Green chips: a new era for the semiconductor industry

Green chips: a new era for the

semiconductor industry

René Penning de Vries

CTO - NXP Semiconductors

CICC, San José, 20th September - 2010

COMPANY CONFIDENTIAL 2

We just have one planet…

CICC - René Penning de Vries – 20 Sept. 2010 2


We just have one planet…

(Source: WWF Living Planet Report 2006)

Russia



1. Energy

2. Water

3. Food

4. Environment

5. Poverty

6. Terrorism & war

7. Disease

8. Education

9. Democracy

10. PopulationSource: MIT Forum 2003

2003: 6.3 billion people

2050: ~10 billion people

with many problems to solve…


COMPANY CONFIDENTIAL

Mega Trends in electronics can help…

Security

Energy

Efficiency

Health

Connected

Mobile

Devices

Secure & private, fit for purpose, low power

Sustainable, energy efficient

Affordable, personalized, self-diagnostics

Connected: always and anywhere, comfortable & safe



And the electronics industry adapts …by going green

Samsung eco phone


http://www.greentouch.org/index.php?page=home


Mega Trends in electronics

Energy

Efficiency

• Efficient power conversion & management

• CFL and LED lighting and TV-back-lighting solutions

• Energy conservation: e-metering, smart appliances



Electricity:

17,000 TWh (12%)

Yearly Global Energy Consumption (TeraWattHour)

Residential

Electricity:

5,000 TWh (4%)

Consumer

Electronics:

700 TWh (0.5%)

Total Energy

Consumption:

140,000 TWh Smart chips can help reduce electricity

consumption in end-applications

8

Source: IEA & DoE

CICC - René Penning de Vries – 20 Sept. 2010


Energy consumption and the IC life cycle

Electric energy used for

chip production

Energy used during

chip operation

UseManufacturing

9

Application

Energy used by all electric

appliances



Energy used during

chip operation


appliances



chip production

UseManufacturing

10

Application


????




chip production

Energy used during

chip operation

UseManufacturing

11

Application


appliances


• NXP‟s mnfg power

consumption : ~1TWh/yr.

• World: est~50TWh/yr




chip production

Energy used during

chip operation

UseManufacturing

12

Application


appliances


WW: est. ~50 TWh/y ????


What do all ICs in the world consume?


Data are estimates by NXP

Annual semiconductor business: 250 * 109 $

@ 2500 $ ASP / 8” wafer: 108 8” wafers

Making an overall silicon area of: 3 * 1010 cm2 produced / year

Estimated active power consumption 1 Watt/ cm2 3 * 1010 Watt

@ 2 hrs / day processing 25 TWh/year

@ application lifetime of 5 years: 125 TWh/year electricity

consumption for all Ics

(~1% of all electricity consumed)




chip production

UseManufacturing

14

Application


Energy used during

chip operation


appliances

~1%

All chips: 125 TWh/y Overall: 17.000 TWh/yWW: est. ~50 TWh/y


Power consumption and the IC life cycle


chip production

UseManufacturing

15

Application


Energy used during

chip operation


appliances

Chips use some energy, but can bring

huge energy savings in appliances!

All chips: 125 TWh/y Overall: 17.000 TWh/yWW: est. ~50 TWh/y


Saving electricity, in the big picture …

World Primary Energy Consumption 140.000 TWh/yr

Conversion of Primary Energy Electricity ~30-40%

Energy-Smart appliances make sense!


//antwrp.gsfc.nasa.gov/apod/image/0011/earthlights2_dmsp_big.jpg


Energy

Examples:

• Power conversion in chargers

• Making solar panels more efficient

• Dealing with CFL lighting drawbacks

• LED drivers

• Smart Grid

Some chip applications for energy efficiency

17CICC - René Penning de Vries – 20 Sept. 2010


Energy

Examples:




• LED drivers

• Smart Grid




Personal

Computing

Consumer

Electronics

Notebook/

Netbook

Desktop PC/

LCD monitor

All-In-One

PC

LCD TV/

PDP

STB+ Video

systems

Audio systemsGaming

consolesMobile phone

chargers

Printers

Key Growth DriversOngoing demand for greater levels of

energy efficiency

Higher level of integration, increasing

silicon content

Fast LED penetration in Display backlight

Focus applicationsDrive for energy efficiency



Global chargers market

Unit CAGR '07-'13 = 6%



Increasing sophistication Increasing

efficiencyBefore 1970; Linear power supplies

1970 Switched mode power supplies– Built with discrete semiconductor components

1980 Power supply IC’s– Convert power in a more efficient way, drive miniaturization

1990 Smart power supply IC’s – Automatically switch between most optimal power conversion modes and frequencies,

increasing power efficiencies at all power levels, special attention for standby power reduction

2000 System management– Power supply management; Systems dictate standby modes to power supplies. Dedicated

standby converters

– Intelligent power supplies that detect standby power modes autonomous, standby functionality

integrated in smart power supply IC‟s

2010 IC consumption management– Managing the internal power consumption of power management IC‟s

– Networks control connected devices

– Energy grid management; Switch appliances on and off from remote locations



Efficiency: a function of load/ mains voltage

High efficiency across full load range, excellent performance at low load

Extremely high efficiency, 25% loading level in line with EPA2.0

Flyback topologies: TEA1751+ TEA1791

LLC resonant topologies: TEA1713 + TEA1795


Mains input 100.0% 75.0% 50.0% 25.0% 17.5% 10.0%

90V / 60Hz 89.31 90.06 89.99 90.22 89.81 88.88

100V / 50Hz 89.70 90.41 90.24 90.43 90.11 89.06

115V / 60Hz 90.43 90.97 90.58 90.99 90.48 89.38

230V / 50Hz 90.61 90.04 87.74 90.54 89.74 88.09

Efficiency GreenChip-3 + GreenChip-SR [90W / 19.5V]

Efficiency GreenChip Resonant + GreenChip SR (90W / 19.5V)

Mains input 100% 75% 50% 25%

115V / 60Hz 92.9 92.6 91.7 87.5

230V / 50Hz 94.2 93.8 92.7 88.0


EnergySTAR EPS and State-of-the-Art Solutions

EPS 1.1>10W supplies

EPS 1.10-10W supplies



No load power requirements

Efficiency

requirements

84%

87%

90%

0,75W 0,50W 0,30W 0,10W 0,01W

93%

EPS 1.1 effective 1.1.2005

EPS 2.0 effective 1.7.2009

Current

performance Green IC solutions

(e.g. NXP GreenChip)

Green IC solutions in

development



30mW active switching power @ no-load

An additional output controller senses the

power demand and switches the AC side off

(*) when possible and on when needed(*the primary control IC remains operational/biased)



Breaking the <10mW barrier AUTONOMOUS No-load input power of <10mW

Rpre-load

Rinrush

Drain

SourceGND

FB

VCC

TEA1721

adapter cable charging port

Total NO-LOAD performance 10mW!

VCC=20V

I=0.1mA

2mW

3mW

FB sensing

Only dissipating during

Prim+sec stroke

0.1mW

Elcap 10u 400V

10uA,325V (estimation)

3.2mW

Vsec=5V

I=0.4mA

2mW

3mW

Snubber

0.9uJ, 220V zener, 625Hz

0.6mW

Prectifier

0.1uA(40C),325V, 2x

0.1mW


IC in normal operation

(all circuits biased);

Icc= 1mA

Vcc=20V

P dissipated in IC = 20mW


Tswitch

Tburst

Vout-peak reaches control value in several cycles

End of burstStart of burst

Minimum supply current for Energy Save

1 2 3 1

Vout

Iprimary

Low active

current

Isupply

Ultra Low Isupply between bursts

IC switches to minimum supply current: Energy Save Mode

Start of next burst

26

Breaking the <10mW barrier Greenchip Energy Saving Mode


IC in Energy Save mode (IC switches only biases essential functionality);

Icc average = 100uA, Vcc=20V P dissipated in IC = 2mW


GreenChip energy balance in power supplies


Typical energy gain in average conditions: ~5-10 W

Typical energy consumption by GreenChip set itself: ~0.5 W

Energy Return-On-Investment: factor 10 – 20!


Energy

Examples:




• LED drivers

• Smart Grid




Sun as our energy source…

“Every 6 hours, enough sunlight energy reaches the Earth

to meet the world‟s energy demand for a whole year”

So, only 0.07% of the energy in sunlight would need to be

harnessed to cover mankind‟s total energy needs

1 - U.S. Department of Energy

1.9 x 108 TWh / yr

(onto land)

1.3 x 105 TWh / yr

energy usedsunlight



From PV-cells to PV modules and array

To increase their utility (Voltage,

Current and Power), dozens of

individual PV cells are

interconnected together in a

sealed, weatherproof package

called a module.

PV-Cell PV-Module/PV-Panel PV-Array

To achieve the desired voltage1

and current, modules are wired

in series and parallel into what

is called a PV array.



Shading kills efficiency in solar panels

National Semiconductor Solar Magic

Even shade on a few cells can

take out complete panel!



Shading in real-life conditions

Common shade sources:

• Trees, chimneys, antennas,

building parts,…

• Residential and commercial

• Even small shaded area (e.g. 10%) can reduce

output power significantly (>30%)



Experimental dataPower losses depending on shaded area

Power loss for Series 1x9 Power loss for Parallel 3x3

Shaded area

(%) Experimental data Experimental data

11.1% 12.6% 29.2%

13.9% 22.2% 36.8%

12.5% 18.3% 17.0%

11.1% 35.6% 30.5%



Typical PV system set-up Grid-tied configuration

• PV module= 32..72 cells in series

• String=many series-connected

current sources

• PV system= parallel strings of

series-connected PV modules

• Central inverter: performs DC/AC

power conversion and tracks MPPT

of the system

• Result: Even at system MPP, string

current is limited by output current of

weakest cell

Inverter

PV

module

ACDC

+

-

Str

ing

= ~

array



Inverter

PV

module

ACDC

+

-

Str

ing

= ~

Improving the power output of a PV system

= == =

Converter

DCDC= == =

Converter

DCDC= == =

Converter

DCDC

= == =

Converter

DCDC= == =

Converter

DCDC= == =

Converter

DCDC

= == =

Converter

DCDC= == =

Converter

DCDC= == =

Converter

DCDC

= == =

Converter

DCDC= == =

Converter

DCDC= == =

Converter

DCDC

= == =

Converter

DCDC= == =

Converter

DCDC= == =

Converter

DCDC

Add DC-DC converter per

module:• More converters to be added

but more power gain because

more granular control

This is the first focus area of the

NXP distributed power

management solutions for PV

applications

D-Converter



Quantification of NXP-concept valueField trial setup

-

+

DC/AC

Measurement box

PDC PAC

AC

lin

e

Eh

tern

et

Reference string

-

+

DC/AC

Measurement box

PDC PAC123456789101112

123456789101112

NXP delta-converter string

Panel converter connector (needed for D)


Quantification of NXP-concept valueField trial setup

Chimney shade

Simulate dust/soiling

Energy

June 22, 2010: duct-tape and chimney

0

2

4

6

8

10

12

14

16

0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00

time

En

erg

y [

KW

h]

E-ref

E-nxp

Energy gain %

June 22, 2010: duct-tape and chimney

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

0:00:00 4:48:00 9:36:00 14:24:00 19:12:00 0:00:00

time

En

erg

y [

KW

h]

delta-E%

30%

Energy - reference

Energy – w Delta-Conv

Energy gain (%)



Energy Return-on-investment delta-converter

Nominal Power: 4kWp installation

Location: Venice, with optimal slope, south oriented

Shading: small chimney for max 2 hours

Expected energy production/year: 5.000 kWh


Typical energy gain in average conditions: ~80-160kWh

Typical energy consumption by Delta-converter itself: ~6kWh

Energy Return-On-Investment: factor 10 – 30!


Energy

Examples:




• LED drivers

• Smart Grid




Breakdown of domestic electricity use

Lighting consumes about 19% of the

global electricity *)

0

200

400

600

800

1000

1200

1400

1600

1800

2000

com

pute

rs

cook

ing

elec

tronics

wash

ing/dry

ing

refriger

ation

cooling

light

ing

wate

r hea

t

heatin

g

othe

r

KW

h/y

ear/

ho

useh

old

USA (2001)

EU-15 (2004)

NL (2005)

EU-12 new

members (2004)


Source: EIA

*) World Watch Institute, Oct 2008

//antwrp.gsfc.nasa.gov/apod/image/0011/earthlights2_dmsp_big.jpg


Efficacy (Lumen/Watt) trends

Source: Datapoint 2008



Lamp technology comparison: Efficacy

CRI = Color Rendering Index (max. 100)

Example LED‟s in production (general lighting)

Example LED‟s in research (general lighting)

Source: Datapoint 2008



Regulation Kicks in: (EC) No 244/200918 March 2009: implementing Directive 2005/32/EC of the European Parliament and of the Council

with regard to eco-design requirements for non-directional household lamps

Functionality

parameter

Stage 1: September 2009 Stage 5: September 2013

Lamp survival factor at

6000 h

≥ 0,50 ≥ 0,70

Lumen maintenance At 2 000 h: ≥ 85 % (≥ 80 % for lamps with

second lamp envelope)

At 2 000 h: ≥ 88 % (≥ 83 % for lamps with

second lamp envelope)

At 6 000 h: ≥ 70 %

Number of switching

cycles before failure

≥ half the lamp lifetime expressed in hours

≥ 10 000 if lamp starting time > 0,3 s

≥ lamp lifetime expressed in hours

≥ 30 000 if lamp starting time > 0,3 s

Starting time < 2,0 s < 1,5 s if P < 10 W

< 1,0 s if P ≥ 10 W

Lamp warm-up time to

60 % Φ

< 60 s or < 120 s for lamps containing

mercury in amalgam form

< 40 s or < 100 s for lamps containing

mercury in amalgam form

Premature failure rate ≤ 2,0 % at 200 h ≤ 2,0 % at 400 h

Lamp power factor ≥ 0,50 if P < 25 W

≥ 0,90 if P ≥ 25 W

≥ 0,55 if P < 25 W

≥ 0,90 if P ≥ 25 W

Requires pre-heat

Needs

compensation for

aging burner

Requires boosting

Needs pre-heat

and protection

features

Key IC

advantages

Active Power

Factor corrections

(>25W)



Challenges for Compact Fluorescent Lamps (CFL)

1. Cost reduction– Leading to broader acceptance

2. Miniaturization– Less volume of electronics and burner to meet form factor of incandescent

lamps

3. Dimmable– Compliant with installed wall dimmers made for incandescent lamps

4. Quality improvements– Increased lifetime from 6khrs to 15khrs– Less early failures in the field – Shorter run-up time– Constant lumen output over life– Less impact of on/off switching cycles on lifetime– Better power factor

• (Supported by new regulations (EU: 2009, US: 2008, SuperCFL)



CFL innovations in multiple directions

Generation

Features

Old discrete

solution

Today: Cost

optimized (NXP’s Dragon)

First IC

solution

Today:

Performance

optimized (NXP’s Phoenix)

Cost 0 ++ + +

Form factor 100% 70% 80% 70%

Dimmable Impossible Not available Down to 10% Down to 1%

Quality &

Reliability- ++ + ++

Non-dimmable Dimmable



CFL startup states controlled

Protections Preheat Ignition Quick start, transition & burn state

Capacitive mode X X

Coil saturation X

Overcurrent X

Overtemperature X

Quick start state

Lamp

drive

frequency

time

Dimmer regulated frequency

Ign

itio

n

sta

te100%

Burn state

1%

start freq

(>100kHz)

preheat freq

Preheat state

Dimming

RMS

Lamp

current1%

100%



Optimized quasi pre-heat

Starting frequency can be set by Rosc/Cosc

Minimum frequency is set by Rsw or voltage divider

Pre-heat time can be set by Csw

Fre

qu

en

cy

fila

me

nt cu

rre

nt

pre

he

at e

ne

rgy

Starting at100 kHz

Starting at75 kHz

Igniting at65 kHz

Time600 ms

Preheat time

Ignition

Burn

Lifetime extension in CFL



Energy

Examples:




• LED drivers

• Smart Grid




LED is the future

LED lighting is booming

LED lighting segment: 5 Billions USD by

2014 (83% HB-White and 17% “high-

end” RGB) *)

Thermal management is a must

– ~75% input energy turns into heat

– LED performance AND lifetime depends

heavily on LED junction temperature

Heat sink


*) Databeans July 2009


Requirements for LED drivers

High energy efficiency low heat

dissipation small form factor

Stable color performance

Deep dimming, compliant to existing wall

dimmers

Cost-competitive

Long lifetime

One solution for isolated and non-isolated

lamp designs



RGB LEDs and High Brightness White LED

C

Red

Green

Blue

x1,y1

x2,y2

x3,y3

xc,yc

HB White: Blue LED + Yellow Phosphor

+ Low cost

+ Lower control complexity

- No color adjustment possible

- Poor color rendering

RGB LEDs

+ Can make any color within the triangular

+ Good color rendering

- Higher cost

- Control complexity

Popular

High-end



LED lights get hot: Shift happens

25°C

50°C

85°C



Conventional LED driving method Pulse Width Modulation Rules

Color mixing Brightness scaling

IT

tt

DC =t

TX 100%

Constant current



External bleeder transistors External Power Mos

LED Drivers solutions exist…

External bleeder transistors External Power Mos

Isolated 7W isolated dimmable LED driver



Next Generation: Smart LED driver

Conventional LED driving method

sensors Thermal modeling

Compensation calc.LED driver

Tj determinationDrive currents

LED control model

force

sense

Next generation: Driver that senses the LED performance and adjusts the

driving conditions accordingly

Smart LED driver

- High Cost

- Complex system

- Slow response

- Less accurate

- Save system cost

- No sensor

- Very fast response

- Accurate



0 10 20 30 40 50 60 70 80 90 100 1100.000

0.002

0.004

0.006

0.008

0.010

0.012

0.014

D

elta u

'v'

Temperature [oC]

Human Eye Detection Limit

Open Loop

Temp Feed Forward

Flux Feed Back

Flux Feed Back + Temp Feed Forward

Color Coordinations Feed Back

Our results

56

Results of next generation LED drivers

Control accuracy using direct Tj measurement versus conventional

close loop controls

Human eye color resolution limit



Robust, HV-IC process technologies required

EZ-HV LDMOS technology ABCD – SOI technology

120-700V HV-SOI technology, 1500C max

NDMOS with Rds(on) of 8 mm2 @ 700V

MHz switching capability because of reduced parasitic capacitance

One process for 12-120 V range

Rds(on) of 300 mm2 @ 100V

Extremely robust: EMC, EMI, ESD, High Temperature



Energy

Examples:




• LED drivers

• Smart Grid




Smart Grid Application drivers

HANFAN/NANWAN

Remote reading, remote (dis)connect, tampering & theft

protection, pre-paymentAMI

Active load management, Dynamic pricingDemand Response

Intermittent alternative energy sources, 2-way use of grid,

distributed energy storage, micro-grids

Distributed Energy

Generation

Efficient charging, Roaming, Vehicle-to-GridElectric Vehicles

Power layer

Communications layer

Eg Dynamic transformer voltage managementGrid Optimization


http://www.clker.com/clipart-14374.html


Smart Home is part of Smart Grid

Smart

Elec.

Smart

Water

Appliances

Temperature

Light

Wind Turbine

Solar Panel

Smart

Gas

Home displays

TV, Computer

In-Home

Energy

Display

Breakes Valves

Gateway

Data centers

Smart metering devices

Smart home devices

Distributed electricity

generation and storage Displays

Communication hub

Hybrid car

Com

munic

atio

n

hub

Hybrid carSmart Elec.

Contactless Contact

Card readers

IP NetworkIndependent service

providers

Smart

Heat

Concentrator

Sensors


•Bill entity

•Distribution network operators

•Law enforcement

• Added value services…


Lighting in a Smart HomeSystem Architecture

AC/DC

standby

AC mains

Trans-

ceiveruC

on/off dim3.3V

remote control

RF link

Capacitive

converter

CFL or LED

Driver


gateway


Conclusions

„‟Green‟‟ has become a major innovation

driver for the IC industry

Smart chips (Greenchips!) make an

excellent energy “Return-On-

Investment”!

High-Performance Mixed-Signal products

are making the difference.



Thank you!


Documents

Green chips: a new era for the semiconductor industry