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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2013. All rights reserved. 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 Copyright © Infineon Technologies 2011. All rights reserved. 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 Copyright © Infineon Technologies AG 2013. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 31 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. 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 Copyright © Infineon Technologies AG 2014. All rights reserved. Page 37
© Copyright 2024 ExpyDoc
