annual meeting transphorm - poweramerica · max. ac apparent power [va] nominal voltage [vrms] ......

December 8 2015

Annual Meeting

Transphorm Peter Smith, Yifeng Wu, Zhan Wang, Feng Qi,

Ricardo Pregitzer, Jason Cuadra, Rakesh Lal & Primit Parikh

January 17-19, 2017

Transphorm- Pioneering leader in high voltage GaN

Epi technology Wafer fab

Power Devices & Modules

Applications-driven resources

Vertically integrated manufacturer and supplier of GaN WBG Solutions

Renewable Energy Solar inverters

Automotive EV and charging

Industrial Motor drives/servo

Telecom/Industrial Power supplies

Company Profile: Role in WBG Technology

2

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PWM/ Driver

Q1

L1

D1 C2 C4

VIN

C1 VOUT

CD

COSS

VD VD

(V)

t (s)

5MHz Converter Circuit & Test

5H 0.3F

0.3F 1nF

Voltage waveform (200V/400V, 5.1MHz, POUT=145W) Test circuit

Boost converter in resonant mode to mimic device performance in flyback converters (the main difference is coupled inductor in flyback converters). Air-core inductor sized to resonant with device output capacitances (COSS & CD) at ~5MHz. Energy transfer times (t2+t3)=120ns=0.62T, reasonable ratio at such high frequency. (Circulation current)/(Main conduction current): 0.6A/2.3A=26%, also reasonably low.

t1 15ns

t2 60ns

t3 60ns

t4 60ns

T 195ns

3 Task #: 2.6.1.3

Demonstrates Transphorms reliable cascode switches operate fine at 5 MHz

Jan 19, 2017

Accomplishments BP1-2: 700V Inverter with 900V GaN

4 Jan 19, 2017 Performer/Task #: Transphorm/2.6.2.3

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Power (W)

Loss (W)

Output waveform Inverter: 720VDC-500VAC at 100kHz

900V GaN Switch demonstrated passing HTRB 720Volts, prelim datasheet done

5

86.00%

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Input Power (W)

Input Power v.s. Efficiency

AC

Load

180V~300V AC

Lf

Cfi

Cfo

Cd

Q12

Q34

220V AC

Vin

Vo

FQS/Bidirectional switch enables 2-4x part count reduction/low on-resistance Initial design & prototyping work done in ARPA-E Solar ADEPT project robust edge termination validated in PA project

Accomplishments BP1-2: Stable FQS/Bidirectional GaN Switch and AC-AC Converter

SO-16 package

Chart3


10.1127.6253.7478.2109.70.872269999999999990.948010000000000020.964799999999999990.970369999999999950.97470999999999997

Input Power (W)

Efficiency

120V 2u2

fswLoadInput VoltageInput CurrentPHSOutput VoltageOutput CurrentPHSInput Apparent PowerInput Active PowerInput Reactive PowerOutput Active PowerOutput Reactive PowerLossEfficiencyWaveformIRLS_TEMPHS_TEMP

100kHzOpen121.50.21188.49121.7088.9425.640.6825.63000.680%1,002,0034092929

100kHz800Ohm122.70.25953.1120.90.150.02731.7819.125.4118.1900.9195.24%7,008,0094113631

100kHz400Ohm124.10.36934.11121.20.3020.001545.7937.925.6736.6101.2996.61%10,011,0124124233

100kHz300Ohm125.10.45627.04121.60.4050.01157.0550.8325.9549.1901.6496.78%13,014,0154135036

100kHz200Ohm1250.63418.48120.20.6030.01179.2575.1825.1372.5402.6596.48%16,017,0184146750

20160819

120V 2u2 ferrite


100kHz200Ohm126.40.63917.4121.70.616080.7677.0724.1574.9402.1397.24%0,1,24155944

100kHz150Ohm129.60.8512.55122.70.8330110.1107.523.9102.205.395.09%3,4,5,6,74168767

20160822

230V 2u2 ferrite


100kHzOpen232.30.32988.26232.9085.3776.432.3176.39002.3108,9,104174546

20160822

230V 330n ferrite


100kHzOpen232.90.05380.17232.7088.6612.42.1212.22002.12011,12,134184242

50kHzOpen233.20.05384.19232.9088.2212.391.2512.32000.0125014,15,164193232

50kHz6k233.60.06850.47232.90.038015.8910.1112.268.82200.012987.23%17,18,194203230

50kHz2k233.30.12923.64231.40.113030.1527.6212.0926.1801.4494.80%20,21,224213630

50kHz1k233.40.23612.63230.40.225055.853.7412.0551.8501.8996.48%23,24,25,264224231

50kHz700Ohm234.50.3388.864230.60.329079.1478.212.275.8802.3297.04%27,28,294235035

50kHz500Ohm235.50.4696.462230.30.4640110.4109.712.4106.902.897.47%30,31,324246042

20160822

100kHz6k233.40.0748.12232.50.038016.3510.9112.178.78602.1380.51%0,1,24254438

100kHz2k236.20.13422.75233.90.114031.5629.1312.2226.7702.3691.88%3,4,54265436

100kHz1k235.80.23912.232320.227056.3855.111.9552.5802.5295.43%6,7,84276035

100kHz700Ohm9,10,114286737

20160823


10.1127.6253.7478.2109.70.872269999999999990.948010000000000020.964799999999999990.970369999999999950.97470999999999997

Input Power (W)

Efficiency

230V 330n ferrite

fswInductorLoadInput VoltageInput CurrentPHSOutput VoltageOutput CurrentPHSInput Apparent PowerInput Active PowerInput Reactive PowerOutput Active PowerOutput Reactive PowerLossEfficiencyWaveformIRLS_TEMPHS_TEMPWindingCoreTime

50kHz3mH700Ohm235.10.3388.7822310.33079.5578.6212.1576.2102.496.94%0,1,24295237

50kHz3mH500Ohm236.30.476.404230.80.4660111.1110.412.4107.502.997.41%3,4,543066483533

50kHz1.5mH500Ohm236.90.4716.692230.60.4650111.7110.913107.303.696.77%6,7,843171534437

20160824

25kHz3mH (1+1)500Ohm237.30.4766.521231.50.4670112.8112.112.810804.196.36%0,1,24335648

50kHz6mH (1+1)500Ohm236.20.4685.984230.50.4650110.5109.911.5107.102.897.45%3,4,543462450 hours

50kHz6mH (1+1)500Ohm236.10.4685.965230.40.4650110.4109.811.5107.102.797.58%6,7,843561452 hours

20160825

Project Title: Modular Open-Source Compact Transformerless Grid-Tied 3kW GaN PV Inverter Major Milestones: Open source system design, core power blocks proto (3mo); H/W & F/W integration (6mo); Grid sync & core PV inverter validated (9mo); Beta system tested (12mo) Deliverables: Open source design of the PV inverter, 2-3 sets of modules with GaN switches, 1-2 sets of 3 kW PV inverters


BP2 Project Objectives

Accelerate adoption of WBG GaN with full reference design: 3-5 kW PV

Focus of work in Q1 & Q2

Focus of work in Q2

Review of Existing Technology

7

Specification

Technical data 240 V

Max. usable DC power [W]Max. DC voltage [V]Rated MPP voltage range [V]MPPT operating voltage range [V]Min. DC voltage / start voltage [V]Max. operating input current per MPPT [A]Max. short circuit current per MPPT [A]Number of MPPT tracker / string per MPPT tracker

AC nominal power [W]Max. AC apparent power [VA]Nominal voltage [Vrms] 240AC voltage range [Vrms] 211 - 264AC grid frequency [Hz]Max. output current [Arms] 12.5Power factorOutput phases / line connectionsHarmonics

Max. efficiency 97.6%CEC efficiency 96.5%

100 / 125

Values

600

100 - 550

1018

60 / 50

11 / 2

3000

< 4 %

3000

155 - 480

3100

2 / 1

Input (DC)

Output (AC)

Efficiency

Current inverters on the market (Single Phase, e.g. SMA, ABB, Fronius, Kaco)

Jan 19, 2017 Performer/Task #: Transphorm/4.18.1.1

Comparison of Typical Inverter Topologies

8

Properties Unipolar Bipolar 3 Level NPC

Simplicity

Cost

Switching Losses

Overall part counts

Efficiency

Output filter size & cost

Overall size & cost

EMI issues

Common mode current injection

Control system complexity

+

- +

- +

-

+ - + +

- + - + + + - + + - +

- + + + +

+

Except for common mode current injection issues, unipolar PWM is the best solution


+ + -

Target Specifications of GaN Open Source PV Inverter-1 Parameter Value Comment(s)

Inpu

t

Max usable input power 4200 W Will be a stretch for passively cooled design

Number of MPPTs | Strings per MPPT | Peak power per MPPT 2 | 1 | 2300 W

Cost goes up but 2 MPPT desirable for system performance & availability

Max DC voltage at the input of a MPPT 600 V Maximum open load panel string voltage

MPPT operating voltage range | Nominal MPPT operating voltage 200-500 V | 360 V Voltage range could be lowered for 3 kW design

Min DC voltage | Start voltage 80 V | 100 V Startup with limited output power

Max input operating current per MPPT 11.5 A

Max input short circuit current per MPPT 12.5 A Electronic & circuit breaker! Cost!

Outp

ut

Max power out at 240 VAC 1 | Max apparent power 4200 W | 4200 VA

Nominal output AC voltage | AC voltage range 240 V | 211-264 V Power derating to start below nominal AC voltage

Max output current | Output short circuit current 17.5 A | 22.5 A Electronic & circuit breaker! Cost!

Nominal AC grid frequencies 50 Hz / 60 Hz

Max DC current injection into grid 87.5 mA 0.5% of rated RMS output current

Max harmonic content of current injected into grid < 3 % upto 25th

harmonic Under non-distorted AC voltage conditions

Parameter Value Comment(s)

Envi

ronm

enta

l &

Ph

ysic

al

Ambient temperature -20C...+60C Output power derating after 45C

Cooling Natural Convection

Weight

Overall System Block Diagram


DC-DC Boost Converter Prototype

12

Input Voltage Efficiency 165VDC 98.37% 210VDC 98.72% 260VDC 98.95%

Note: These achieved without any switching algorithm optimization; > 99% possible

Two phase CRM boost topology Lower ripple through DC link

capacitors improved life time & reliability

A 2.2 kW prototype built will be scaled up in the final design

to 2x2.2kW

Efficiency measurements done

165VDC measurement taken at 250kHz switching, 330VDC/2 kW output Jan 19, 2017 Performer/Task #: Transphorm/4.18.2.1

DC-DC Boost Efficiency Curves

13

High Power Curves Low Power Curves

MPPT: Two modes of operation for higher efficiency over a larger power band


DC-AC H-bridge Inverter Prototype Grid-tied operation

14

H-bridge inverter topology Simple, low cost, reliable work in progress for EMI

mitigation with unipolar switching

A 1.5 kW prototype was built first Basic hardware only will be modified for 4.2 kW

Different control algorithms tried Open loop with resistive load

Prototype Prelim test data

Voltage: 125Vpk

Current: 1.25Apk

Showing excellent current waveform for even low power levels [when unipolar designs can give large distortion of current waveform]

4.2 kW DC-AC GaN Inverter design done


Additional CM filter if needed

4.2 kW DC-AC GaN inverter prototype


Space for test filters &/or MPPT on integration

Inverter undergoing tests for various input voltage and power levels

Challenges we expect are: (a) EMI due to fast switching; (b) stability under transient load conditions; & (c) common mode current injection when PV module leakage to ground is high

Test of bridge 600VDC & 30A

Yellow Current 5A/div Blue Voltage 100V/div

Task partially completed, but steady state testing should be over by Jan 31, 2017


System Controller Board

18

Board with DSP controller for real time control of MPPT & inverter modulation & inter-block control


Block diagram of system for PV Inverter test

19

PV

Emulator

AC Grid

Emulator PA PA PA

PA = One channel of a power analyzer

* For a system with 2x MPPT a second PV emulator/DC source would be needed * A three or four channel power analyzer is needed for measuring DC & AC V, I & P

Adapted from IEC62116


SOPO Milestone and Deliverable Status

20

MS No. Description Due Status Notes

4.18.1.1 Commercial inverter teardowns, finalized specification for GaN Inverter Month 3 Completed Proposed to increase power range from 3kW (original) to 4.2 kW (wider market)

4.18.2.1 Boost converter tested with 99% efficiency Month 6 Completed Boost / MPPT done EMI test to be done

4.18.2.2 Inverter tested with 99% efficiency Month 6 In Progress 1.5 kW inverter tested; 4.2 kW inverter protyped & under test

4.18.2.3 Boost + Inverter tested Month 6 Not Done To complete after inverter testing, no issues anticipated

Jan 19, 2017 Performer/Task #: Transphorm/4.18.

Project Timeline (Actual project start- July 2016)

21

Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May

Subtask 4.18.1

Subtask 4.18.2

Subtask 4.18.3

Subtask 4.18.4

Firm-up Specs, architecture & design

Prototype & bench test

System integration & test

Full Integration & Test

Go-No-go decision

GaN OS PV Inverter

Completed Work in Progress Risk of Delay Work not started

Existing technology review Paper designs

Simulations

First round of power train design

Boost converter optimized

Inverter running

Powertrain system integration

Final mechanical layout

EMI pre-compliance

Documentation


22

Broader Impact on the WBG Community


Advances over SOA approaches: High frequency low loss GaN switches enable 50% reduction in size with higher efficiency

System cost reduction due to smaller heatsinks, filters and reduced BoM (e.g. diode-free)

Market segments impacted: 1-5 kW PV inverters & UPS, and motor drives (with additional software)

Potential for job creation: R&D workforce and substantial US production, end system use in US

Workforce Development and Training: WBGS aware engineers through manufacturing and project execution in PV inverter production & installation

Timeframe for commercialization: 2017 (Enabled by Transphorms proven reliability GaN Platform)

Market / Commercialization

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500

1,000

1,500

2,000

2,500

3,000

3,500

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5,000

10,000

15,000

20,000

25,000

30,000

35,000

2009 2010 2011 2012 2013 2014

Inve

rter

Rev

, USD

(M$)

Volu

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)

World Single Phase PV Inverter Market

3kW Equivalent Inverter Volume GaN Volume Revenue

Product Customers / Partner Targets

End User / End Customer Target

Key Impact

3kW PV Inverter / Full Reference Design

PV Inverter manufacturers- US/WW

PV System Installers/ Integrators in US Solar city, Sun Edison Solar World

Accelerate insertion of GaN in Residential /small scale commercial PV Market for US

National labs Promote GaN standard for PV Proposed effort accelerates insertion of GaN in the US residential / small scale commercial segment while simultaneously creating broad based awareness through suitable partnerships with National labs. All of the IP generated will be US based.

Jan 19, 2017 Performer/Task #: Transphorm/4.18. 23

Slide Number 1Transphorm- Pioneering leader in high voltage GaNSlide Number 3Accomplishments BP1-2: 700V Inverter with 900V GaNAccomplishments BP1-2: Stable FQS/Bidirectional GaN Switchand AC-AC ConverterSlide Number 6Review of Existing Technology Comparison of Typical Inverter TopologiesTarget Specifications of GaN Open Source PV Inverter-1Target Specifications of GaN Open Source PV Inverter-2Overall System Block DiagramDC-DC Boost Converter PrototypeDC-DC Boost Efficiency CurvesDC-AC H-bridge Inverter Prototype Grid-tied operation4.2 kW DC-AC GaN Inverter design done4.2 kW DC-AC GaN inverter prototypeTest of bridge 600VDC & 30ASystem Controller BoardBlock diagram of system for PV Inverter testSOPO Milestone and Deliverable StatusProject Timeline (Actual project start- July 2016)Broader Impact on the WBG CommunityMarket / Commercialization

annual meeting transphorm - poweramerica · max. ac apparent power [va] nominal voltage [vrms] ......

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