the cutting edge of power electronics for high-power...
TRANSCRIPT
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Tokyo Institute of Technology
Power Electronics Lab.
The Cutting Edge of Power Electronics
for High-Power Applications
Hirofumi Akagi
Tokyo Institute of Technology
July 28, 2015
1
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Tokyo Institute of Technology
Established in 1881 2
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Environmental Energy Innovation (EEI) Building with
650-kW Photovoltaic, 100-kW Fuel-Cell, and 100-kWh
Lithium -Ion Battery Energy Storage Systems
3
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Tokyo Institute of Technology
Power Electronics Lab.
Energy Efficiency of Passenger Aircrafts
Airbus A340-300
Number of seats: 261
Max. take-off weight: 250,000 kg
Range: 12,800 km
Cruising speed: 875 km/h
Fuel Consumption (Energy Efficiency):
0.039 liters per seat/km
Airbus A330-300
Number of seats: 261
Max. take-off weight: 233,000 kg
Range: 9,700 km
Cruising speed: 875 km/h
Fuel Consumption (Energy Efficiency):
0.035 liters per seat/km
source: SCANORANAM, FEB 2007
A340-300
A330-300
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Tokyo Institute of Technology
Power Electronics Lab.
What is Power Electronics? (1/2)
The IEEE Power Electronics Society with a membership
of 8,000 is one of some 40 IEEE Societies.
Power Electronics is based on switching operation of
power semiconductor devices such as MOSFETs and
IGBTs for achieveing efficient power conversion.
Power Electronics Technology encompasses
1. the effective use of electronic components,
2. the application of circuit and control theory,
3. the development of analytical tools toward conversion,
control, and conditioning of electric power.
5
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Tokyo Institute of Technology
Power Electronics Lab.
What is Power Electronics? (2/2)
Power range: from several watts to 6.3 GW
Frequency range: from 0 Hz(dc) to 13.56 MHz
Devices: semiconductors, magnetics, and capacitors
Controls: DSPs, PLDs, FPGAs, A/D converters, and
sensors of voltage, current, magnetic flux, position,
speed, acceleration, temperature, etc.
Power Electronics is on the basis of
Devices, Circuits, Controls, and Systems
6
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Tokyo Institute of Technology
Power Electronics Lab.
Practical Applications of Power Electronics
Switching power supplies for computers and servers
Home appliances:air conditioners, refrigerators, induction-heating
cookers, microwaves, vacuum cleaners, laundry machines, electric
fans, LED lamps, and so on.
UPS (uninterruptable power supply):from 1 kW to 1 MW
Industrial induction heating:200 kHz 200 kW for surface quenching
Industrial ac motor drives: fans/blowers, pumps, compressors, steel
mils, and so on
Transportation: high-speed and commuter trains, trams/street cars,
electric vehicles, fuel-cell vehicles, ships/boats, and aircrafts
Electric power utilities: photovoltaic inverters, battery energy
storage systems, adjustable-speed pumped hydro storage, reactive-
power controllers, high-voltage dc transmission systems
7
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Tokyo Institute of Technology
Power Electronics Lab.
A Flexible, Effective, and Fault-Tolerant
Battery Energy Storage System (BESS)
To be published in the IEEE Transactions on Power
Electronics, or Early access
8
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Tokyo Institute of Technology
Power Electronics Lab.
An Existing Battery Energy Storage System (BESS)
5.8 kV
EDF Energy Networks, UK
600-kW 200-kWh BESS
for peak shaving
Neutral-Point Clamped
(NPC) Converter[1]
Li-ion battery system
N. Wade, P. Taylor, P. Lang, and J. Svensson, “Energy storage for power flow management and
voltage control on an 11kV UK distribution network,” in Proc. CIRED’09, Jun. 2009.
9
[1] A. Nabae, I. Takahashi, and H. Akagi, “A New Neutral-Point-Clamped PWM Inverter,”
IEEE Trans. Industry Applications, vol. 17, no. 5, pp. 518-523, Sep./Oct. 1981. Cited by 3214
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Tokyo Institute of Technology
Power Electronics Lab.
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
AC
DC
Comparisons between Existing and New BESSs
Single Large
Converter
Multiple Small
Converters
One converter-to-one battery module
Parallel connection
of series-connected
battery modules
From 6.6 to 66 kV
Existing System
A New System
10
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Tokyo Institute of Technology
Power Electronics Lab.
Three-phase 10-kW, 22-kWh Downscaled System
Th
e v-
ph
ase
clu
ster
Th
e w
-ph
ase
clu
ster
Bridge
cell 2
Bridge
cell 6
CB
LS
vS
LAC
M
vuv
The u-phase cluster
Cu1
200 V/140 V
50 Hz
Li-ion
Battery
Module
25.9 V
Nominal line-to-line
rms voltage VS
140 V
Rated power 10 kW
Cascade number 6
Background system
Inductance LS
0.10 mH
(1.6%)
AC link Inductance
Lac
0.33 mH
(5.3%)
DC capacitor
capacitance 47 mF
Nominal battery
voltage
25.9 V
Each battery capacity 1.2 kWh
PWM carrier
frequency fC 1.75kHz
Equivalent PWM
carrier frequency 21 kHz
Circuit parameters
vuM vvM vwM
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Tokyo Institute of Technology
Power Electronics Lab.
18 Li-Ion Battery Modules (25.9 V, 47.5 Ah )
Nominal voltage: 25.9 V (=3.7 V/cell times 7 cells)
Weight: 15 kg/module, Total capacity: 22 kWh 12
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Tokyo Institute of Technology
Power Electronics Lab.
Control System
BMS:
Battery
Management
System
Digital controller
Signals
Input: 43
Output: 72
(Active-power reference)
13
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Tokyo Institute of Technology
Power Electronics Lab.
Phase-Shifted-Carrier PWM (One-Cell Update)
Hold
Carrier signal
Calculation (within 40 μs)
Hold time = N × Calculation time 14
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Tokyo Institute of Technology
Power Electronics Lab.
Phase-Shifted-Carrier PWM (All-Cell Update)
Hold Calculation
Hold time = Calculation time 15
Carrier signal
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Tokyo Institute of Technology
Power Electronics Lab.
Comparisons between Theory and Simulation in Open-Loop
Transfer Function of Current Control
Phase margin: 70°
Cascade count: N=6
Gain margin: 12 dB
16
All-cell update with K=1.7 V/A
One-cell update
with K=0.6 V/A
All-cell update One-cell update
Simulation
Solid lines: Theory
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Tokyo Institute of Technology
Power Electronics Lab.
Critical Damping Gain vs Cascade Count N
All-cell update is better in current controllability
than one-cell update
Three times at N=6
17
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Tokyo Institute of Technology
Power Electronics Lab.
Experimental Waveforms (All-cell update)
vSu
[V]
vuM
[V]
vuv
[V]
iu
[A]
vC
[V]
Charge mode Discharge mode
-140
0
140
-60
0
60
-140
0
140
-280
0
280
0
15
30
-140
0
140
-60
0
60
-140
0
140
-280
0
280
0
15
3025 V 25 V
13 levels 13 levels
THD = 1.70 % THD = 1.87 %
18
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Tokyo Institute of Technology
Power Electronics Lab.
Published in the IEEE Transactions on Industry Applications,
vol. 50, no. 4, pp. 2648-2659, July/Aug. 2014
A Grid-Level High-Power DSCC-Based BTB
(Back-To-Back) System Without Common
DC-Link Capacitor
19
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Tokyo Institute of Technology
Power Electronics Lab.
Self-commuted devices (e.g., high-voltage GCTs)
Fast response, Easy to self-start
No dc capacitor or voltage sensor at 264-kV dc-link
A Grid-Level DSCC-Based BTB System
AC AC
DC
132 kV
264 kV
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
cell
Bidirectional
chopper-cell
DSCC-A DSCC-B
132 kV
100 cells
per arm
20
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Tokyo Institute of Technology
Power Electronics Lab.
p
Downscaled BTB Unit for Experiment
DSCC-A
cell 1uA
cell 8uA
cell 9uA
cell 16uA
cell 1vA
cell 8vA
cell 9vA
cell 16vA
cell 1wA
cell 8wA
cell 9wA
cell 16wA
Lac : 2 mH
(16%)
AC
200 V / 50 Hz 200 V / 50 Hz
LZ :
3 mH
(24%)
VC : 50 V
C : 6.6 mF
(40 ms)
Vdc :
400 V
DC
AC
cell 1uB
cell 8uB
cell 9uB
cell 16uB
cell 1vB
cell 8vB
cell 9vB
cell 16vB
cell 1wB
cell 8wB
cell 9wB
cell 16wB
Three-phase 200-V, 10-kW BTB system
iSuA
Power
idc
vuvA
8 cells/arm DSCC-B
Without dc-link capacitor Carrier frequency
fC : 450 Hz 21
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Tokyo Institute of Technology
Power Electronics Lab.
u-phase
v-phase
w-phase
DSCC-A DSCC-B
Module Structure:
16 cells/leg
Chopper Cell: 150-V 70-A
MOSFET×4×2
50-V 6.6-mF
Capacitor
Photo of three-phase 200-V 10-kW 50-Hz BTB System
Digital Controller:
A DSP board and
Two FPGA boards
PC based data acquisition systems 22
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Tokyo Institute of Technology
Power Electronics Lab.
Digital Control System
Line-to-line voltages 2×2
Arm currents 6×2
Capacitor voltages 48×2
Detected signals Output: 192 (= 96×2) gate signals
Sampling frequencies in digital control
arm currents: 7.2 kHz (= 450Hz×16)
capacitor voltages: 450 Hz
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Tokyo Institute of Technology
Power Electronics Lab.
Rectification (DSCC-A) at p* = +8.7 kW, qA* = -5.0 kVA
Source voltages
Source currents
Capacitor voltages
AC-terminal
voltages
-400
vSuvA vSvwA vSwuA
iSuA iSvA iSwA
vuvA vvwA vwuA
400
0
-400
400
0
-50
50
0
0
50
vC1uA vC9uA
Experiment Simulation
20 ms
-400
vSuvA vSvwA vSwuA
iSuA iSvA iSwA
vuvA vvwA vwuA
THD: 0.27% (u)
400
0
-400
400
0
-50
50
0
0
50
vC1uA vC9uA
20 ms
DC-link voltage
0
vdc
400
0
400
vdc
vC* = 50 V
vdc* = 400 V
THD: 0.28% (u)
vC* = 50 V
vdc* = 400 V
24
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Tokyo Institute of Technology
Power Electronics Lab.
[kW]
Transition (DSCC-A) at p* = +10 kW → -10 kW
-400
vSuvA vSvwA vSwuA
iSuA iSvA iSwA
vuvA vvwA vwuA
400
0
-400
400
0
-50
50
0
0
50
vC1uA vC9uA
20 ms
-400
vSuvA vSvwA vSwuA
iSuA iSvA iSwA
vuvA vvwA vwuA
400
0
-400
400
0
-50
50
0
0
50
vC1uA vC9uA
Power-flow
reference -10
p*
10
0
-10
p*
10
0
Source voltages
Source currents
Capacitor voltages
AC-terminal
voltages
qA* = qB
* = 0 Experiment Simulation 20 ms
25
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Tokyo Institute of Technology
Power Electronics Lab.
A Low-Speed, High-Torque Motor Drive Using the
Modular Multilevel Cascade Converter Based on
Triple-Star Bridge Cells (MMCC-TSBC)
To be Published in the 2015 Sep./Oct. Issue of
the IEEE Transactions on Industry Applications, or Early access
26
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Tokyo Institute of Technology
Power Electronics Lab.
Medium-Voltage High-Power Motor Drives
Blower fan from
Mitsubishi Heavy Industry
Cement mill drive
from ABB
Line-commutated cycloconverters using thyristors
Problems: Low lagging power factor
Complicated line harmonic currents
27
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Tokyo Institute of Technology
Power Electronics Lab.
Three-phase 400-V 15-kW TSBC Converter
Su
bco
nve
rte
r b
Su
bco
nve
rte
r c
200 V
50 Hz L = 5 mH
(4.9%)
C = 1.7 mF
Vc = 200 V
H = 81 ms
200 V/400 V
IM
320 V, 15 kW
38 Hz, 41 A
6 poles, 750 min-1
Rated Torque Load
Carrier freq.:
1 kHz Equiv. carrier freq.:
8 kHz Dead time:
4 ms
Three three-legged
three-winding
ac inductors
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Tokyo Institute of Technology
Power Electronics Lab.
Overview of the Experimental System
TSBC converter IM
IG
TG
FPGAs & A/D Converters DSP
MUX
200 V 50 Hz
200 V / 400 V
PT
Regenerative Load
Gate signals
144 9 18
36
2
320 V
15 kW
41 A
Tacho-
generator
29
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Tokyo Institute of Technology
Power Electronics Lab.
Three-phase 400-V 15-kW Experimental System
4 Bridge Cells per Cluster
a b c
I/F
- 36 Bridge Cells
- 144 IGBTs
L = 5.0 mH (5%)
Three three-legged
three-winding ac inductors
C = 1.7 mF
Vc = 210 V (rated)
H = 89 ms
Carrier frequency: 1 kHz
30
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Tokyo Institute of Technology
Power Electronics Lab.
Three-phase 320-V 15-kW Induction Motor
4 poles, 50 Hz, 15 kW
6 poles, 38 Hz, 15 kW
Rated Values
Power 15 kW
Voltage 320 V
Current 41 A
Frequency 38 Hz
Rotating
speed
750 r/m
Poles 6
Torque 191 N・m
31
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Tokyo Institute of Technology
Power Electronics Lab.
Start-up Performance Loaded at 100% Torque
Rotating speed
[r/m]
Cluster current
[A]
Motor current
[A]
Motor voltage
[V]
Capacitor
voltages [V]
12.5 s
≎ ⊤ ≲ ≭ ∻ ≎ ≲ ≭
≩ ≵ ≡
≩ ≍ ≡
≶ ≍ ≡ ≢
≶ ≵ ∱ ≃ ≡ ∻ ≶ ≶ ∱ ≃ ≡ ∻ ≶ ≵ ∱ ≃ ≡
1000
500
0 80
0
-80 80
0
-80 1000
0
-1000 240
0
Controlled in a
range of 120 V
to 210 V Fluctuation-mitigating control
750 r/m (100%)
42 A in rms
(𝑓M ≈ 38 Hz)
120
32
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Tokyo Institute of Technology
Power Electronics Lab.
Nrm = 100 r/m (13%) Loaded at 100% Torque
Supply currents [A]
Cluster currents [A]
Motor currents [A]
Motor voltages [V]
Supply voltages [V]
Supply-side output voltages [V]
≶ ≵ ≶ ≓ ∻ ≶ ≶ ≷ ≓ ∻ ≶ ≷ ≵
≓
≶ ≵ ≶ ≡ ∻ ≶ ≶ ≷ ≡ ∻ ≶ ≷ ≵
≡
≩ ≵ ≓ ∻ ≩ ≶ ≓ ∻ ≩ ≷ ≓
≩ ≵ ≡ ∻ ≩ ≶ ≡ ∻ ≩ ≷ ≡
≩ ≍ ≡ ∻ ≩ ≍ ≢ ∻ ≩ ≍ ≣
≶ ≍ ≡ ≢ ∻ ≶ ≍ ≢ ≣ ∻ ≶ ≍ ≣ ≡
≶ ≵ ≃ ≡ ∻ ≶ ≶ ≃ ≡ ∻ ≶ ≷ ≃ ≡
Capacitor voltages [V]
1000
0
-1000 1000
0
-1000 80
0
-80 80
0
-80
80
0
-80 1000
0
-1000
240
0
400 V
50 Hz
Mean dc voltage: 200 V
Nine-level
40 ms
13 level
40 ms
No active voltage control with active voltage control
Mean dc voltage : 132 V
1000
0
-1000 1000
0
-1000 80
0
-80 80
0
-80
80
0
-80 1000
0
-1000
240
0
THD: 4.4%
1000
0
-1000 20
0
-20 10 ms
[V]
[A]
1000
0
-1000 20
0
-20
THD: 6.8%
10 ms
[V]
[A]
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Tokyo Institute of Technology
Power Electronics Lab.
Power-Loss Breakdown of a 750-Vdc, 100-kW,
20-kHz Bidirectional Isolated DC-DC
Converter Using SiC-MOSFET/SBD
Dual Modules
Published in the IEEE Transactions on Industry Applications,
vol. 51, pp. 420-428, Jan./Feb. 2015
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Tokyo Institute of Technology
Power Electronics Lab.
1.2-kV, 800-A SiC-MOSFET/SBD Dual Module
R. Wood and T. Saken, “Evaluation of a 1200-V, 800-A All-SiC Dual Module,”
IEEE Trans. on Power Electronics, vol. 26, no. 9, 2011 35
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Tokyo Institute of Technology
Power Electronics Lab.
Bidirectional Isolated DC-DC Converter
Two Technical Terms
Functionality: Bidirectional Isolated DC-DC Converter
Circuit Topology: Dual-Active-Bridge Converter
Function/Operation
Both buck and boost function: E1 > E2 and E1 < E2 When N=1
Zero-voltage-switching (ZVS) operation
Synchronous Rectification (limited to Si and SiC MOSFETs)
R. W. De Doncker, D. M. Divan, and M. H. Khealuwala, IEEE Trans. IA, 1991.
36
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Tokyo Institute of Technology
Power Electronics Lab.
Experimental System at 750 V, 100 kW, and 20 kHz
Converter (dc-to-dc) efficiency
with a tolerance of 0.03%
1.2-kV, 400-A SiC-MOSFET/SBD Module
37
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Tokyo Institute of Technology
Power Electronics Lab.
Experimental Waveforms at 750 Vdc and 100 kW
750 V
750 V
152A
38
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Tokyo Institute of Technology
Power Electronics Lab.
0 20 40 60 80 10090
92
94
96
98
100
0
1
2
3
Pow
er L
oss
[k
W]
Power Loss and Efficiency
Efficiency
Power Loss
ηmax = 98.7%
@38 kW
η = 97.9%
@100 kW
Maximum Efficiency: 98.7 %
Rated-Power Efficiency: 97.9%
Output Power [kW]
Eff
icie
ncy
[%
]
ZVS
Incomplete
ZVS
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Tokyo Institute of Technology
Power Electronics Lab.
Power-Loss Breakdown at 100-kW Operation
Conduction 675 W
(31.6%)
Switching 547 W
(25.6%)
Copper 394 W
(18.4%)
Iron 259 W
(12.1%)
Unknown
261 W
(12.2%)
• Power Loss in SiC-MOSFET/SBD: 60%
• Power Loss in Magnetic Devices: 30%
• Conducting and Switching Losses are Nearly Equal.
SiC-MOSFET/SBD
1222 W (57%)
Magnetic devices
653 W (31%)
1:1
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Tokyo Institute of Technology
Power Electronics Lab.
SiC-MOSFET/SBD and Si-IGBT/PND Modules
SiC- MOSFET/SBD
Dual Modules
Si-IGBT/PND
Dual Modules(1)
Power rating 100 kW 60 kW
Reference voltage 750 Vdc 750 Vdc
Frequency 20 kHz 4 kHz
Power device 1.2 kV and 400 A 1.2 kV and 300 A
Maximum efficiency 98.7% 97.8%
Rated-Power Efficiency 97.9% 96.9%
Both dual modules have the same packaging in size,
shape and pin/terminal arrangement.
(1) T. Chocktaweechock, K. Hasegawa, and H. Akagi, IEEJ IAS Annual Meeting, 1-94, Aug. 2012
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Tokyo Institute of Technology
Power Electronics Lab.
Past, Present, and Future of the DC-DC Converters
20-50 kHz
(1) M. H. Kheraluwala, et al., IEEE Trans. Ind. Applicat., vol. 28, no. 6, pp. 1295-1301, 1992
1990(1) 2014 (Tokyo Tech) 2020?
Switching
Devices Planar-Gate IGBTs
Planar-Gate
SiC-MOSFETs
Trench-Gate
SiC-MOSFETs
Core Material in
Transformer Ferrite FINEMETTM*
New Magnetic
Materials
Efficiency
(DC to DC)
Below 90%
@50 kW, 50 kHz
98%
@100 kW, 20 kHz
Over 99%
@100 kW, 20 kHz
* Nano-crystalline soft-magnetic material from Hitachi Metals
42
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Tokyo Institute of Technology
Power Electronics Lab.
What I want to emphasize
Power electronics people have been making a long
voyage
from a Silicon planet to a Silicon-Carbide planet.
It will take five years from now to complete the
wonderful voyage. This completion, as well as
the continuous development of “Control”
by leaps and bounds,
will bring a new world to power electronics.
43