Semiconductor generations

Transcription

1 Smionutor gnrtions ABB looks k on 60 yrs of progrss in smionutors CHRISTOPH HOLTMANN, SVEN KLAKA, MUNAF RAHIMO ANDREAS MOGLESTUE Mny of th grt trnsformtionl prios in humn history wr rivn y thnologil rkthroughs, ut h onsquns rhing fr yon thnology. Progrss in mritim nvigtion in th 15th ntury opn up tr routs twn ontinnts. Rfinmnt in mhnil nginring nl inustriliztion in th 18th n 19th nturis. Rnt s hv n mrk y hngs of similr imnsions, ttriut to progrss in omputing n ommunitions n thus ultimtly y progrss in smionutors. But smionutors hv t th sm tim lso rivn nothr rvolution on tht is my lss visil ut qully signifint: From th huml hrging of moil phons to th trnsmission of powr ovr thousns of kilomtrs, powr ltronis hs om vitl nlr of th morn lifstyl. ABB hs ovr th pst 60 yrs ply pivotl prt in th vlopmnt of powr smionutors n thir pplitions. 84 ABB rviw 3 14

2 ABB s prssor ompnis, ASEA n BBC, oth ommn smionutor vlopmnt in th rly 1950s. Just s thr wr lrg ships for Hnry th Nvigtor n stm ngins for Jms Wtt, th sis of toy s smionutor pplitions prt th smionutors thy us. Erly omputrs us rlys, rios us tus n powr onvrtrs us mrury-r vlvs 1 or mhnil swiths. Th si iruit topologis t th hrt of ths xmpls wr not too iffrnt to thos still in us toy. But us smionutors l to mor ompt signs, grtr rliility, lowr losss, lowr osts n grtr s of us, thy opn th thnology to nw pplitions whil vloping it to lvls of prformn n sophistition orrs of mgnitu yon wht woul othrwis hv n possil. Titl pitur 300 V / 800 A thyristors mnuftur y BBC in th rly 1970s Smionutor sis A smionutor is ll s suh us it isplys n intrmit lvl of onutivity twn onutor n nononutor. Its ltril hvior n furthrmor influn y ftors inluing th prsn of impuritis, ltri fils, light n tmprtur. Mny of ths phnomn h lry n rogniz in th 19th ntury 1 ut it ws not until th rly 1930s tht workl xplntion mrg in th form of th n thory of onution, rwing on insights from quntum physis. In powr ltronis, smionutor proprtis r us to rt vis tht n ltrnt twn ing on, i, onuting lrg ltril urrnts with s low n on-stt voltg s fsil, n off, i, loking s high voltg s rquir with minimum lkg urrnt. Th trnsition phs twn th two stts shoul kpt s short s possil. Th simultnous prsn of nonzro voltg n urrnt ls to vi-lvl losss, rprsnting not only wst nrgy ut lso thrtning thrml mg of th vi. Th io Th io is th simplst of ll powr smionutor vis. It simply onuts urrnt in on irtion n loks it in th othr. It is thus wll suit for simpl rtifir (AC to DC onvrsion) pplitions. ABB s prssor ompnis, ASEA n BBC, oth ommn smionutor vlopmnt in th rly 1950s. BBC s tivitis wr s in Bn, Switzrln, n ASEA s in Luvik, Swn. BBC rt its first smionutor io in Th first ommrilly vill io (100 V / 100 A), trgt t rtifition for ltrolysis follow in BBC s rly io signs us grmnium, ut us Footnot 1 S lso A. Moglstu, From mrury r to hyri rkr: 100 yrs in powr ltronis, ABB Rviw 2/2013, pp Smionutor gnrtions 85

3 In rtifir pplitions, thyristors prsnt th vntg ovr ios tht th phs ngl n ontroll n hn th flow of powr rgult. 1 Erly milstons of smionutor history Antoin Lvoisir proposs th xistn of th hmil lmnt silion Jöns Jo Brzlius isolts pur silion Mihl Fry osrvs tmprtur pnny in th rsistivity of silvr sulfi, not onforming to tht of mtl Alxnr-Emon Bqurl osrvs th photovolti fft Krl Frinn Brun osrvs rtifition in mtl sulfis Clmns Winklr isovrs th lmnt grmnium 2 BBC s first smionutor io (grmnium, 1954) s 1926 Josph John Thomson isovrs th ltron Jgish Chnr Bos, Grnlf Whittir Pikr n othrs vlop th t s whiskr ttor, primitiv smionutor rtifir for rio rivrs Hnry Josph Roun invnts th light-mitting io First ommril io-s rtifirs ppr for low-powr pplitions Julius Egr Lilinfl proposs th prinipl of th fil-fft trnsistor rnt n rmov, with onution not sing until th min urrnt flls low thrshol vlu (usully t th zro-rossing of th urrnt). A turn-off nnot ritrrily triggr unlss uxiliry iruits r us to rtifiilly for suh zro rossing Aln Hrris Wilson xplins nrgy ns 1939 Russll Ohl isovrs th p-n juntion Willim Shokly, John Brn, Wltr Brttin n othrs prou th first trnsistor t Bll Ls Willim Shokly sris th prinipl of th thyristor (th first thyristor is prou y Gnrl Eltri in 1956 n ommriliz in 1958; BBC lunhs its first thyristor in 1960) BBC n ASEA inpnntly ommn vlopmnt of powr smionutors Improvmnts in smionutors From 1960 to 1980, loking voltgs n th powr tht oul hnl pr of th mtril s thrml n lokingvoltg limittions, this ws soon rpl y silion. Th thyristor Moving yon simpl rtifir pplitions, vi ws rquir tht oul swith on t n ritrry point in tim. Th sign st suit to this ws th thyristor vi whos prinipl h n propos y Willim Shokly in A thyristor hs two min ontts rthr lik io (th no n tho) ut lso hs n uxiliry ontt (th gt). A urrnt ppli t th gt uss th thyristor to strt onuting (if positiv voltg is prsnt twn no n tho). On onution hs gun, th triggr ur- Thyristors r thus wll suit for invrtr (DC to AC onvrsion) pplitions in whih th riving ntwork is strong nough (g, through support of lol gnrtion) to nl for ommuttion of th invrtr. Thy r lso wll suit for rtifirs whr thy prsnt th vntg ovr ios tht th phs ngl n ontroll n hn th flow of powr is rgult. BBC prou its first thyristor in Sussful trtion pplitions An rly sussful trtion pplition for ios ws th typ R4/4 loomotiv (4,980 kw) uilt for th BLS rilwy (Switzrln) from Ths loomotivs, still fturing thir originl rtifir iruits, rmin in us toy. Hving no mns to irtly ontrol io rtifir, trtion ws ontroll y tp hngr on th trnsformr. Suh ws th rt of progrss, howvr, tht in 1967, ASEA gn prouing loomotiv ontroll y thyristors. This ws th 3,600 kw typ R for SJ (Swish Rilwys) 5. Agin, mny of this typ rmin in us toy. 86 ABB rviw 3 14

4 3 In 1961, BBC lunh its first thyristor (1,200 V / 100 A). Th io rng rh 650 V / 200 A. 4 Th R 4/4 loomotiv (1964) of BLS (Switzrln) uss BBC ios. 5 Th R loomotiv (1967) of SJ (Swn) uss ASEA thyristors. 6 Evolution of swithing powr 1E mm 125 mm 150 mm Swithing powr (VA) 1E+07 1E+06 GTO IGCT Prss pk Insult Thyristor GTO/IGCT IGBT 1E Yr An rly sussful trtion pplition for ios ws th typ R4/4 loomotiv uilt for th BLS rilwy (Switzrln) from vi grw in roughly linr fshion 6 7. In 1976, BBC m th first Europn mnufturr to introu nutron trnsmuttion oping (s n ltrntiv to oping with phosphorous toms, nutrons woul irrit into th silion, onvrting som silion toms to phosphorous). This l to vry homognous opnt onntrtion n prmitt loking voltgs to vn to 4 kv. In 1969, BBC quir Séhron n sought to onsolit this ompny s smionutor tivitis with its own. Plns to uil joint mnufturing plnt on Séhron-own ln in Gln, Switzrln, fll through. Howvr, wllquipp n morn fility ws opn t Lmprthim, Grmny, in Th following yr th ision ws m to onntrt ll mnufturing tivitis thr. Dspit this, som of th Enntn tivitis wr trnsfrr to Birr, Switzrln. Ativitis thr wr mostly fous on vlopmnt n pilot proution ut smll volums of ommril mnufturing lso ourr. HVDC During th mrury-r r, ASEA h mintin position s unisput lr in HVDC thnology u to th high loking voltgs of its vlvs. Nvrthlss, th ompny rogniz tht smionutors wr th wy forwr. Th worl s first ommril HVDC link, whih t to 1954, twn th Swish isln of Gotln n th minln ws supplmnt y n xprimntl smionutor vlv in Th first ommril pplition of smionutors for HVDC follow t th sm lotion in Footnot 2 S lso A. Moglstu, 60 yrs of HVDC: ABB s ro from pionr to mrkt lr, ABB Rviw 2/2014, pp Smionutor gnrtions 87

5 7 Milstons from ABB s 60 yrs in smionutors 8 Th Chor Bss (Mozmiqu) HVDC projt of Smionutor vlopmnt ommns in Luvik (ASEA) n Bn (BBC) 1956 BBC lunhs its first io (100 V / 100 A) 1961 First BBC thyristor introu (1,200 V / 100 A) Dios rh 650 V / 200 A 1969 Nw plnt opn in Lmprthim (BBC) 1970 Thyristors rh 3,000 V / 800 A 1976 Nutron trnsmuttion oping introu (BBC) 1977 Nw plnt opn in Lnzurg (BBC) 1980 Thyristors rh 5 kv / 2 ka 1988 ASEA n BBC mrg to form ABB 1990 Lmprthim plnt is sol to IXYS 1991 ABB s smionutor tivitis r onntrt in Lnzurg kv / 600 A IGBT smpl is prsnt 1995 First smpls of 4.5 kv / 3 ka IGCT r prsnt GTO n io offring rhs 4.5 kv / 4 ka kv / 1.2 ka IGBT moul for trtion is introu Biirtionl ontroll thyristor (BCT) thnology is introu ABB lunhs omplt lin of IGCTs from 500 kw to 9 MW 4.5 kv / 1.2 ka IGBT moul for trtion with intgrt ht sink is introu 2.5 kv / 700 A IGBT for HVDC Light is introu inh IGBT wfr f opns in Lnzurg 2.5 kv StkPk mouls for HVDC light r 2000 introu 1.2 kv 1.7 kv thin wfr soft punh-through 2001 pltform (SPT) IGBT is lunh High-voltg SPT IGBT/io pltform is lunh (with ror-rking sf oprting r) 2.5kV 3.3kV SPT-IGBT HiPk moul pltform is lunh Lnzurg upgrs to 6 inh IGBT wfr f 3.3kV-6.5kV SPT IGBT HV-HiPk moul pltform is lunh 1.2 kv 6.5 kv low loss SPT+ IGBT pltform is lunh High-powr thnology (HPT) IGCT pltform is introu 8.5 kv / 8 ka thyristor is introu High-voltg BIGT thnology is introu Cpity xtnsion is t Lnzurg n Polovoi is quir 4.5 kv StkPk mouls for HVDC Light r introu 10 kv IGCT thnology is monstrt 2011 BIGT is monstrt for HVDC rkr Groun is rokn for WBG l in Bn-Dättwil Improv HiPk 2013 is introu 2013 BGCT thnology (IGCT with rvrs-onution io on th sm wfr) is introu 2014 Enhn-trnh IGBT thnology is introu 60 yrs of smionutors t ABB Th isruptiv innovtion us y th option of smionutors for HVDC opn up th mrkt to omptition from othr plyrs. A onsortium onsisting of AEG, Simns n BBC suppli th Chor Bss projt in Mozmiqu in 1977 (1,920 MW, 1,450 km) 8 n th Nlson Rivr projt in Cn in 1978 (900 MW, 940 km in 1985). Thyristor mnufturing for ths projts ws split qully mong th thr prtnrs, with BBC s shr ing mnuftur in Birr (Lmprthim ws not st up for th prosss rquir). This tivity ws trnsfrr to nw plnt in Lnzurg, Switzrln in In rspons to th nw omptition, ASEA sought to onsolit its lrship y intnsifying its thyristor vlopmnt tivitis. In 1984, th ompny suppli th ror-rking Itipu link in Brzil (780 km, 500 kv / 6,300 MW). Th GTO Th mjor rwk of th thyristor is its n for uxiliry iruitry to support ommuttion whn th riving AC ntwork is wk, or in DC to DC onvrsion. This hllng ws mt y th gt turn-off thyristor (GTO). A GTO is similr to thyristor, ut n turn off using ngtiv urrnt t th gt. GTOs m spilly populr in motor riv pplitions. Although GTOs wr vill from s rly s 1960, oth BBC n ASEA wr lt in ntring this mrkt. BBC introu its first GTOs in 1980 (1,400 V). Howvr, it ws th- nology trnsfr grmnt with Toshi in 1985 tht finlly prmitt th ompny to th up. Dspit this ly strt, ABB ws in ltr yrs to om worl lr in GTO mnufturing, not lst us mny omptitors h rronously ssum th thnology ws hing for osolsn (u to IGBT vlopmnts) n h prmturly rmp own thir tivitis. Th mrgr Following th mrgr of ASEA n BBC to form ABB in 1988, it ws i to onntrt ll tivitis in Lnzurg. Th Lmprthim fility ws sol to IXYS in 1990 n tht t Västrås ws los in ABB s smionutor mnufturing tivitis wr vst in susiiry ompny, ABB Smionutors Lt. Prviously, ABB h onsir smi on u tors lrgly intrnl tivity, with vis ing vlop n mnuftur first n formost to mt th rquirmnts of othr prts of th ompny. ABB Smionutors rok with this prigm n grw ABB s smionutor mrkt y tivly slling smionutors to xtrnl systm mnufturrs. ABB Smionutors CEO, Anrs Nilrp, soon rn himslf rputtion s hrismti mngr, onstntly sking to motivt n mpowr mploys. His ontinuous striving for highr qulity 88 ABB rviw 3 14

6 9 Cross-stion of prssur ontt vi 10 Cross-stion of HiPk IGBT moul kv HiPk moul lunh in 2003 In prssur ontt mouls, th lo urrnt ntrs through on surf () n lvs through th opposing surf. Low ltril n thrml rsitns of th ontts r ssur through high mhnil prssur on thos surfs. In insult housing mouls, th smionutor (f) is glvnilly isolt from th ht sink (). Eltril ontts within th moul r provi y oning wirs. f g Ht sink CTE ompnstion (Mo) Housing (rmi) Coppr Smionutor Powr n ontrol onntions Boning wir Ht sink f g Crmi (usully AlN) Bs plt (usully AlSiC) Smionutor Housing in oth prouts n prosss m ABB Smionutors finlist for th 1995 Europn Qulity Awr. In 1996 it ws nomint Supplir of th Yr y Gnrl Eltri. Nilrp lso hmpion th smionutor usinss within th ABB Group t tim tht th Group sw its prioritis lswhr. His grtst hivmnt in this rspt ws gining funs n pprovl for th nw BiMOS (IGBT n io) ftory, whih opn in Lnzurg in IGBT An IGBT (insult-gt ipolr trnsistor) is swithing vi tht n ontroll y pplying voltg rthr thn urrnt to th gt, hn grtly Following th mrgr of ASEA n BBC to form ABB in 1988, it ws i to onntrt ll tivitis in Lnzurg. simplifying th sign of gt rivs. Anothr vntgous proprty lis in th IGBT s short-iruit pility. Whn th on-stt voltg riss ov ritil lvl, th vi will intrinsilly limit th urrnt. An IGBT n thus surviv xptionl oprting onitions without rquiring itionl prottiv iruitry. All ths ftors llow for simplr onvrtr signs. A furthr vntg of IGBTs lis in thir mhnil instlltion. GTOs n thyristors of highr rtings r prssur ontt vis 9, mning th urrnt flows vrtilly from on surf of th pkg to th othr. To ssur rlil ltril n thrml onutivity, vis r mount in stks t spifi prssur. Mintnn stff n thus not rpl fil vi without ismntling n ntir stk. In IGBT insult mouls, urrnt flows through th moul s xtrnl trminls, whih r ll rrng on th sm si of th moul 10. Th intrnl ltril ontt to th vis is ssur y on wirs, whrs thrml onutivity is ssur through th nononuting s plt 11. Both mhnil n ltril onntions us olts. Iniviul vis n thus rpl with fr grtr s. Thr r, howvr, pplitions tht rquir prss-pk mouls (for xmpl, runny rquirmnts my rly on fil mouls going into n rmining in short iruit). ABB s StkPk IGBT mouls rss ths pplitions 12. As ABB s mnufturing filitis wr initilly not st up for th omplxity of th IGBT mnufturing pross, th ompny s rly proution rli on prts of th pross ing prform t xtrnl filitis. Th 1998 ompltion A GTO is similr to thyristor, ut it n turn off using ngtiv urrnt t th gt. Smionutor gnrtions 89

7 kv StkPk Mouls for HVDC light lunh in IGCT mouls for vrious powr lsss (1997) of th BiMOS ftory in Lnzurg finlly nl ABB to hnl th ntir IGBT proution pross in-hous. In th following yrs, with furthr thnologil improvmnts in trms of lowr losss n highr roustnss, IGBTs ntr mny mrkts prviously omint y GTOs, suh s mrin rivs n rilwys, ut lso nw pplitions suh s onvrtrs for win powr, powrltronis-s trnsformrs n th grounrking hyri rkr for HVDC tht ABB lunh in Thyristors n GTOs hol thir own Although on might forgivn for ssum ing tht th rpi vn of th IGBT woul spll n qully rpi n to th GTO r, mn for ths vis is still strong toy. In, vlopmnt is ongoing. In 1997, ABB lunh nw GTOs vi: th IGCT (intgrt gtommutt thyristor). An IGCT is ssntilly GTO with n intgrt gt unit. Th oping profil ssurs lowr losss whil n intns ut rif urrnt puls ssurs rpi turn-off 13. Th thyristor mrkt too ontinus to thriv, s th vi rmins th unhllng smionutor of hoi for Footnot 3 S lso M. Cllvik t l., Brkthrough!: ABB s hyri HVDC rkr, n innovtion rkthrough nling rlil HVDC gris. ABB Rviw 2/2013, pp An IGBT is swithing vi tht n ontroll y pplying voltg rthr thn urrnt to th gt, hn grtly simplifying th onstrution of gt rivs. high-powr HVDC links. In 2009, ABB introu 150 mm, 8.5 kv thyristor for suh projts. Furthr strngthning its prsn in th ipolr mrkt, ABB quir th Prgu-s ompny, Polovoi, in Toy, ipolr proution ours in oth Prgu n Lnzurg. In th sm yr, furthr pity nhnmnt ws omplt in Lnzurg for BiMOS n ipolr proution. ABB thus hs strong position n mnufturing pility in oth mrkts. Silion ri Looking towr th futur, groun ws rokn t th ABB Corport Rsrh Cntr in Bn-Dättwil, Switzrln, in 2013 for rsrh l it to wingp powr-ltronis mtril. SiC (silion ri) smionutors, g, offr lowr losss thn silion n ttr tolrn to ht. ABB s prssor ompnis h lry rsrh SiC in th 1960s n 1990s, ut unrstning of th mnufturing thniqus hs sin vn to th point tht suh vis r gnuinly oming fsil. Ry for th futur Th hin of th livry of ltril powr, spnning trnsmission, onvrsion n livry, is mrking on n r of xiting hngs. On th mn si this is ing rivn y th growth n intgrtion of rnwl nrgis n th grtr mphsis on ffiiny. But ths mns woul rmin wishful thinking wr it not for th progrss t th smionutor lvl tht is mking this rvolution possil. Christoph Holtmnn Svn Klk Munf Rhimo ABB Smionutors Lt. Lnzurg, Switzrln hristoph.holtmnn@h..om svn.klk@h..om munf.rhimo@h..om Anrs Moglstu ABB Rviw Zurih, Switzrln nrs.moglstu@h..om Furthr ring H. Zllr, Th winning hips: History of powr smionutors t ABB. ABB Rviw 3/2008, pp ABB rviw 3 14