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rc - drives cost - optimized igbt for consumer drive application 1 rc - d fast : rc - drives igbt optimized for high switching frequency application note application engine e ring igbt july 2012 , mitja rebec po wer ma nage m ent dis c r etes
rc - drives cost - optimized igbt for consumer drive application 2 published by infineo n technologies ag 81726 munich, germany ? 2012 infineon technologies ag all rights reserved. legal disclaimer the information given in this document shall in no event be regarded as a guarantee of conditions or character istics. with respect to any examples or hints given herein, any typical values stated herein and/or any information regarding the application of the device, infineon technologies hereby disclaims any and all warranties and liabilities of any kind, includin g without limitation, warranties of non - infringement of intellectual property rights of any third party. information for further information on technology, delivery terms and conditions and prices, please contact the nearest infineon technologies office ( www.infineon.com ). warnings due to technical requirements, components may contain dangerous substances. for information on the types in question, please contact the nearest infineon technologies office. infineon t echnologies components may be used in life - support devices or systems only with the express written approval of infineon technologies, if a failure of such components can reasonably be expected to cause the failure of that life - support device or system or to affect the safety or effectiveness of that device or system. life support devices or systems are intended to be implanted in the human body or to support and/or maintain and sustain and/or protect human life. if they fail, it is reasonable to assume tha t the health of the user or other persons may be endangered.
rc - drives cost - optimized igbt for consumer drive application 3 table of contents 1 introduction and sho rt description of th e product family ................................ ........................... 4 2 static and dynamic b ehavior ................................ ................................ ................................ .................. 7 2.1 s tatic b ehavior ................................ ................................ ................................ ................................ .............. 7 2.2 d ynamic b ehavior ................................ ................................ ................................ ................................ .......... 8 3 in - circuit application test on 200w motor d rive board ................................ ................................ . 10 3.1 e fficiency ................................ ................................ ................................ ................................ ..................... 10 3.2 t hermal behavior ................................ ................................ ................................ ................................ ......... 11 3.3 c ooling consideration s ................................ ................................ ................................ ................................ 13
rc - drives cost - optimized igbt for consumer drive application 4 1 introduction and short description of the product family the rc - drives igbt technology was released by infineon at the e nd of 2009 as a cost - opt imized solution to address the p rice - sensitive consumer drives market. this basic technology provides outstanding performance in bldc motor drives adopting block commutation C type of modulations, were one or both igbt in the half - bri dge are left conducting for 120 of the motor electrical angle ( dae - woong chung et al., ieee transactions on industrial electronics, vol. 46, n o. 3, june 1999 ) . thanks to the low conduction losses of both igbt and integrated diode the overall losses are dr astically reduced. this type of control is commonly found in fridge compressors: by limiting the hard switching events the dv/dt and di/dt commutation slopes are avoided, therefore the harmonic content injected in to the motor windings (hence the emi) is re duced . below a typical example of this type of commutation found on a 100w commercial fridge compressor: figure 1 : high side and low side gate signals for 120 pwm commutation switching
rc - drives cost - optimized igbt for consumer drive application 5 another applica tion that benefits from th e low on - state losses or the rc - drives is found in d omestic aircon systems: the ~1.5 kw bldc compressor is driven by igbts switched by full sinusoidal pwm hard switching at moderate switching frequencies of 5 to 8 khz. again in this case a device optimized for low conduction losses provides an overall loss reduction. however the trend observed in low power drives for outdoor and indoor fan of domestic aircon systems as well as industrial funs and pumps up to ~200w is to in crease the pwm switching frequency . the reason is twofold: on one side the size of the output filter can be reduced by keeping the same current ripple . on the other side in small motor drives adopting sensor - less foc (field oriented control) , were a high dynamic control (torque and speed ) of the pmsm motor is required, the higher switching frequency allows to increase the sampling rate of current and hence the accuracy of reconstructed rotor position . in order to meet the rising demands of the igbts for the low power motor drive consumer ma rket, a new version of the rc - drives igbt is developed: the igbt and diode losses are optimized to reduce the inverter losses at switching frequencies of 18~20k hz. the new family is called rc - df , and released in the curren t classes from 2.5a to 15 a in d - pa k packages.
rc - drives cost - optimized igbt for consumer drive application 6 part number package type power [w] switching frequency vce [v] ic [a] vcesat [v] ets [mj] tsc [s] vf [v] qrr [c] 25 100c 25c 175c 25c 175c 25c 175c 25c 175c ikd03n60rf d - pak 40..80 4 ..30 khz 600 5 2.5 2.2 2.3 0.09 0.14 5 2.1 2.0 0.06 0.19 ikd04n60rf d - pak 80..150 4 ..30 khz 600 8 4 2.2 2.3 0.11 0.19 5 2.1 2.0 0.09 0.26 ikd06n60rf d - pak 150..250 4 ..30 khz 600 12 6 2.2 2.3 0.18 0.28 5 2.1 2.0 0.16 0.34 ikd10n60rf d - pak 250 - 600 4 ..30 khz 600 20 10 2.2 2.3 0.35 0.5 2 5 2.1 2.0 0.27 0.62 ikd15n60rf d - pak 600..1 000 4 ..30 khz 600 30 15 2.2. 2.3 0.52 0.78 5 2.1 2.0 0.42 1.00 iku04n60r i - pak 80..150 dc..5 khz 600 8 4 1.65 1.85 0.24 0.4 5 1.7 1.7 0.22 0.52 ikd04n60r d - pak iku06n60r i - pak 150 - 250 dc..5 khz 600 12 6 1.65 1.85 0.33 0.56 5 1.7 1.7 0.37 0.80 ikd06n60r d - pak IKU10N60R i - pak 250 - 600 dc..8khz 600 20 10 1.65 1.85 0.59 0.93 5 1.7 1.7 0.56 1.22 ikd10n60r d - pak iku15n60r i - pak 600 - 1 0 00 dc..8khz 600 30 15 1.65 1. 85 0.9 1.25 5 1.7 1.7 0.76 1.7 ikd15n60r d - pak table 1 : product specification for rc - drives and rc - drives fast
rc - drives cost - optimized igbt for consumer drive application 7 2 static and dynamic behavio r 2.1 static behavior due to the optimization for fast switching, the v ce sat of the rc - df is increased compared to the rc - d. however for the target inverter applications in the range of ~100w the rms curr ents are usually limited below 1a and here the v ce sat increase is limited to ~ 200mv both at 25 c and 175c. a negative temperature coefficient of v cesat is observed in this current range, contributing to a reduc tion of conduction losses in normal operating conditions, with junction tempera ture tj typically ranging from 60 to 100c. figure 2 : v cesat compari son of the rc - df vs. the rc - d technology
rc - drives cost - optimized igbt for consumer drive application 8 2.2 dynamic behavior the rc - df maintains the smooth switching behavior and rg controllability of the basic rc - d technology, by providing drastically reduced turn - off losses of the igbt. the internal di ode is al so opti mized to reduce the turn - on losses. the devices are characterized in a classical half - bridge test circuit with inductive load: the ls igbt (dut) is commutated over the hs diode. therefore the diode switching improvement is visible in the igbt turn - on behav ior (see below). figure 3 : dynamic switching behavior as a function of external rg. the turn - on and turn - off waveforms are c learly showing significantly faster switching : both t he tail current of the igbt, the qrr, irrm and trr of the integrated diode are drastically reduced. - 55% - 23 % - 33 % - 44 %
rc - drives cost - optimized igbt for consumer drive application 9 figure 4 : dynamic switching waveforms: turn - off (top) and turn - on (bottom). note that the current scales are different. rc - df rc - d rc - df rc - d
rc - drives cost - optimized igbt for consumer drive application 10 3 in - circuit application test on 200w motor drive board 3.1 efficiency in order to v erify the improvement of the rc - df in a real application conditions, the new devices were tested on a demo board developed by infineon and used as test bench to simulate a real air - conditioning outdoor fan. the board is designed for a 200w output and consists of a n input rectifier stage, inverter stage and output filter. the igbts are driven by a 600v 3 - phase driver ic from infineon ( 6ed 003l06 - f) , and the modulation pattern i s provided by an 8 bit infineon m icrocontrolle r (xc - 878) mounted on an external card. no heat - sink is required , j ust thermal vias through the pcb . the control method is sensor - less foc using a single shunt - based feedback loop. the board is driving a 200w induction motor coupled to an adju stable dc bra ke, which allows controlling the output power from the inverter. the efficiency is monitored by a siemens power meter and case temperature is monitored by an ir camera. figure 5 : t est set - up for the application measurements
rc - drives cost - optimized igbt for consumer drive application 11 alrea dy at switching frequency of 10 khz a clear efficiency improvement is observed. at the target f_sw of 18 khz the rc - df provides 2.8 % impr ovement at 50w input power and 1.6 % at 100w: figure 6 : i nverter efficiency as a functio n of input power and switching frequency 3.2 thermal behavior the i ncreased efficiency for the rc - df translates in lower case temperature, as verified by thermal images with infrared camera: figure 7 : case temperature as a functi on of input power and switching frequency the rc - df shows outstanding thermal performance providing lower case temp erature over the entire frequency range: a t the target swi tching frequency of 18 khz, the case temperature is lowered by 20c. - 17c - 20c +2.8% +1.6%
rc - drives cost - optimized igbt for consumer drive application 12 the temperatu re distribution is quite uniform, as demonstrated by detailed analysis of the thermal images : figure 8 : thermal images at pin=50w, f_sw=20 khz this translates in increased reliability and longer life expectancy for the device, especiall y in the harsh thermal environment s to be encountered in a real application. in the case of outdoor fan for domestic split aircon systems, for example, the board is mounted directly on the back of the motor in a close environment without airflow. in this case high ambient temperature up to ~ 60c can be expected:
rc - drives cost - optimized igbt for consumer drive application 13 figure 9 : c ommercial air - co nditioning split system, showing the motor drive card housed on the back of the bldc fan motor 3.3 cooling consideration s when the power r ange of the inverter exceeds ~200w, along with careful pcb design (avoid placing devices too close to each other or to the edge of the pcb), some type of cooling is required for the smd devices. in case of dpak packages, top side cooling is not effective d ue to the relatively high thickness of the mold compound on top of the chip and the poor heat exchange. infineon recommends cooling from the bottom of the chip by thermal vias through the pcb. several methods for v ias formation are adopted in the industry:
rc - drives cost - optimized igbt for consumer drive application 14 copper inlays production limited and quite expensive concept. adopted in high efficiency converter for smps applications copper inlays (ruwel gmbh) therm al vias place d around th e leadframe or partially under the drain contact . typical via s diameter is 400um. f illed with synthetic resin to avoid solder voids at rc - driv es l eadframe due to a solder re flow through the via s . most common solution in consumer drives . classical thermal vias with resin small drill holes holes diameter below 0.2 mm for the thermal vias are filled during cu galvanic deposition to avoid solder re flow. they can be placed under the drain for th e most effective heat exchange. thin - via - concept (small drill holes) figure 10 : commonly adopted via s concepts
rc - drives cost - optimized igbt for consumer drive application 15 infineon recommends, when allowed by the process capability of pcb supplier , the small drill holes concept for optimum power dissipation. the concept was tested successful ly on several reference designs and allowed to reach up to 1.2kw output power utilizing rc - d devices in dpak package. below an example of small drill holes vias design and related heatsink mounting with isolation foil: fig 11 : example of thermal v ias and heatsink mounting for rc - d and rc - df test boards
rc - drives cost - optimized igbt for consumer drive application 16 w w w . i n f i n e o n . c o m / r c d f published by infineon technologies ag

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