OUT
directly at the device using remote sense leads placed at
the device terminals, allowing the precision-measurement
power supply to compensate automatically for any volt-
age drops across the test leads that supply current to the
device. These sense leads have very high input impedance,
so they place virtually zero load on the test circuit. Using 24-16. Precision-measurement power supplies reduce
these features, precision-measurement power supplies are the amount of equipment necessary to make a low-
capable of performing very accurate characterization of current measurement on a device.
Use the front panel to configure the instrument from with the Related Articles
following steps: 1. Steve Sandler, A New Technique for Testing Regulator Stability
S et the instrument to 6 digits of resolution. Non-Invasively, powerelectronics.com, September 2011.
T urn Auto Zero On, which will automatically measure an 2. Steve Sandler, Use A Signal Analyzer To Measure Power Supply,
internal reference to zero the instrument for each triggered Regulator, and Reference Noise, powerelectronics.com, August
measurement, resulting in measurements with greater 2012.
accuracy. 3. Steve Sandler, Making Accurate Ripple Measurements,
S et the NPLC value to 15 (12 for 50Hz power systems), powerelectronics.com, September 2012.
the maximum measurement aperture time. This increases 4. Faride Akretch, Power Analysis of PWM Motor Drives,
both measurement resolution and accuracy. powerelectronics.com, July 2013.
T urn the averaging filter on, so the instrument will return 5. Sam Davis, Testing GaN and SiC Devices: FAQs,
readings that are the average of several measurements. powerelectronics.com, October 2013.
Averaging measurements causes the readings to be more 6. Steve Sandler, Software Enables Accurate Stability Test,
stable, enabling greater precision. Improves Non-Invasive Phase Margin Measurement Accuracy,
T urn the Filter State on and set the filter count to 10. Filter powerelectronics.com, April 2014.
count can be increased all the way up to 100 for even 7. Sam Davis, Comprehensive Power Semiconductor Testing Will
more stable readings. Ensure Optimal Device Selection, powerelectronics.com, May 2014.
S et the Sample Count to 10 to match the filter count, which 8. Sam Davis, Power Analyzer Optimizes Power Conversion System
will fill the averaging filter with 10 back-to-back readings Designs, powerelectronics.com, February 2015.
with very little time between readings. 9. Henry Santana, Electronic Load Achieves 0 Ohms,
F or low-current measurements, it is necessary to allow powerelectronics.com, April 2012.
time for currents in the test system to settle to their final 10. Lee Stauffer, Test Equipment Must Keep Pace with New High
values before making measurements in order to obtain Power Semiconductor Developments, powerelectronics.com, June
accurate results. By setting a source delay, measurements 2012.
can be delayed long enough for the currents to settle. 11. White Paper, The Fundamentals of Three-Phase Power
S et the Source Delay long enough to give the current time Measurements, powerelectronics.com, April, 2014.
to settle. Although 10ms is adequate for most microamp
level measurements, a longer source delay may be BACK TO TABLE OF CONTENTS
necessary if the DUT has a lot of input capacitance or
there is an external filter capacitor on the fixture.
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CHAPTER 25:
DATA-CENTER
POWER MANAGEMENT
Bob Conner ICT Energy Consumption
CEO and Co-Founder, Sarda Technologies According to one study, ICT systems in 2012 consumed
www.sardatech.com 920 terawatt-hours of power, which is 4.7% of global elec-
tricity consumption. That power requires the equivalent of
Why More-Than-Moore Power Management Is 300 coal plants and emits 2 trillion pounds of CO2-equiva-
Required to Keep Up With Exponential Growth in ICT lent greenhouse-gas emissions.
Data Consumption A second study forecasts that improvements in energy
Significant gains in energy efficiency are required to efficiency will slow the growth in ICT electricity consumption
keep up with the exponential growth in the data consump- from the historical 6.7% per year to 3.8% per year due to the
tion of Information and Communications Technology (ICT) following:
systems: end-user devices, networks, and data centers. E ach new generation of ICT systems and components is
Moores Law scaling (monolithic integration in silicon) is the more energy[efficient. For example, improvements in op-
historical technology driver, but it no longer achieves the tical components enable an order-of-magnitude increase
required gains. Fortunately, a new power-management tech- in data rates of optical modules within roughly the same
nology has emerged. It achieves More-than-Moore scaling power envelope.
by integrating different components and materials to in- U sage is shifting from energy-intensive TVs and con-
crease functional diversity and parallelism. This technology ventional desktop PCs to energy-efficient smartphones,
can improve voltage regulator power density, response time ultrathin notebooks, tablets, and fanless all-in-one desktop
and granularity by an order-of-magnitude to reduce the ICT PCs. In 2011, the average annual electricity consumption
system energy consumption by 30% or more. This paper was just 5.5 kilowatt-hours for smartphones and 16kWh for
explains why a Heterogeneously Integrated Power Stage tablets, compared to 219kWh for PCs.
(HIPS) enables power management scaling to keep up with Increasingly, networks and data centers will be optimized
the rising demands on data centers and network systems. for energy efficiency rather than capacity. One example
of an industry initiative is Greentouch, whose mission is to
Exponential Growth in Data Consumption deliver the architecture, specifications, and roadmap to
The digital universethe data we create and copy annu- increase network energy efficiency by 1,000x compared to
allywill grow 10x, from 4.4 zettabytes to 44ZB, from 2013 2010 levels.
to 2020. The forecast for 2020 compared to 2014 expects However, a third study estimates that ICT systems per-
many more Internet users (3.9 billion versus 2.8 billion), more centage of global electricity consumption was 9.3% in 2012
connected devices (24.4 billion versus 14.2 billion), faster and will grow in 2017 to 9.2%, 11.7%, or 15.6% according
average broadband speeds (42.5Mbps versus 20.3Mbps) to three different growth scenarios, as Fig. 25-1 shows. Da-
and more video streaming (80% versus 67% of traffic). Most ta-center operating costs (OPEX) are beginning to exceed
people will use a tablet or smartphone for all online activi- capital expenditures (CAPEX) in the total cost of owner-
ties by 2018. Mobile data traffic is increasing 10x from 3.3 ship. As applications and data move into the cloud, energy
exabytes per month in 2014 to 30.5EB/month in 2020. Many consumption is shifting from client devices to networks and
websites (e.g., Facebook) require an order of magnitude data-center infrastructure. This shift highlights the need to
more power to build a web page than to deliver it. increase the energy efficiency of data centers and networks.
25-3. HIPS Module has two independent outputs or a 25-5. Comparison of the switching characteristics of
two-phase input. GaAs, GaN, SiC, and Silicon MOSFETs
10,000 500
Sardas Rev2 HIPS Public Cloud
(6m-nC) Networking
4,000 5MHz Storage
2MHz Workstation
Sardas Rev1 HIPS
Power Train Density
2,000
(12m-nC)
mA/mm3
W/in.3
1,000 1MHz 50
1MHz
1 MHz
400
MOSFET Power
200 Stages (30m-nC) High
Performance
Computing
100 5 Enterprise
80% 85% 90% 95% 100%
Power Stage Peak Efficiency
25-7. Comparison of the performance of a typical MOSFET output 25-8. $10.3 Billion Market for Processors
stage and the HIPS, Rev1 and Rev2. The Figure of Merit for Rev2 Used in Data Centers in 2018
HIPS is 6m-nC vs. 30m-nC for a typical MOSFET output stage. (Source: The Linley Group)
These results are for a 12Vin and 1.2Vout power stage.
required to minimize parasitics for the high switching fre- inates reverse recovery loss). GaAs FETs also are more
quency (Fig. 25-6). reliable, because they have no gate oxide, higher activation
An HIPS module is an evolutionary leap over the Driv- energy, higher bandgap, and the primary failure mechanism
er-MOSFET (DrMOS) integrated power stage module. (sinking gates) is self-limiting.
It replaces the MOSFET dies with a GaAs die, reducing The HIPS module can increase the voltage regulator
packaging parasitics and integrating performance-critical switching frequency by 10x or more. Its switching frequency
components in a very small package. GaAs FETs have range of 2 to 5MHz reduces the size of the output capac-
much lower switching-power loss than MOSFETs due to itors and inductors while reducing the transient response
their superior intrinsic material properties: 5x higher electron time. An HIPS can readily be used in industry-standard syn-
mobility (8,500 versus 1,400 cm2/Vs), 5x lower on-resis- chronous buck converters with complementary components
tance x gate charge (FOM), and no body diode (which elim- (PWM controllers and inductors) from third-party suppliers.
No new architectures, materials, or
TABLE 25-1. DETAILED CHARACTERISTICS OF POTENTIAL components are required. A typical
POWER SWITCHES FOR THE HIPS MODULE use for the HIPS is in point-of-load
Parameter Units GaAs FETs GaN-on Vertical GaAs Benefits (POL) converters.
Si FETs MOSFETs HIPS also increases the power
Electron Mobility cm2/Vs 8,500 1,800 1,400 Faster switching density and granularity (provid-
RDS(ON) x QG FOM m-nC 123 20-30 20-60 Lower switching loss ing more than one output) for
FET Switch Speed nS <1 1-2 2-5 board-mounted voltage regulators.
Body Diode No No Yes The HIPS uniquely enables Pack-
Loop Inductance nH ~0.2 ~0.4 1-2
age-Integrated Voltage Regulators
(PIVRs) that integrate many fast,
FET Structure Lateral Lateral Vertical UFET/LFET
monolithic integration small VRs in the processor pack-
Reduced age as close as possible to the
parasitics processor die without increasing its
Multiple phases
cost or heat dissipation.
Bandgap eV 1.4 3.4 1.1 Higher junction HIPS modules enable many
temperature
fast, small VRs that can reduce
Activation Energy eV 2.5 1.1-2.5 0.3-1.2 Higher reliability
the energy consumption of ICT
Gate Oxide? No No Yes systems by 30% or more through
2014 Market Size $6B $0.015B $13B Leverages proven fine-grain power management
manufacturing
of multi-core processors, energy
proportionality and reduced cooling Base Station and, hence, the performance of
requirements. Fig. 25-7 compares ultrathin, fanless all-in-one desk-
the characteristics of a typical power top PCs, notebooks, tablets, and
MOSFET output stage with the first Embedded smartphones within a very challeng-
and second versions of the HIPS. ing thermal envelopea small, thin
Samples of the HIPS were avail- case that must remain cool enough
able in 2016 with full production to touch.
scheduled for 2017. The GaAs industry today makes
Since VR-supplied current scales products for RF and microwave
roughly with processor performance communications. In 2013, the
and price, we can check the pro- FPGAs industry produced 29.3 million
cessor market to estimate the HIPS square inches of GaAs, which is
market size. The market for proces- equivalent to 100,000 GaAs 150mm
sors, application-specific standard Wireless Communications wafers per month. GaAs industry
products (ASSPs), and FPGAs in revenue exceeded $6 billion
data centers and network systems, 25-9. $11.6 Billion Market for Processors, revenue in 2014. Hence, the GaAs
the initial target markets for HIPS, is ASSPs, and FPGAs Used in Voice and industry has ample well-proven,
forecast to grow to $21.9 billion in Data Networks in 2018 (Source: The Linley high-volume manufacturing capacity
2018: Group) for producing HIPS modules.
$ 10.3 billion for server processors,
most of which are used in data centers (Fig. 25-8). Captive Related Articles
processors, such as IBMs Power and Oracles SPARC, are 1. Brian Griffith, PMBusTakes Command of Data Center Power
excluded. Issues, powerelectronics.com, April 2008.
$ 11.6 billion for processors, ASSPs, and FPGAs used in 2. Sam Davis, 380V DC Input Supplies Enable Data Centers to Use
voice and data networks (Fig. 25-9). Communications HVDC Power Distribution, powerelectronics.com, February 2014.
semiconductors include components for Ethernet, broad- 3. Sam Davis, 400VDC Power Distribution for Data Centers
band infrastructure, customer premise equipment, home/ Emerges, powerelectronics.com, October 2014.
access networking, network processors (NPUs), transport 4. EET, Energy-Management Chip Suits Servers and Data Centers,
(Sonet/SDH, OTN), PCI Express, RapidIO, and network EET, March 2011.
search engines. 5. Technologies Under Development to Reduce Datacenters
Assuming its approximately 5% of the processor con- Energy Consumption, powerelectronics.com, October 2015.
tent, the HIPS content for these systems is approximately
$1.1 billion. HIPS modules also improve energy efficiency BACK TO TABLE OF CONTENTS
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