TRENCHSTOP™ 5 IGBTs in Welding
Machines: Benefits and Optimizations
Dr. Vladimir Scarpa
Applications Engineer IGBTs and SiC Devices
Andrea Merello
Field Applications Engineer
Fortronic Power Forum, Bologna, Italy
September 2014
 TRENCHSTOP™ 5: Benefit
 Case Study 1 : Optimization Welding Machine Half Bridge
 Case Study 2 : Further Optimization & Full Bridge
 Key Messages & Conclusion
 Questions & Answers
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 2
 TRENCHSTOP™ 5: Benefits
 Case Study 1 : Optimization Welding Machine Half Bridge
 Case Study 2 : Further Optimization & Full Bridge
 Key Messages & Conclusion
 Questions & Answers
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 3
What is the Benefit?
Turn-OFF Losses
-40%
40A HighSpeed 3
40A Best Comp.
40A TRENCHSTOP™ 5
H5
BC
H3
Conditions:VCC=400V, IC=20A, TC=25°C, VGE=0V/15V, RG=15Ω, Ls=45nH
 Increasing switching frequency  reduce dimensions and volumes
 Reduce IGBT current rate
 Reduce cooling effort
2014-09-17
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Page 4
 TRENCHSTOP™ 5: Benefits and Challenges
 Case Study 1 : Optimization Welding Machine Half Bridge
 Case Study 2 : Further Optimization & Full Bridge
 Key Messages & Conclusion
 Questions & Answers
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 5
Welding Machine: Simplified Schematic
IGBTs Half-Bridge
Output Rectifiers
HB C-Bank
PFC Inductor
PFC (IGBT+FRD)
Trafo
BR+EMI+Main switch
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 6
How does it work?
System Level Electrical Simulation
 Typical Current and Voltage waveforms of an HB MMA Welding

Zero Current Turn-on (ZCS)

Hard turn-off
I(RL1)
Diode conduction
ZCS Hard turn-off
System Level Simulations via PowerSIM-Tech
2014-09-17
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Page 7
Description of IGBT Switching Behaviour in
typical welding application: turn-on
 Zero Current in turn-on.

Turn-on is performed at Zero current in HB, FB and TTF.

With ZCS is possible to strongly reduce switching losses

Smaller heatsinks or higher efficiency can be achieved
― Green, Ic @ 2,5A/div
― Brown: Vge @ 2,5V/div
― Blue: Vce @ 100V/div
― t=0.5µs/div
2014-09-17
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Page 8
TRENCHSTOP™ 5
used in high stray inductance environment

Excellent switching losses, but when used in layouts with
large stray inductance:
―High Voltage peaks during switching off may happen
―Oscillations on gate and collector are possible
―Challenges with EMI
350V
75V
HighSpeed 3
2014-09-17
TRENCHSTOP™ 5
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 9
TRENCHSTOP™ 5
used in high stray inductance environment
 Slowing down TRENCHSTOP™ IGBT in real application condition
 RG.OFF=33
195V
VCE @100V/div
IC @ 10A/div
t=100ns/div
Eoff=10,7µJ/A
120V
 RG.OFF=56
VCE @100V/div
IC @ 10A/div
VGE @ 10V/div
I(out)DC @ 100A/div
100ns/div
Eoff=12,2µJ/A
2014-09-17
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Page 10
Measurement of thermal performance
 Thermal performance on Commercial welding machine,
fsw=38kHz, Iout=200A.

Test critera: Tamb=25°C, VCE(max) < 160V, VGE(max) < ±25V
T=3°C
2014-09-17
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Page 11
Welding Machine Schematic
 2kW Commercial Welding machine.

Simplified schematics:
IGBTs Half-Bridge
Output Rectifiers
HB C-Bank
PFC Inductor
PFC (IGBT+FRD)
Trafo
BR+EMI+Main switch
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 12
WELDING DEMONSTRATOR
HB C-Bank
PFC Inductor
Improvement in PCB design
Output Rectifiers
Trafo
 Commercial Design (High Ls)
BR+EMI+Main switch
160+ nH
S1
S2
 New Concept (Low Ls)
<100 nH
S1
S2
+
0
-
+
0
2014-09-17
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Page 13
Performance Analysis. Test Vehicle 2
IFX Demonstrator HB MMA Welding, 2,5kW
ISOFOIL
50A H5 IGBT
IKW40N65H5
RAPID DIODES
HALF BRIDGE
TOPOLOGY
Drive card with 1ED-compact
1EDI60I12AF
set date
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Page 14
Test vehicle 1. Commercial MMA
2xIKW50T60 per switch (half di/dt)
 Vce(max) at 200A = 540V, IGBT´s Ic=20A per device
 Load Conditions:
steady state
welding, 25°C,
94mhom, 82µH,
100% Imax:
Ic (*)
 Purple, IC @
5A/div
 Yellow: Vce @
100V/div
 Cyan: Vdiode (sec.
side) @ 100V/div
 Green: load
current @
200A/div (i.e. 4
wires in parallel at
50A/div each).
 t=20µs/div
Set date
(*)
Ic has been measured with high resolution Hall-Effect probe.
Copyright © Infineon Technologies 2011. All rights reserved.
Page 15
Test Vehicle 2. IFX MMA
1 IKW40T60 per switch
 TF Machine, same IGBT, same load and test conditions:

Vce(max)=380V at ILOAD=110A, (IGBT´s Ic=20A)

Vce(max)=470V at ILOAD=250A, (IGBT´s Ic=55A)
[std: Vce(max)=540V at ILOAD=200A, (IGBT´s Ic=20Ax2)]
Set date
Copyright © Infineon Technologies 2011. All rights reserved.
Page 16
Comparison results between standard
machine and demonstrator
2xIKW50T60
1xIKW40T60
Original HB
MMA/TIG
welding
machine
Demonstrator HB
MMA/TIG
welding machine
210A
260A
Transformer primary
side current
38Apk
57Apk
Single IGBT collector
current
2x 19Apk
1x 57Apk
540Vpk
450Vpk <80% derating
Features
DC output current
Vce voltage
overshoot
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Page 17
Set date
Test Results with New Demonstrator
 Measurement of thermal performance on New Demonstrator

Acceptance critera: VCE(max) < 160V
TRENCHSTOP™
H3
T=16°C
TRENCHSTOP™ 5
 Test results from Customer with layout < 60nH who confirmed our data
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 19
 TRENCHSTOP™ 5: Benefits and Challenges
 Case Study 1 : Optimization Welding Machine Half Bridge
 Case Study 2 : Further Optimization & Full Bridge
 Key Messages & Conclusion
 Questions & Answers
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 20
Further improvements achievable with
TRENCHSTOP™ 5
 Demonstrator 2

1x IKW50N65H5 in place of 2x 40A
Competitors´ IGBTs.

Isolated solution with single Heatsink on
primary side electronics.

Dimensions down to 35% possible

Weight down to 30% possible

Possible to reduce the number of
Electrolytic capacitors down to half.

Switching frequency up to 100kHz.

Possible to reduce the transformer size.

Digital control available.

Isolated drivers available.
Drive card with
1EDI60I12AF
March 2014 - INTERNAL USE
Latest demonstrator
with Ls < 60nH
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 21
HB demonstrator 2
 Improven layout, HighSide loop shown
 60nH
September 3, 2013
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Page 22
Full bridge
 Improvements can be achieved also in FB configurations
 Example; 2.5kW MMA/TIG welding machine

Replacement of 3x HV-mosfets vs 1x TrenchStop™5 IGBT per
switch
2014-09-17
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Page 23
200A System solution for Chinese market
Collaboration IFX China- Local Design House
Original (MOSFET)
New (IGBT H5)
Size: 370mm×290mm×150mm
Size: 280mm×235mm×175mm
Weight: 9.2Kg
Weight: 6Kg
2014-09-17
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Page 24
Full Bridge layout design
PBC Design enhancements:
Former power PCB design with
3×HV-MOSFETs
 210nH loop inductance
PCB Design change using a
single TRENCHTOP™ 5 IGBT
 100nH loop inductance
2014-09-17
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Page 25
Max deliverable output current of welding machine
- by competitor devices
 Take the same thermal result as criteria, the max output current
of welding machine using competitor 40A devices are listed as
below.
Competitor
Max
output
current of
welder
Efficiency
IFX H5
200A
84.68% @100A
440V@200A
~83%@160&200A 431V@160A
420V@120A
Rgoff 6.2
Rgon 20
Cge 20pF
ST V series 1
Competitor
150A
82.05% @ 150A
406V@160A
Plug and
play (vs
H5)
FCS SMD
Competitor
2
series
120A
80.44%@120A
387V@120A
Rgoff 33
Rgon 20
Cge 1nF
2014-09-17
(best case 160A)
(best case 130A)
Voltage
overshoot
Copyright © Infineon Technologies AG 2014. All rights reserved.
Driving
paramet
er
Page 26
TRENCHSTOP™5 IGBT
Product Spectrum – Portfolio Extension
TO-220
TO-247-3
TO-220FP
DuoPak
Single IGBT
Continuous
collector
current
at TC=100°C
TO-247-4
New
TO-247
4 pin
20A
IGP20N65F5 / H5
30A
IGP30N65F5 / H5
40A
IGP40N65F5 / H5
IGW40N65F5 / H5
IGW50N65F5 / H5
50A
75A
100A
IGZ50N65H5**
IGZ75N65H5
IGZ100N65H5
8A
IKP08N65F5 / H5
IKA08N65F5 / H5
15A
IKP15N65F5 / H5
IKA15N65F5 / H5
20A
IKP20N65F5 / H5
30A
IKP30N65F5 / H5
40A
IKP40N65F5 / H5
IKW30N65H5
IKW40N65F5/H5
IKW50N65F5/H5
IKZ50N65EH5
IKZ50N65NH5
IKZ75N65EH5
IKZ75N65NH5
** Engineering samples available now, mass production Oct14
50A
75A
www.infineon.com/trenchstop5
2014-09-17
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Page 28
Overview 650V Rapid Diode Family
 The Rapid diode Family is …





a brand new silicon diode technology
split into two families
is optimized to address specific switching frequency range
silicon based (not silicon carbide)
complementary to Infineon’s existing high voltage diodes
NEW
0Hz
2014-09-17
NEW
EmCON
Rapid 1
Rapid 2
SiC
Diode
Ultrafast
Hyperfast
thinQ!™
18kHz
40kHz
100kHz
Copyright © Infineon Technologies AG 2014. All rights reserved.
>100kHz
Page 30
650V High Speed Power Silicon Diodes
Target Applications
Rapid 1: 18 to 40kHz
Rapid 2: 40 to 100kHz
2014-09-17
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650V High Speed Power Silicon Diodes
Product Portfolio – First Wave
TO-220
TO-247
The New
Rapid TO-220FP
Diode Families
TO-220 (real 2-leg)
Rapid 2
Rapid 1
Continuous
Current IC
TC=100°C
8A
IDP08E65D1
15A
IDP15E65D1
TO-220 FullPAK (real 2-leg)
TO-247
30A
IDW30E65D1
40A
IDW40E65D1
8A
IDP08E65D2
IDV08E65D2
15A
IDP15E65D2
IDV15E65D2
40A
IDP40E65D2
IDW15E65D2
IDW40E65D2
www.infineon.com/rapiddiodes
2014-09-17
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Page 32
 TRENCHSTOP™ 5: Benefits and Challenges
 Case Study 1 : Optimization Welding Machine Half Bridge
 Case Study 2 : Further Optimization & Full Bridge
 Key Messages & Conclusion
 Questions & Answers
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 33
Conclusion
Savings in terms of
 weight and dimensions, as well as
 improvements in performance,
 welding quality and
 EMI figures
can be achieved using a holistic approach
which take into account
 Semiconductors
 PCB-design and
 thermal management
2014-09-17
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Page 34
KEY MESSAGE
+
Fast Car
=
Bad Road
Oooopss!!
IC
350V
=
+
TRENCHSTOP™ 5
2014-09-17
Bad Layout Routing
Copyright © Infineon Technologies AG 2014. All rights reserved.
Power
VCE
UCE Overshoot!!
Page 35
 TRENCHSTOP™ 5: Benefits and Challenges
 Case Study 1 : Optimization Welding Machine Half Bridge
 Case Study 2 : Optimization Welding Machine Full Bridge
 Key Messages & Conclusion
 Questions & Answers
2014-09-17
Copyright © Infineon Technologies AG 2014. All rights reserved.
Page 36
Questions & Answers
2014-09-17
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Page 37