Econo IPM / R-IPM3 Aug-28-2002 Fuji Electric Co.,Ltd.
Application of Intelligent Power Module Motor Drive General Purpose Inverter Servo Amplifier Motor Drive for Air conditioning Motor Drive for Elevator NC Machine Tool Industrial Robbot Plastic Injection Machine General Machine Compressor Fan Lifting Door closure Rated Current (Arms) 1000 500 200 100 50 Electric Vehicle Application High Voltage High Power Motor Drive - 3 Level Inverter - Matrix Converter - High Voltage Motor Drive Fuji Intelligent Power Module - General Purpose Inverter - Servo Amplifier - Air Conditioning - Elevator Power Supply UPS Solar System 20 10 0 600 1200 Rated Breakdown Voltage (Volts)
Issue for Intelligent Power Module Market Requirements Down Sizing of Equipment - Thinner Frame - Smaller Footprint Save Energy, High Efficiency Lower EMI Noise Longer Life Cycle Reliable Protections Issues for IPM Compact and Slim Package - PC Board on the Top - Common Height with Converter Module Improvement of IGBT Performance Soft Recovery of FWD Optimized Drive Circuit Improvement of Power Cycling Capability Current Sensing IGBT of Over Current Protection. On-chip Temperature Sensor for Tj Protection. Alarm Output from upper arms.
Trend of Fuji s s IGBT IPM 1993 1995 1997 2002 J-IPM N-IPM R-IPM R-IPM3 2004~ Next Gen. Standard Package Monolithic Gate Driver On-chip Temp. sensor Upper arm alarm PKG NPT IGBT FS-PT IGBT MPS Diode Compact Package (Upper arm alarm) Econo-IPM
Progress of Fuji s s IPM 600V/100A Package volume Effective volume 100% 137% 90% Current density of IGBT 147% 70% 100% 125% year Series IGBT Number of elec.parts 170 75 19 19 1993 1995 1997 2002 J-IPM N-IPM R-IPM Econo-IPM PT-IGBT (J) PT-IGBT (N) PT-IGBT (R) NPT-IGBT (T)
Concept of Econo IPM R-IPM All Silicon Concept - Monolithic Gate Driver IC with wire bonding - On-chip Temperature Sensor Econo Module Compact & Easy Mounting - All Al-wire Bonding Technology - PC Board on the Top with solder process - Same Height with Converter Module R-IPM3 Standard Package - Screw Terminal - Monolithic Gate Driver - On-chip Temperature Sensor Econo IPM - Compact & Thinner Package as Econo Module - Monolithic Gate Driver - On-chip Temperature Sensor R IPM3 Econo IPM Econo Module Terminal Main Signal Screw terminal Pin terminal Pin terminal Pin terminal Pin terminal Pin terminal Height of PCB 22mm 17mm 17mm Dimensions L W D(mm) P610,P611 109 88 22 P622 122 55 17 PC3,EP3 122 62 17
Package comparison between R-IPM3 R and Econo IPM R-IPM, R-IPM3 (Standard type) Terminal Main Signal Height of PCB Dimensions L W D(mm) R IPM3 Screw terminal Pin terminal 22mm 109 88 22 Econo IPM (Compact type) Econo IPM Pin terminal Pin terminal 17mm 122 55 17
Comparison of cross section structures for IGBTs NPT-IGBT Emitter PT-IGBT Gate 600V Emitter N- Gate Next Gen. Trench-FS-IGBT Emitter N- P N+ N- P+ Collector N- Trench-FS-IGBT N- N+ P+ Collector P+ 1200V P Emitter N+ 70μm Process for 600V IGBT Gate N- Collector Conventional Process with Epi wafer N- N+ P+ Collector 100μm Process with FZ wafer
Power loss trend for IGBT Power loss transition for IGBT (600V/150A) IGBT Power loss ratio(%) (per 1arm without FWD) 100 90 80 70 60 50 BJT (1970 s~) Condition: cosφ=0.85 fc=3khz fo=50hz Io=63Arms 2nd Gen. Planer PT 3rd Gen. Planer PT New 3rd Gen. Planer PT 4th Gen. Fine Pattern Planer PT NPT IGBT? Next Gen. (Trench NPT FS Trench)
Features of the NPT-IGBT Turn-off Loss (mj/pulse) 600V/100A device Vcc=300V Ic =100A Rg =24 Vge=15V 3 rd Gen Vce(sat) (V) Trade-off of Vce(sat) and Turn-off Loss
Comparison between MPS and PiN Diodes PiN-Diode MPS-Diode Schottky Anode P + n - n - P + Next Gen. FS-MPS-Diode Schottky n + n + P + n + n - Cathode Thin wafer Process with FZ wafer Conventional Process with Epi wafer MPS:Merged PiN Schottky Diode
Soft-switching FWD Conventional PiN Diode MPS Diode dv/dt=9.8kv/μs dv/dt=6.8kv/μs
Improvement of power cycling withstand capability Al wire Si chip DCB R-IPM=Pb based solder Econo IPM,R-IPM3 =Sn-Ag solder Cu base plate
Progress of Power cycle capability 10 8 10 7 Sn-Ag 10 6 10 5 Sn-Pb 10 4 10 3 10 100
Function of the drive circuit in IPM IC for Driving and Protection IGBT Chip with Temp. Sens. FWD Chip +15V Supper Supply for Control Circuit Signal Drive Circuit Alarm Alarm Output Low Voltage Protection Temperature Protection Over Current Protection GND 0V On-chip Temperature Sensor Current Sensing IGBT
Tj Detecting Function Cross section of IGBT chip Equivalent circuit Poly silicon diode Cathode Anode Emitter Gate SiO2 Vcc IC IGBT chip n p p + n + Input pulse Alarm signal output OC protection UV protection Logic circuit n - n + 1msec delay Tj sensing diode p ++ Ground Collector
Internal Views of R-IPM3 R and Econo IPM R-IPM, R-IPM3 R Econo-IPM
Installation of IPM in Servo Amp. A cooling fin at the side of amplifier Cooling fin A cooling fin at the rear of amplifier Cooling fin Di-Module IPM PCB IPM
Installation image of IPM in side-fin User s PCB Main terminal Optocouplers Econo DiM Econo IPM Cooling Fin
Improvement of Power dissipation loss Power dissipation losses [W] 100.0 80.0 60.0 40.0 20.0 0.0 82.8W 11.9 12.2 58.8 R-IPM -10% 73.2W 4.8 10.3 58.1 Econo-IPM R-IPM3 Tj=125C Ed=300V cosφ=0.85, fo=50hz fc=4khz, Io=84Arms Sample:600V150A 5kW servo amp. turn-off loss turn-on loss on-state loss
Package Comparison between R-IPM3 R and Econo-IPM < R-IPM, R-IPM3 R > < Econo IPM >
R-IPM3 with upper arms alarm : Outline
Line-up of Econo IPM Econo-IPM 600V 50A 75A 100A 150A 6in1 6MBP50TEA060 6MBP75TEA060 6MBP100TEA060 6MBP150TEA060 7in1 7MBP50TEA060 7MBP75TEA060 7MBP100TEA060 7MBP150TEA060 1200V 25A 6MBP25UEA120 7MBP25UEA120 *1 50A 6MBP50UEA120 7MBP50UEA120 *1 75A 6MBP75UEA120 7MBP75UEA120 *1 Note *1 1200V25A to 75A will be developed by April of 2003.
Line-up of R-IPM R and R-IPM3 R R-IPM R-IPM3 R-IPM3 with upper arm alarm 6in1 7in1 6in1 7in1 6in1 7in1 600V 50A 6MBP50RA060 7MBP50RA060 6MBP50RTB060 7MBP50RTB060 6MBP50RTJ060 060 7MBP50RTJ060 75A 6MBP75RA060 7MBP75RA060 6MBP75RTB060 7MBP75RTB060 6MBP75RTJ060 7MBP75RTJ060 100A 6MBP100RA060 7MBP100RA060 6MBP100RTB060 7MBP100RTB060 6MBP100RTJ060 7MBP100RTJ060 150A 6MBP150RA060 7MBP150RA060 6MBP150RTB060 7MBP150RTB060 6MBP150RTJ060 7MBP150RTJ060 200A 6MBP200RA060 7MBP200RA060 300A 6MBP300RA060 7MBP300RA060 R-IPM R-IPM with upper arm alarm 6in1 7in1 6in1 7in1 1200V 25A 50A 6MBP25RA120 6MBP50RA120 7MBP25RA120 7MBP50RA120 6MBP25RJ120 6MBP50RJ120 7MBP25RJ120 7MBP50RJ120 75A 6MBP75RA120 7MBP75RA120 6MBP75RJ120 7MBP75RJ120 100A 6MBP100RA120 7MBP100RA120 150A 6MBP150RA120 7MBP150RA120
IPM with upper alarm : Block Diagram & Terminal Main circuit Control circuit Symbol P U V W N B Description Positive input supply voltage. Output (U). Output (V). Output (W). Negative input supply voltage. Collector terminal of Brake IGBT. Symbol Description 1 GNDU High side ground (U). 2 ALMU High side alarm signal output (U). 3 VinU Logic input for IGBT gate drive (U). 4 VccU High side supply voltage (U). 5 GNDV High side ground (V). 6 ALMV High side alarm signal output (V). 7 VinV Logic input for IGBT gate drive (V). 8 VccV High side supply voltage (V). 9 GNDW High side ground (W). 10 ALMW High side alarm signal output (W). 11 VinW Logic input for IGBT gate drive (W). 12 VccW High side supply voltage (W). 13 GND Low side ground. 14 Vcc Low side supply voltage. 15 VinDB Logic input for Brake IGBT gate drive. 16 VinX Logic input for IGBT gate drive (X). 17 VinY Logic input for IGBT gate drive (Y). 18 VinZ Logic input for IGBT gate drive (Z). 19 ALM Low side alarm signal output.
Internal Views of R-IPM3 R and Econo IPM R-IPM, R-IPM3 R Econo-IPM