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With the ongoing introduction of renewable energy systems including photovoltaic power generation
systems, whose output tends to vary according to the weather conditions, power generation systems with
high efficiency over a wide output range are required. Power transmission systems must also offer high
efficiency, in order to minimize energy losses while transmitting electricity from widely distributed power
systems to distant power-consuming areas. Furthermore, there is a growing need for energy storage sys-
tems to balance supply and demand. On the other hand, to avoid wastage of precious energy, it is also
important to make greater efforts to enhance energy conservation.
To fulfill these diverse requirements, Toshiba has been continuously engaged in the development
of state-of-the-art power electronics technologies for optimal efficiency of electricity operation in each
process from electricity generation through to transmission, storage, and consumption, aimed at the con-
struction of smart communities.
10
ics equipment is often represented by its
General-purpose inverters
power density, which is defined as the (as researched by JEMA) Prediction for 2017
1 SiC matrix converters
output per unit volume of equipment. (Takahashi model: 48 W/cm3)
Power density therefore increases as the Unit power supplies
Inverters for air conditioners
0.1
volume of equipment is reduced. Figure 1
shows the trends in power density of Packaged power supplies
0.01
power electronics equipment. Since 1970, 1970 1980 1990 2000 2010 2020
four years. This means that the volume * Plotted based on information in the articleTrends in the latest power devices(in Japanese) written
by Hiromichi Ohashi
of equipment has been reduced by half JEMA: THE JAPAN ELECTRICAL MANUFACTURERSASSOCIATION
every four years for the same amount
of output. Power densit y has been Figure 1. Trends in power density for power electronics equipment Power density has been
doubling every four years and is expected to continue to increase at this rate.
increasing at a rate that approaches the
increase in circuit density predicted by
Moores law*1. This trend is expected to of smart communities, the prevalence of an increase in assembly density. Toshiba
continue, driven by changes in the social electric vehicles (EVs), and demand for has been continually developing the tech-
situation such as the accelerating uptake of further reduction in carbon dioxide (CO2) nologies necessary to improve the power
renewable power generation, the building emissions. density of power electronics equipment.
Multiple technologies have sup-
ported the high growth rate of power
(*1) Observation made by G. Moore in density, including a reduction in equip-
Evolution of power devices
1965 that the transistor density in
a semiconductor integrated circuit ment losses, an improvement in cooling The performance of power devices
doubles every 18 to 24 months performance, a rise in heat resistance and contributes most to the reduction of
Evolution of Devices Supporting Power Electronics and Expansion of Technologies for Mounting, Circuits, and Application to Products 3
amount of current, I, is passed. Moreover,
since the new chip has a current density
twice as high as the previous chip, it is
also necessary to double the current-
carrying capacity of on-chip wires.
Therefore, we need a technology for
efficiently dissipating heat that concen-
trates in the chip. We also need a wiring
technology for conducting an electric
current through a small chip without
Diode-clamped topology Neutral-pointed switch topology
a loss. In order to get the best perfor-
mance from a chip, it is also necessary to Figure 2. NPC circuits NPC circuits are broadly classified into two categories. In recent years,
improve the device cooling and assembly the neutral-point switch topology has been finding more use in grid connection inverters.
technologies at the same time.
Toshiba developed an assembly
structure in which both sides of a chip Consequently, electromagnetic noise ers (a) and neutral-point switch inverters
are cooled inside an IGBT module and increases. In order to solve this problem, (b). In a diode-clamped inverter, two
put it into practical use. As a result, the Toshiba developed an effective circuit vertically adjacent diodes are connected
new IGBT module has 60 % less thermal technology for damping electromagnetic in series. Since a voltage is applied across
resistance and one half the volume of the noise. the ends of the series-connected diodes,
previous module. The new IGBT module We developed a small electromag- diodes with a lower breakdown voltage
was mounted on a hybrid electric vehicle netic interference (EMI) filter with can be used. Although device utilization
(HEV) to demonstrate that it exhibits excellent noise suppression performance is high, a voltage drop occurs across two
excellent heat dissipation performance suitable for high-frequency switching diodes, causing a significant conduction
and high reliability when the vehicle is applications. The new EMI filter has loss. In contrast, two vertically adjacent
accelerating and driving at a constant intra-phase capacitors at both the input diodes are not series-connected in the
speed. and output. Connecting the phases at the neutral-point switch. Although diodes
neutral point helps to significantly reduce with twice the breakdown voltage are
common-mode noise (i.e., noise caused needed, this topology causes a voltage
Evolution of
by a current that flows through an earth drop across only one diode and thus a
circuit technology line to the earth). lower conduction loss. In the late 1970s,
NPC circuit Another solution for improving the Toshiba led the world in R&D of NPC
PCS and other PV grid connec- efficiency and reducing the size of a inverters and proposed original circuit
tion systems need to shape the pulse- sine-wave filter is the use of a multilevel topologies that subsequently led to the
width modulated (PWM) output from inverter that provides multiple levels of circuits shown in Figure 2. In recent
an inverter to sine-wave voltage with output voltage. It is true that a multilevel years, the neutral-point switch topology
minimal harmonic distortions. Grid inverter is more complex and consists has frequently been used for grid connec-
connection systems have a sine-wave of a larger number of components, but tion inverters and other applications,
filter at the output stage for this purpose. the benefit of even the simplest three- vindicating our foresight.
However, the use of a sine-wave filter is level inverter is equivalent to quadrupling
a bottleneck in improving the efficiency the switching frequency of a two-level Recovery-assist and A-SRB
and reducing the size of a grid connec- inverter. Moreover, a three-level inverter circuits
tion system. One way to overcome this has one-half the voltage step of a two- A parasitic diode is formed inside
bottleneck is by increasing the switching step inverter and therefore reduces EMI the SJ-MOSFET. The slow recovery of
frequency of an inverter, but this, in turn, noise by half. Figure 2 shows two typical the parasitic diode causes a switching
causes its switching loss to increase. The examples of a three-level inverter called a loss. This switching loss can be reduced
switching operation of the inverter must neutral-point-clamped (NPC) circuit that by adding an external circuit called a
be completed in a short period of time to has been proposed in the semiconductor recovery-assist circuit. Figure 3 shows an
reduce its switching loss. However, high- industry. example of a recovery-assist circuit.
speed switching causes abrupt changes in The currently proposed NPC circuits In 2003, Toshiba used a recovery-
voltage and current, as well as an increase are broadly classified into two types assist circuit for the first time in the com-
in the number of switching operations. shown in Figure 2: diode-clamped invert- pressor drive inverter of the GDR series of
100,000
Even in the off state, when the
applied voltage is low, a wide
depletion layer forms, causing a
large output capacitance.
Output capacitance (pF)
SJ-MOSFET Pre-charging
10,000 current
Reduction by
two orders of
Very large output magnitude High-speed
capacitance flywheel diode
1,000
Gate
signal
Auxiliary voltage
application circuit
100
0.1 1 10 100 Reverse blocking FET
Depletion region
Output voltage (V) Main current
Figure A. Depletion layer
immediately after turn-off Figure B. Example of output capacitance
of SJ-MOSFET characteristics of SJ-MOSFET Figure C. A-SRB circuit
Evolution of Devices Supporting Power Electronics and Expansion of Technologies for Mounting, Circuits, and Application to Products 5
ment as well as backup power supplies used
C C C to ensure uninterrupted power in the event
Multiple modules are
connected in series. of a power failure.
C C C
The voltage across the terminals of a
rechargeable battery varies with the state
R S T
of charge (SOC). In addition, since a volt-
Unnecessary
C C C age drop also occurs due to the internal
resistance of a battery, the battery voltage
C =
C C C changes during charging and discharg-
ing. In order to use rechargeable batter-
MMC circuit Unit module
ies effectively, it is necessary to convert
Figure 4. MMC circuit The MMC circuit eliminates the need for capacitors along HVDC lines,
the constantly changing voltage to an
making it suitable for HVDC applications. appropriate voltage. For power conver-
sion, high efficiency is required for power
electronics equipment. The conventional
surface of the conductor). High-voltage reliable power converters can be realized power electronics equipment has low
direct current (HVDC) transmission without using a snubber circuit. Further- efficiency in the low output voltage
provides effective solutions for these more, the MMC does not require any region. When a rechargeable battery is
issues. For HVDC transmission, power capacitors along the HVDC lines, elimi- charged and then used to operate power
converters are required at the interface of nating the need for ultrahigh-voltage electronics equipment that is frequently
HVDC and AC systems in order to con- capacitor banks. Therefore, the MMC is operated at low output voltage, almost
vert electricity from AC to DC and from suitable for HVDC applications. half of the charged energy is lost. This
DC to AC. For full conversion of power We have been working on R&D to loss occurs mainly because the efficiency
between AC and DC, very high-capacity achieve practical applications of the of power electronics equipment decreases
converters are needed. Conventionally, MMC to self-commutated HVDC. We at low power. Efficiency in the low output
a high-voltage, high-current thyristor have developed a unique three-winding region is therefore important for systems
was commonly used in line-commutated transformer MMC by applying basic with a rechargeable battery. Toshiba is
converters for HVDC. In recent years, principles of the MMC. The new AC-DC committed to the development of equip-
self-commutated converters that do converter reduces the number of passive ment that delivers high efficiency even in
not require a harmonic filter or a phase components required. It helps reduce the the low output region.
adjuster have been attracting much atten- transformer footprint area and cost and Toshiba Elevator and Building Sys-
tion. Self-commutated converters can be eliminates the need for provisions for tems Corporation developed a battery
operated without any AC voltage. For harmonic filtering. energy storage system using SCiBTM and
example, even when the AC system at applied it to an elevator. SCiBTM recov-
the receiving end has stopped due to a ers regenerative energy during braking
power failure, self-commutated convert-
Technologies for power
and releases it during traction machine
ers can keep transmitting electric power
electronics applications operation. As a result, the power con-
and can be started under power failure Energy storage systems sumption of the elevator was reduced
conditions. using rechargeable batteries by approximately 25 %. In the event of a
Toshiba has been focusing on the Toshiba offers the SCiBTM recharge- power failure, SCiBTM releases the stored
modular multilevel converter (MMC) able batter y, an improvement over power instantaneously until the eleva-
shown in Figure 4 that is suitable for self- lithium-ion batteries. SCiBTM features tor reaches a certain speed so that it can
commutated HVDC systems. The MMC rapid charging/discharging and has gradually decelerate and safely stop at the
consists of multiple series-connected many other outstanding characteris- nearest floor. This function helps allevi-
modules that comprise a capacitor and a tics compared to lithium-ion batteries, ate the impact of an emergency stop.
half-bridge circuit. Each module can be including enhanced safety, long life and
configured to provide either the capacitor low-temperature operation. Because of Motor drive technology
voltage or a zero voltage. The MMC com- these features, SCiBTM has been widely C onvent iona l ly, ma nu fac t u rers
bines voltages from individual modules used for hybrid electric vehicles (HEVs) emphasized the importance of sufficient
to produce multiple voltage levels. Since and other vehicles. In addition, due to cooling performance at the rated output
voltage processing is completed in each long life and low operating temperature, for motor drive inverters. Their efficiency
module during switching, simple and SCiBTM is now utilized in stationary equip- generally decreases at low to intermedi-
Evolution of Devices Supporting Power Electronics and Expansion of Technologies for Mounting, Circuits, and Application to Products 7