Intelligent Power Module: Drive
your Power with more
Integration
14th of June 2016
Vase Klandjevski
Field Application Engineer
Outline
1
IPM: Why? Market?
2
IPM: Where? Applications?
3
Product Line
4
µIPM – Innovative Packaging
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
2
Outline
1
IPM: Why? Market?
2
IPM: Where? Applications?
3
Product Line
4
µIPM – Innovative Packaging
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
3
Necessity for Inverter and PFC
› VSD (Variable Speed Drive) is implemented with AC  DC  AC
power conversion
– Inverter (power conversion for DC  AC) is key component
› Electrical appliances must comply with IEC61000-3-2 which
limits harmonic current emissions
– Power Factor Correction (PFC) solution is needed
Inverter Stage
Rectifier
PFC Stage
DC link
capacit
or
AC
source
NTC
Motor
Driver
Stage
NTC
ϑ
Driver
Stage
Boot
strap
ϑ
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
4
IPM
Benefits of Integration
Complete inverter stage in
one compact package
›
›
Isolation included
Just add
– 3 bootstrap caps
– 2 mounting screws
2015-06-14
Customer benefits
›
Simplified logistics
›
Improved manufacturability
›
Space saving
›
Shorter time to market
›
Increased reliability
›
Reduced system cost
Copyright © Infineon Technologies AG 2016. All rights reserved.
5
IPM
Benefits of Integration
› Over current protection
Line-line
short
– IGBT with short circuit rating
– Integrated protection features
› Temperature feedback and protection
– Built-in thermistor
– Correlation between thermistor and IGBT
temperatures
› Designed for EMI
– Optimized trade-off between losses and EMI
performance
– Homogenous dV/dt helps customers design a
platform across different power ranges
› Quality
– Fully qualified by Infineon
– Meets UL standards
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
6
Outline
1
IPM: Why? Market?
2
IPM: Where? Applications?
3
Product Line
4
µIPM – Innovative Packaging
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
7
Where can you use an IPM ?
› Refrigerator
AC
source
Rectifier
DC link
Inverter
(optional)
Compres
sor
 ~ 300W
 5A
› Washing machine
– Inverterized drum drive – main function
– Some have other functions: dryer fan, drain pump, compressor
AC
source
Rectifier
DC link
Inverter
Drum
Motor
 400W ~ 1.5kW
 8/10/15A
Drum drive
2015-06-14
Inverter
Dryer
Fan
 ~ 600W
 8/10A
Inverter
Drain
Pump
 ~ 100W
 1~2A
Inverter
Compre
ssor
 1kW
 15A
Copyright © Infineon Technologies AG 2016. All rights reserved.
8
Where can you use an IPM ?
› Room air conditioner
– For compressor and fan drives
– Some have IPM for PFC
AC
source
Rectifier
PFC
DC link
 Partial switching PFC (<2kW typ.)
 Full switching PFC (> 2kW typ.)
 15A-30A
AC
source
2015-06-14
Rectifier
DC link
Inverter
Compres
sor
 1.5kW~3kW
 8/10/15/
20/30A
Inverter
Outdoor
Fan
 40W~120W
 1/2/3A
 500V MOSFET
Inverter
Indoor
Fan
Copyright © Infineon Technologies AG 2016. All rights reserved.
 40W~120W
 1/2/3A
 250V/500V MOSFET
9
Where can you use an IPM ?
› Other applications
AC
source
2015-06-14
Rectifier
DC link
Inverter
Motor
 Dish washer
 2 ~ 5A
 MOSFET / IGBT
 Fan and Pump
 2 ~ 10A
 MOSFET / IGBT
 Elevator door
 10A
 Treadmill
 20 ~ 30A
 General Purpose
Inverter (GPI)
 5 ~ 50A
 Vacuum cleaner
 10 ~ 20A
Copyright © Infineon Technologies AG 2016. All rights reserved.
10
Outline
1
IPM: Why? Market?
2
IPM: Where? Applications?
3
Product Line
4
µIPM – Innovative Packaging
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
11
Product Line
The Best Fit for Your Application
36 x 21 x 3.1 mm
36 x 21 x 3.1 mm
34 x 15 x 3.8mm
29 x 12 x 2.9mm
12x12x0.9mm
8x9x0.9mm
7x8x0.9mm
CIPOS™ Mini
4-30A
600V-650V
Inv, Inv+Bridge
CIPOS™Tiny
IGBT: 6 - 15A/600V
µIPM™-DIP
UNDER DEVELOPMENT
MOSFET:
CIPOS™ Mini-DCB
15-30A
600V-650V
Inv, PFC, SRM
250,500V
IGBT: 600V
µIPM™, Smart µIPM™
1-4A/500V,2-8A/250V
µIPM™ Half-Bridge:40V,100V
µIPM Lineup
0.1Arms
2015-06-14
Standard IPM Lineup
Performance IPM Lineup
Motor Current
Copyright © Infineon Technologies AG 2016. All rights reserved.
15Arms
12
Outline
1
IPM: Why? Market?
2
IPM: Where? Applications?
3
Product Line
4
µIPM – Innovative Packaging
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
13
µIPM – Innovative Packaging
Fast Time to Market
2015-06-14
Innovation
Copyright © Infineon Technologies AG 2016. All rights reserved.
14
Inside µIPM
12x12x0.9mm
Built-in Bootstrap Function
Overcurrent Protection
Fault Reporting
VB1 VB2 VB3
Programmable Fault Clear Function
Optimized dV/dt
250V
0.45 – 2.4Ω
500V
600V
1.7 – 6.0Ω
V+
VCC
HIN1
HIN2
HIN3
LIN1
LIN2
LIN3
FAULT
ITRIP
EN
RCIN
COM
Under
Development
VSS
2015-06-14
U, VS1
V, VS2
W, VS3
600V
3-Phase
Driver
HVIC
Copyright © Infineon Technologies AG 2016. All rights reserved.
VRU
VRV
VRW
15
Inside Half Bridge µIPM
VS
HO G1
26, 27
18 to 23
V+
1
25
8x9x0.9mm
7x8x0.9mm
24
Ho
2
HIN
LIN
2 FETs + Half Bridge Gate Driver
4
5
10, 16, 17
Gate
Driver
IC
VS
3, 6, 8
Lo
IRSM001-100MH
Higher Power than 3-Phase
7
9
11 to 15
LO G2
VB
V-
IRSM80x-xxyMH
V+
Built-in Bootstrap Function
VCC
HIN
40-100V
5mΩ – 21mΩ
250V
0.15Ω
500V
0.8Ω - 1.7Ω
Driver IC with
Built-In
LIN
or LIN
Vs
Bootstrap
Functionality
VSS
VCOM
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
16
Thermally Efficient Design
Standard IPM requires large package for thermal mass. Heat
dissipated via leads
LEADFRAME
FET
PCB
µIPM has a thermally efficient design, allowing heat to
dissipate directly into PCB resulting in a much smaller package
FET
2015-06-14
LEADFRAME
Copyright © Infineon Technologies AG 2016. All rights reserved.
PCB
17
Performance Example
500V, 2.2Ω µIPM
(IRSM836-035MA)
100
90
IRMCS1173-1-M1 Ref PCB
Ta = 25℃, No Airflow
VBUS = 320V
Fan Motor (1400rpm):
Ke = 35VL-N/krpm
80
Power to Motor [W]
1oz (35µm) Cu Traces
Labels indicate RMS motor current (mA)
500
70
410
60
370
480
50
40
3 Phase
30
20
310
260
2 Phase
10
0
6
8
10
12
14
16
18
PWM Frequency [kHz]
20
PF = 0.95
2015-06-14
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18
Performance Example:
3-Phase vs 2-Phase Modulation
Duty Cycle
90%
44% increase in power
capability (Example A)
0.6
0.4
60%
0.2
50%
0.0
40%
-0.2
30%
-0.4
20%
-0.6
10%
-0.8
Duty Cycle
Duty HS
0.8
80%
0.6
70%
0.4
60%
0.2
50%
0.0
40%
-0.2
30%
-0.4
20%
-0.6
10%
-0.8
0%
0.00E+00
2015-06-14
2.00E-03
4.00E-03 6.00E-03
Time (s)
8.00E-03
-1.0
1.00E-02
2.00E-03
4.00E-03 6.00E-03 8.00E-03
Time (s)
SVM_Discontinuous_High
-1.0
1.00E-02
SVM_Discontinuous_Symmetrical
2-Phase
Modulation
(Symmetrical)
Duty LS
Duty HS
Duty LS
Duty HS
1,0
1.0
0,8
0.8
0,6
80%
70%
70%
60%
0.6
0,4
0.4
0,2
60%
50%
50%
40%
0.2
0,0
0.0
-0,2
40%
30%
30%
20%
-0.2
-0,4
-0.4
-0,6
20%
10%
10%
0%
-0.6
-0,8
-0.8
-1,0
Cycle
Duty
Cycle
Duty
Duty LS
90%
0.8
70%
100%
100%
90%
90%
80%
1.0
Modulation Index
SVM_Discontinuous_High
2-Phase
Modulation (Flat Bottom)
1.0
Duty HS
80%
0%
0.00E+00
100%
Duty LS
Modulation Index
2-Phase modulation results
in lower switching losses
3-Phase Modulation
SVM_Continuous_Symmetrical
Index
Modulation
Index
Modulation
100%
0%
-1.0
0,00E+00 2,00E-03 4,00E-03 6,00E-03 8,00E-03 1,00E-02
0.00E+00 2.00E-03 4.00E-03 Time
6.00E-03
8.00E-03 1.00E-02
(s)
Time (s)
Copyright © Infineon Technologies AG 2016. All rights reserved.
19
Design Tips for Improving Thermal Efficiency
1. Copper traces used to
dissipate heat from the
module
2. Use of thermal vias to spread
heat to bottom layer
3. Power capability increases
with thicker copper traces
2oz (70µm) > 1oz (35µm)
4. Air flow improves
performance further
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
20
Performance Example: 2oz vs 1oz
23% increased power capability
using 2oz Cu Traces
100
Cu Trace
90
580
µIPM
PCB
Thermal
Via
1oz = 35µm
2oz = 70µm
Power to Motor [W]
80
490
70
500
60
460
+23%
50
410
370
40
1oz Cu Trace
30
20
2oz Cu Trace
10
0
6
2015-06-14
8
10
12
14
16
PWM Frequency [kHz]
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18
20
21
Performance Example: Forced Airflow
44% increased power capability
w 1m/s airflow
100
660
90
580
540
No convection:
TJ (max) = 107℃
With 1m/s airflow:
TJ (max) = 75℃
Power to Motor [W]
80
70
+44%
500
60
50
410
370
40
Natural Conv
30
20
1m/s airflow
10
0
6
2015-06-14
8
10
12
14
16
PWM Frequency [kHz]
Copyright © Infineon Technologies AG 2016. All rights reserved.
18
20
22
Conclusion
› IPM‘s simplify the power design and reduce the time to market
significantly,
› The showed fan example has showed the most recent
developments and possibilities of IPM solution,
› Choosing the right component with a adequate design of cooling
and control algorithm allows increasing power density and
reducing the size of the system,
› The use of high performance IPM‘s increase the cost of the IPM
component, but in overall aspect it contributes to reduction of
overall system cost,
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
23
Thank you !
Contact your local distributor
Papland 4a
NL-4206 CL Gorinchem
T: +31 183 646050
F: +31 183 646051
E: rutronik_nl@rutronik.com
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
24
2015-06-14
Copyright © Infineon Technologies AG 2016. All rights reserved.
25