IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS HYBRID POWER MODULES utilize a unique INJECTION-MOLDED LEAD-FRAME DESIGN and provide cost-effective integration of power devices, gate drive, and protection. 26 HE USE OF INVERTERS IN APPLI- There are several factors driving the expansion of ANCE APPLICATIONS is increasing rap- inverterized appliances in the United States. The primary idly. Although the idea of inverterized motivation for inverterized appliances is to conserve utili- appliances is new for the United States, it is ties. Environmental concerns and interests have become not in other parts of the world. The charts in Fig. 1 show more prevalent. The public is concerned about energy us- T age and water consumption. The gov- the appliance market for air conditioners, refrigerators, washing machines, BY JOHN DONLON, ernment is pushing for efficiency in and vacuums in North America and Ja- JOANNE ACHHAMMER, appliances that often make it necessary pan. In Japan, 37% of the appliance HIDEO IWAMOTO, & to use inverters. Inverterized appli- market is already inverterized, while MITSUTAKA IWASAKI ances mean increased efficiency, improved performance, and added value less than 1% of the U.S. market is. There is a great deal of potential for inverterized appliances in the United States. to the consumer. The consumer will pay more for inverter features, but The charts in Fig. 2 break down the Japanese appliance not that much more. So, it is important that the cost of new market specifically for air conditioners, washing machines, inverterized appliances remains low. There are other re- and refrigerators greater than 12 cubic ft. Over 80% of quirements and challenges for appliance inverters. Appli- their air conditioners and refrigerators, and nearly 40% of ances are usually assembled in high volume, so the Japan’s washing machines, are already inverterized. There- manufacturing process must be as simple as possible; the fore, there are good opportunities for inverters in all of inverters must be easy to manufacture. Another inverter re- these appliances in the U.S. as well. quirement is small size. The addition of an inverter should 1077-2618/02/$17.00©2002 IEEE not increase the size of the appliance. Since there is limited heat sinking available in appliances, high-efficiency inverters are required. High reliability is also required. Adding electronics should not degrade the equipment; ideally, inverters should make it more reliable. Also, inverters should not adversely affect the life span; there must be no reduction in expected service life. These are the basic issues for inverterized appliance applications. The DIP-IPM Concept The DIP-IPM concept evolved from conventional IPMs. IPMs containing power semiconductors 5,900 k 1,700 k Data Based on SY00 Japanese appliance market. Data Based on SY00 2,650 k Data Based on FY00 IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS along with gate-driving integrated circuits (ICs) and protection funcCOMPARED TO tions have been widely accepted for general-purpose and high-perforDISCRETE mance industrial motor drive applications ranging from 200 W to more SEMICONDUCTORS, than 150 kW [1], [2], [4]. The success of these modules is the direct reINTEGRATED sult of advantages gained through MODULES OFFER increased integration. Some of these advantages include LOWER SYSTEM ■ reduced design time and improved reliability offered by the COST, IMPROVED factory-tested, built-in gate drive and protection functions Inverters in Appliances MANUFACTURABILITY, Effective utilization of ac and ■ lower losses resulting from sibrushless dc motors in appliance apmultaneous optimization of AND INCREASED power chips and protection plications requires motor control that functions cost effectively meets stringent perRELIABILITY. formance, efficiency, reliability, and ■ smaller size resulting from the size requirements. Currently, most use of bare power die and consmall motor controls utilize discrete trol chips power semiconductors in TO-220 or TO-247 packages ■ improved manufacturability resulting from lower along with high-voltage integrated circuits (HVICs) for external component count and isolated heat sink their power stage. There are several deficiencies in this apmounting surface. proach. Manufacturing costs associated with mounting and isolating multiple high-voltage discrete components are Inverter Noninverter significant. Relatively large and complex printed circuit designs are required to meet all of the spacing and layout reJapan North America quirements of the HVIC and discrete power device combination. Equally perplexing is the challenge of mainTotal Market – 25,697 k Units Total Market – 47,834 k Units taining consistent performance and reliability when the characteristics of the HVIC drivers and insulated-gate bipo129 k lar transistors (IGBTs) are not properly matched. 9,609 k An obvious solution to these problems is to use an integrated power device that contains all the required power semiconductors along with matched drivers in a single isolated base module. Unfortunately, most integrated devices 16,088 k 44,705 k require relatively expensive insulated-metal substrate Data Based on FY99 (IMS) or direct-bond copper (DBC) isolated packages that 1 add considerable cost compared to transfer-molded discrete components. To meet the demanding cost and size re- Appliance market (air conditioner, refrigerator, washing quirements of consumer appliance inverters, a unique, machine, vacuum). completely transfer-molded intelligent power device has been develInverter Noninverter oped. The dual-in-line-package intelligent-power-module (DIPWashing Machine Refrigerator Air Conditioner IPM) offers the low cost of a disTotal Market – 4,300 k Units Total Market – 7,000 k Units ≥12 ft3 crete approach with all the advanTotal Market – 2,050 k Units 1,100 k tages of an IPM. Compared to a 350 k 1,650 k discrete approach, these devices offer high reliability, small size, and reduced manufacturing costs by integrating optimally matched power devices and HVIC drivers in a single factory tested module. 2 27 DIP-IPM CPU HVIC Level Shift Gate Drive UV Prot. 15 V 3 AC Line Motor LVIC Gate Drive UV Prot. SC Prot. RSHUNT 3 DIP-IPM block diagram. Fig. 3 presents a basic block diagram of the DIP-IPM integrated features that include the power devices and custom control ICs for gate drive and protection. The key to the DIP-IPM is the integration of HVICs to provide level shifting and gate drive for high-side IGBTs. This results in significant cost savings by enabling direct connection of all six IGBT control signals to the controller. The HVIC also provides undervoltage lockout protection to allow simplified implementation of the required floating power supplies using bootstrap techniques. With just a few external components, the entire three-phase power stage can operate from a single 15-V control power supply. The DIP-IPM also utilizes a custom low-voltage IC (LVIC) to provide gate drive, short-circuit (SC) protection, and undervoltage lockout for the low-side IGBTs. Incorporating level shifting into the DIP-IPM reduces high-voltage spacing requirements on the control printed-circuit board (PCB), allowing a significant savings in circuit-board space. The factory-verified coordination of ICs and power chips assures high reliability. All of these features are combined in a compact, low-cost transfer-molded package that allows miniaturization of inverter designs. IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS The DIP-IPM Package 28 4 Internal view of the DIP-IPMs. Control Pins Power Pins Al Bond Wire Power Chips IGBT, FWDi Mold Resin HVIC Au Bond Wire Aluminum Block DIP-IPMs are made using two different packages. A larger package, designated the Original DIP-IPM, is produced for higher power ratings. Lower power ratings are in a smaller package, the Mini DIP-IPM. Both packages (Fig. 4) are manufactured in a similar manner. The DIP-IPMs are fabricated using a transfer molding process like that used for very large ICs. First, bare power chips and the custom HVIC and LVIC die are assembled on a lead frame. Ultrasonic bonding of large-diameter aluminum wires makes electrical connections between the power chips and lead frame. Small-diameter gold wires are bonded to make the signal-level connections between the IC die and lead frame. This part of the process is the same for both devices. Next, they are encapsulated. This is where the two packages differ. The cross-section of the Original DIP-IPM is shown in Fig. 5. These larger devices are fabricated using a two-step injection molding process. In the first step, a thin layer of thermally conductive epoxy is formed between the lead 5 Original DIP-IPM package cross-section. Power Pins Al Bond Wire Control Pins Au Bond Wire Power Chips IGBT, FWDi HVIC Mold Resin Mini-DIP-IPM package cross-section. 7 6 The DIP-IPMs. Level Shift Gate Drive UV Prot. Level Shift Gate Drive UV Prot. V Vcc Gate Drive UV Prot. Motor Gate Drive W RSHUNT N RSF CSF 8 Optimum PWM Frequency Typical Motor Ratings 220 VAC low 750 W PS21254-E 15 A/600 V high 750 W A schematic diagram including a typical external circuit for the DIP-IPM is shown in Fig. 8. All devices contain the six IGBT/free-wheel diode pairs required for a three-phase motor drive. There is one LVIC for the three low-side IGBTs that provides the gate drive and protection functions. There are three HVICs for the three high-side IGBTs that provide gate drive, protection functions, and level shifting. PS21245-E 20 A/600 V low 1,500 W PS21255-E 20 A/600 V high 1,500 W PS21246-E 25 A/600 V low 2,200 W PS20341-G 3 A/500 V low 125 W PS20351-G 3 A/500 V high 125 W Power Chip Design and Ratings PS20342-G 5 A/600 V low 200 W PS20352-G 5 A/600 V high 200 W PS20353-G 10 A/600 V high 400 W Electrical Characteristics of the DIP-IPM The input voltage for most consumer appliance and low-end industrial applications is between 100-240 VAC. To cover this range, IGBTs and free-wheel diodes with a 500-600 V breakdown rating were selected. The IGBT Mini-DIP-IPM IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS Overcurrent Protection Level Shift Input Condition HVIC HVIC + + U Input Condition HVIC 5-V Logic Interface to MCU P Input Condition frame and an aluminum block. The thin VUFS layer of epoxy and the aluminum block VUFB allow good heat transfer and provide electrical isolation between the power chips VP1 and heat sink. The Original DIP’s inteUP +Vcc grated aluminum block provides the thermal characteristics needed for the VUFS higher power devices. Then, the second VUFB injection-molding step encapsulates the entire lead frame assembly to achieve the VP1 final form. The two-step molding process VP +Vcc allows fabrication of modules with IGBT ratings of up to 25 A at elevated case temVWFS peratures. This performance is comparaVWFB ble to assemblies utilizing discrete TO-247 style copackaged devices (i.e., VP1 containing both IGBT and free-wheel diWP +Vcc ode chips). The cross-section of the Mini NC DIP-IPM is shown in Fig. 6. The lead UN frame is formed to produce a thin, flat VN Input Signal layer of thermally conductive epoxy beConditioning WN tween the power chips and heat sink FO mounting surface of the device. This thin Fault CFO layer of epoxy and bent lead frame allow Logic CIN good heat transfer and provide electrical VNC isolation. The molding process encapsuUV VN1 lates the entire lead frame assembly to Prot. + +Vcc LVIC achieve the final form. The single step molding process has been utilized to fab15 V ricate modules with IGBT ratings of up to 10 A at elevated case temperatures. The performance is comparable to assemblies utilizing discrete TO-220 style DIP-IPM functional diagram. copackaged devices. Fig. 7 is a photograph of the two DIP-IPMs in their final form. The Original DIP is pictured TABLE 1. DIP-IPM RATINGS on the bottom and the Mini DIP is on the top. The photograph shows their relative size compared to a U.S. quarter-dollar coin. The transfer molded DIP-IPM is less IGBT Ratings Type (IC/VCES) Number expensive to produce than conventional hybrid modules, because it does not require an IMS or ceramic substrate and plastic shell housing. The transfer molding process is also Original DIP-IPM well suited for high-volume, automated mass production, PS21244-E 15 A/600 V thus substantially reducing cost. 29 Floating Supply HVIC (P) D High Voltage Level Shifters E A PIN RQ S F Gate Drive B One-Shot Pulse Logic C +15 V Gate Drive NIN (N) A B IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS C 30 D E F 9 High-voltage level shift. Charging Path chips are fabricated using a fourth-generation 1-µm planar process to achieve high efficiency with low switching and conduction losses. To obtain the lowest cost in a given application, it is necessary to maximize the power silicon utilization. To do this, the IGBT chip is further optimized, taking advantage of the fundamental trade-off between switching and conduction losses. For low-frequency applications operating at pulsewidthmodulation (PWM) frequencies less than 5 kHz, the IGBT chips are optimized for low VCE(sat) in order to minimize conduction losses. For higher frequency applications operating at PWM frequencies of more than 10 kHz, the IGBT chips are optimized for low switching losses. All free-wheel diodes used in DIP-IPMs are super fast/soft recovery shallow diffused types. These diodes have been carefully optimized to have soft recovery characteristics over a wide range of currents and temperatures in order to minimize electromagnetic/radio-frequency interference (EMI/RFI) noise. The available ratings for DIP-IPMs are summarized in Table I. The types shown in the table have a rated isolation voltage of 1,500 V. There are also 2,500-V isolation types available. The device/motor rating coordination is based on typical requirements. More stringent overload requirements may necessitate using the next higher rated device. Floating Supply V(U,V,W) (P) + Collector Current (A) Gate Drive Bootstrap Supply Diode Protection Level Filter Set By RSF × CSF =1.5-2.0 µs (U,V,W) Overcurrent Trip Level + 15 V CIN(n) Gate Drive VSC(ref) RSHUNT (N) Typical IC Waveform 0 ~2 µs Pulse Width (µs) 10 Bootstrap supply operation. 11 DIP-IPM short-circuit and overcurrent protection. 5V + 15 V + VD DIP-IPM Vreg (6.2-V Typ.) Controller 5.1 k 4.7 k R C R UP, VP, WP, UN, VN, WN Rreg (57-k Typ.) Gate Drive RIN (1k Typ.) Vth(off)=3.0-V Typ. Vth(on)=1.4-V Typ. Fault Logic FO C GND 12 DIP-IPM interface circuit. 13 High-Voltage Level Shift The main feature of DIP-IPMs is the high-voltage level shifting provided by the integrated HVIC. The built-in level shift eliminates the need for optocouplers and allows direct connection of all six control inputs to the central-processing unit/digital signal processor (CPU/DSP). The omission of an isolated interface circuit results in significant savings. The detailed operation and timing diagram for the level shift function is shown in Fig. 9. The falling and rising edges of the p-side control signal (A) activate the one shot pulse logic that generates turn-on pulses (B, C) for the high-voltage level-shifting metal-oxide-semiconductor field-effect transistors (MOSFETs). Narrow on pulses are used to minimize the power dissipation within the HVIC. The high-voltage MOSFETs pull the inputs to the high-side driver latch (D, E) low to set and reset the gate drive for the p-side IGBT (F). 14 DIP-IPM used in an air-conditioner circuit. ode. When the n-side IGBT is off, the energy stored in the capacitor provides power for the high-side gate drive. Using this technique, it is possible to operate all six IGBT gate drivers from a single 15-V supply. The bootstrap circuit is a very low-cost method of providing power for the high-side IGBT gate drive. Loss is Improved By Approximately 20% Bootstrap Supply Scheme 100 Relative Comparison Power for the high-side gate drive is normally supplied using external bootstrap circuits (Fig. 8). The bootstrap circuit typically consists of a low-current 600-V fast-recovery diode with a small series resistor to limit the peak charging current and a floating supply reservoir capacitor. The operation of the bootstrap supply is outlined in Fig. 10. When the low-side IGBT is turned on, the floating supply capacitor is charged through the bootstrap di- 80 STATIC Di STATIC Tr SW. OFF SW. ON 60 40 20 0 Bipolar Tr DIP-IPM Loss reduction with DIP-IPM in an air-conditioning application. IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS Discrete approach versus DIP-IPM. 15 31 Bipolar Module Base Drive Circuit MultiOutput Power Source Circuit Microprocessor Undervoltage Lockout Configuration of Existing Circuit Board The DIP-IPM is protected from failure of the 15-V control power supply by a built-in undervoltage (UV) lockout circuit. If the voltage of the control supply falls below the UV trip value, the low-side IGBTs are turned off, and a fault signal is provided. In addition, the p-side HVIC gate drive circuits have independent undervoltage lockout circuits that turn off the IGBT to protect against failure if the voltage of the floating power supply becomes too low. In the case of a high-side undervoltage lockout, the affected IGBT will be turned off, but a fault signal is not generated. SC Protection The DIP-IPMs have an integrated SC protection function. The LVIC monitors the voltage across an external shunt resistor (RSHUNT) to detect excessive current in the dc link. A resistance-capacitance (RC) filter (RSF, CSF) with a time constant of 1.5-2 µs is normally inserted (Fig. 8). It prevents erroneous fault detection due to di/dt induced noise on the shunt resistor and free-wheel diode recovery currents. The RC time constant produces a time-dependent trip level (Fig. 11). When the voltage at the CIN pin exSingle DIP-IPM ceeds the VSC reference level, the lower arm IGBTs are Output Power turned off, and a fault signal is asserted at the FO pin. When Source selecting the external shunt, it is very important that the Circuit maximum trip current setting not exceed the short-circuit saturation current of the IGBTs. If the shunt resistance is too small, the short circuit may not be detected, as the Configuration of DIP-IPM Circuit Board 16 IGBTs themselves will limit the current to a level below the trip point. If this happens, the SC protection function is PCB area reduction with DIP-IPM in an air-conditioning apeffectively disabled. When a short-circuit condition is deplication. tected, the IGBTs remain off until the fault time (tFO) has expired and the input signal has cycled to its off state. The duration of tFO is set Number of by an external timing capacitor CFO. The recNumber of Components on Circuit Components on Existing ommended CFO is 22 nF, which will yield a Board with DIP-IPM - 80 Circuit Board - 140 fault output duration of about 1.8 ms. 32 Component Count Reduced By 40% Interface Circuit 17 Component count reduction with DIP-IPM in an air-conditioning application. 100 Relative Comparison IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS Microprocessor Circuit Board Area Is Reduced By 25% 80 60 40 Failure Rate Is Improved By Approximately 40% 20 0 Bipolar Tr DIP-IPM 18 Reliability improvement with DIP-IPM in an air-conditioning application. The DIP-IPM has seven microprocessor-compatible input and output signals. The built-in HVIC level shifters allow all signals to be referenced to the common ground of the 15-V control power supply. The signals are 5-V transistor-transistor logic/complimentary metal-oxide-semiconductor (TTL/CMOS) compatible in order to permit direct connection to a PWM controller. The interface circuit between the PWM controller and the DIP-IPM can be made by either direct connections or optocouplers, depending on the requirements of the application. Fig. 12 shows the internal structure of the DIP-IPMs control signals and a simplified schematic of a typical external interface circuit. On and off operations for all six of the DIP-IPM’s IGBTs are controlled by the active low-control inputs UP, VP, WP, UN, VN, and WN. Normally, these inputs are pulled high to the 5-V logic supply of the controller with an external 4.7-kΩ resistor. The controller commands the respective IGBT to turn on by pulling the input low. Approximately 1.6 V of hysteresis is provided on all control inputs to help prevent oscillations and enhance noise immunity. The optional capacitors C and resistors R, shown dashed in the figure, can be added to further improve noise filtering. The fault signal output FO is in an open collector configuration. Normally, the fault signal line is pulled high to the 5-V logic supply with a 5.1-kΩ resistor (Fig. 12). When a short-circuit condition or improper control power supply voltage is detected, the DIP-IPM turns on the internal open collector device and pulls the fault line low. Loss Is Improved By 22% 100% 80% 60% STATIC Di STATIC Tr SW OFF SW ON 40% 20% 0% MOSFET DIP-IPM System Advantages DIP-IPM (PS20351) 19 Cost (in US $) IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS Fig. 13 shows a comparison of the components required in a typical three-phase motor drive using discrete Loss reduction with DIP-IPM in a refrigeration application. copackaged IGBT devices versus the DIP-IPM. Clearly, there are significant manufacturing advantages to the DIP-IPM approach. Each of the Component Count of Component Count discrete devices must be individually Existing Circuit Board of Circuit Board with mounted and isolated, which typically results Inverter Region - 76 DIP-IPM - 48 in a very complex assembly and significant manufacturing time. On the other hand, the 37% Reduction DIP-IPM contains all six of the required of Component Count IGBT/free-wheel diode pairs and has a fully isolated mounting surface. Mounting is accomplished with only two screws, and no ad20 ditional isolation material is required. The reduced manufacturing time and simplified Component-count reduction with DIP-IPM in a refrigeration application. assembly provided by the DIP-IPM will allow improvements in both cost and reliability of the finished system. US$0.44 Another advantage of the Details of Cost DIP-IPM is that the integrated Baseplate Cost HVIC and LVIC gate drive and US$0.83 protection functions are factory Production Cost Cost Before tested with the IGBTs as a subsysIncorporating IPM Materials Cost tem. This eliminates uncertainty about the critical coordination of the electrical characteristics of these components. The result is Cost Reduction better, more consistent system perCost after IPM of US$1.74 formance and reliability. The ultra-compact DIP-IPMs MR-M38T(Old Type) MR-M38X(New Type) offer many benefits for appliance 21 motor controls. Fig. 14 shows an inverter for compressor speed con- Cost savings with DIP-IPM in a refrigeration application. trol in a home air conditioner. In this application, it is easy to see how the DIP-IPM simplifies the design. This particular plementation was with discrete MOSFETs. The DIP-IPM application was originally implemented using discrete bi- design reduced losses by 22% (Fig. 19) and reduced the polar transistors. Examining the benefits of the DIP-IPM component count by 37% (Fig. 20). Using the DIP-IPM approach in detail, it reduced losses by 20% (Fig. 15), brought the original equipment manufacturer (OEM) a shrank the printed circuit board area by 25% (Fig. 16), and significant cost reduction of US$1.74 per unit (Fig. 21). reduced the component count by 40% (Fig. 17). In addition to these benefits, which are directly measurable, the Conclusion DIP-IPM produced an additional benefit of an improve- DIP-IPMs consisting of a combination of power devices, low ment in reliability by reducing the failure rate by 40% voltage ICs, and high voltage ICs in a unique, low-cost, (Fig. 18). transfer-molded package have been developed. These deThe same types of savings were achieved in a commer- vices have been optimized to simplify and miniaturize incial refrigeration application. In this case, the existing im- verters in appliance applications. Compared to discrete 33 semiconductors, these new integrated modules offer lower cost, improved manufacturability, and increased reliability. References [1] G. Majumdar, et al., “A new generation high performance intelligent module,” presented at PCIM’92 Europe. [2] E.R. Motto, J.F. Donlon, G. Majumdar, S. Hatae, S. Ohshima, and K. Takanashi, “A new generation of intelligent power devices for motor drive applications,” in Conf. Rec. IEEE IAS Annual Meeting, 1993, vol. 2, pp. 1332-1338. [3] E. Motto, “Protecting high current IGBT modules from over current and short circuits,” in Proc. PCIM’95, San Jose, CA, vol. 10, pp. 445-451. [4] J. Donlon, E. Motto, G. Majumdar, S. Mori, W. Taylor, and R. Xu, “A new converter/inverter system for windpower generation utilizing a new 600 amp, 1200 volt intelligent IGBT power module,” in Conf. Rec. IEEE IAS Annual Meeting, 1994, vol. 2, pp. 1031-1042. IEEE INDUSTRY APPLICATIONS MAGAZINE • JULY|AUG. 2002 • WWW.IEEE.ORG/IAS [5] E.R. Motto, J.F. Donlon, G. Majumdar, and S. Hatae, “A new intelligent power module with microprocessor compatible analog cur- 34 rent feedback, control input, and status output signals,” in Conf. Rec. IEEE IAS Annual Meeting, 1996, vol. 3, pp. 1287-1291. [6] E. Motto, “A new ultracompact ASIPM with integrated HVASIC,” in Proc. PCIM’97, Baltimore, MD, vol. 36. [7] G. Majumdar, K.H. Hussein, M. Iwasaki, H. Kawafuji, T. Iwagami, and H. Yoshida, “Novel intelligent power modules for low-power inverters,” in Proc. 1998 IEEE Power Electronics Specialists Conf., vol. 2, 1173-1179. [8] S. Noda, S. Yamada, G. Majumdar, and T. Yamada, “A novel super compact intelligent power module,” in Proc. 1997 PCIM Europe, Nurnberg, Germany, Power Conversion vol., pp. 1-10. [9] E.R. Motto, “Application specific intelligent power modules—A novel approach to system integration in low power drives,” in Proc. PCIM’98, Santa Clara, CA, vol. 37, pp. 115-129. John Donlon (jdonlon@pwrx.com) and Joanne Achhammer are with Powerex Incorporated in Youngwood, Pennsylvania, USA. Hideo Iwamoto and Mitsutaka Iwasaki are with Mitsubishi Electric Corporation in Fukuoka, Japan. This paper first appeared in its original format at the 2001 IEEE International Appliance Technical Conference.