New 4.5kV IGBT Solution Expands IXYS Power Portfolio

IXYS Corporation has announced the introduction of a new addition to its 4.5kV power semiconductor family, designed to support high-voltage industrial power conversion and advanced IGBT module applications. Developed by IXYS UK, the new device is a high-performance fast recovery diode (FRD) optimized for use alongside the company's extensive range of press-pack IGBT modules.

The new component features a rated operating current of 460A and incorporates advanced semiconductor processing and assembly technologies. Compared to older floating silicon designs, the updated structure offers improved thermal stability, enhanced mechanical robustness, and superior switching performance. The device is capable of supporting extremely high current change rates, exceeding 2kA per microsecond, while maintaining soft recovery characteristics and low switching losses.

Packaged in a fully hermetic ceramic housing with copper electrodes, the diode is designed for high-reliability power electronics environments. Its construction allows compatibility with series-connected press-pack IGBT modules used in demanding industrial applications, including high-voltage converters, power transmission systems, and railway traction equipment.

The new E0460QC45E diode is optimized for use with IXYS UK's 4500V IGBT modules and can serve as an antiparallel diode, neutral-point clamp diode, or snubber diode in multilevel converter topologies. These applications are commonly found in renewable energy systems, industrial motor drives, HVDC power transmission, and large-scale power conversion equipment.

As demand continues to grow for high-voltage IGBT modules, power semiconductors, railway traction systems, renewable energy converters, and industrial power electronics, advanced devices such as the E0460QC45E help improve efficiency, reliability, and overall system performance. This latest addition further strengthens IXYS UK's portfolio of high-power semiconductor solutions for modern energy and industrial applications.

Mitsubishi Targets Leadership in the IGBT Market

While many industry observers consider the power semiconductor market mature, Mitsubishi Electric has expressed ambitious plans to expand its presence and strengthen its position in the global IGBT market. The company has outlined growth objectives focused on industrial power electronics, automotive applications, renewable energy systems, and power transmission technologies.

A key part of Mitsubishi's strategy is its subsidiary, Vincotech, which specializes in power module solutions. The company has also strengthened its power semiconductor portfolio through investments and acquisitions aimed at expanding its capabilities in automotive power devices and advanced power electronics technologies.

Mitsubishi's growth strategy focuses on four major sectors: home appliances, industrial factory automation, renewable energy, DC power transmission, and automotive electronics. The company is also investing in higher-volume manufacturing of silicon and silicon carbide (SiC) power semiconductor devices to meet growing demand for energy-efficient power conversion solutions.

The global IGBT module market continues to benefit from increasing demand in electric vehicles (EVs), industrial motor drives, renewable energy systems, railway traction, and smart power infrastructure. These applications require high-performance IGBT modules capable of delivering efficient switching, reliable operation, and long-term durability.

As the power electronics industry continues to expand, Mitsubishi Electric aims to increase its market share and strengthen its position among the world's leading IGBT manufacturers. With growing demand for power semiconductors, IGBT modules, silicon carbide devices, electric vehicle power systems, and industrial automation technologies, the company remains focused on long-term growth in the global power semiconductor market.

IGBT in Traction Inverters for Railway Systems

In modern locomotives powered by diesel-electric systems or fully electric operation, as well as EMU and DEMU vehicles using AC traction motors, advanced microprocessor-based AC-AC traction systems have become a key technological solution. These systems integrate IGBT-based traction converters with DSP and microprocessor-controlled embedded systems to deliver efficient and reliable motor control for railway applications.

The locomotive control system works in combination with IGBT-based traction converters to manage power delivery to the traction motors. Each traction converter can be configured with single or multiple inverters depending on system design requirements. These inverters may operate in independent axle control mode, where each inverter drives a single traction motor, or in bogie control mode, where multiple motors are driven together for coordinated performance.

Typical system configurations range from approximately 650 kW per inverter for bogie control applications to around 550 kW per inverter for independent axle control systems. Depending on the application, between 2 to 6 inverters can be integrated into a single traction converter, resulting in total power ratings between 1.3 MW and 3 MW. These modular designs allow flexibility in scaling the system based on locomotive power requirements.

Thermal management is a critical aspect of traction inverter design. IGBT switching devices generate significant heat during operation, so heat pipe-based heat sinks combined with forced-air cooling systems are commonly used. These cooling systems can be installed either onboard or underframe, depending on available space, weight limitations, and airflow conditions.

In modern designs, blower systems used for cooling are often speed-controlled or dynamically switched off based on heat sink temperature. This approach improves energy efficiency and extends blower lifespan while maintaining safe operating temperatures for IGBT modules.

Overall, IGBT-based traction inverters play a vital role in modern railway systems by enabling high-power, efficient, and flexible motor control solutions that support reliable and scalable locomotive performance.

Alpha and Omega 1200V Fast-Switching IGBT for Industrial Applications

Alpha and Omega Semiconductor Limited (AOS), a global designer and supplier of a wide range of power semiconductors and power integrated circuits, is expanding its family of fast-switching IGBT devices in its H-series 1200V class. These new devices are designed to meet the growing demands of high-frequency industrial applications, particularly in welding systems and high-voltage power converters.

One of the latest products, the AOK40B120H1, has been developed to support industrial welding equipment and high-frequency converters operating with three-phase AC input or high-voltage power systems. It delivers strong performance in high switching frequency environments, making it well suited for heavy-duty industrial welding machines and other demanding power conversion systems.

The AOK40B120H1 is built on Alpha and Omega Semiconductor’s proprietary AlphaIGBT™ technology platform. It features fast switching capability and a low VCE(sat) of approximately 1.8V, which helps reduce both conduction and switching power losses. This improves overall system efficiency and thermal performance in industrial applications.

With a 1200V minimum BVCES rating and strong latch-up robustness, the device provides improved safety margins and more reliable operation under challenging electrical conditions. These characteristics make it suitable for engineers designing high-reliability industrial systems that require both performance and durability.

According to Dr. Brian Suh, Vice President of the IGBT Product Line at AOS, the AOK40B120H1 is designed specifically to meet the needs of system designers working with 1200V IGBT-based welding applications. Its low conduction losses and optimized switching behavior enable efficient and reliable operation while also supporting cost-effective system design. AOS IGBTs are positioned to address key challenges faced by customers through innovative semiconductor technology and application-focused solutions.

Overall, the new generation of Alpha and Omega Semiconductor IGBTs demonstrates continued advancements in power semiconductor design, supporting higher efficiency, improved reliability, and better performance in industrial welding and high-power conversion applications.

IGBT in Hybrid Electric Vehicle (HEV) Systems

Nearly two decades ago, IGBT modules were primarily used in industrial equipment, but their application has since expanded into a wide range of electric power conversion systems. Today, IGBTs are widely used in motor control applications across industries, from household appliances such as air conditioners to large-scale systems in rail transportation. In recent years, their use in automotive applications has grown significantly, with continuous improvements aimed at achieving higher efficiency, power density, and reliability.

A hybrid electric vehicle (HEV) system consists of an electric motor, a battery, and an inverter. To operate efficiently, the system requires an electric power conversion unit that transfers energy from the battery to the motor and also captures regenerative energy from the motor back into the battery. This function is performed by the inverter, where IGBTs serve as the primary switching devices in modern power electronics designs.

IGBTs are widely used in HEV inverter systems because of their high efficiency, fast switching capability, and strong reliability under demanding operating conditions. They enable precise control of motor torque and speed while improving overall energy efficiency and reducing power losses in the system.

Hybrid vehicle architectures can generally be classified into dual-motor systems, which use separate traction and generator motors for optimized driving performance, and single-motor systems, which combine both functions into one unit for improved compactness and reduced weight. The single-motor configuration, commonly referred to as a parallel hybrid system, is particularly suitable for small vehicles where size and weight reduction are critical design goals.

As automotive electrification continues to advance, IGBT technology remains a key enabling component in hybrid electric vehicle systems, supporting efficient energy conversion, regenerative braking, and reliable motor drive performance in modern hybrid powertrains.

IGBT in Vacuum Cleaner Motor Drive Systems

A vacuum cleaner is a household appliance that uses an air pump to create a partial vacuum for collecting dust and dirt from floors and other surfaces. The debris is typically stored in a dust bag or container for later disposal. Since its invention by Hubert Cecil Booth in 1901, vacuum cleaners have become essential tools in maintaining clean and healthy living environments. Today, major manufacturers such as Hoover, Bissell, and Dyson continue to innovate vacuum cleaner technologies for improved performance and efficiency.

In earlier designs, universal motors were commonly used in vacuum cleaners because of their high rotational speed and low cost. However, these motors rely on mechanical brushes that wear out over time, especially at high speeds, which limits long-term performance and durability.

Modern high-performance vacuum cleaners increasingly use switched reluctance motors (SRM) to achieve higher output power and improved suction performance. These motor systems require advanced power electronic control circuits, where IGBTs play a critical role in ensuring efficient and reliable operation.

IGBT-based power circuits are used in vacuum cleaner motor drives to solve the start-up challenges associated with switched reluctance motors and to maintain stable high-speed operation. By providing precise switching control, IGBTs help improve motor efficiency, responsiveness, and overall system performance.

According to industry observations, IGBT-driven motor systems can extend motor lifetime by up to four times compared to conventional designs while also increasing suction power by approximately 20 percent at the same motor size. This makes IGBT technology highly valuable in compact, high-performance vacuum cleaner applications.

As a result, many modern vacuum cleaner designs incorporate IGBT-based drive circuits to achieve better efficiency, longer lifespan, and improved suction capability, supporting the growing demand for advanced and energy-efficient home appliances.

MOSFET and IGBT to Motive Power Semiconductors Market

INFINEON is still the pioneer in the force semiconductors business, with huge development from the IGBT and MOSFET segments. Another report from The Information Network demonstrates that Infineon has lost the lead on the MOSFET segment, worth US$6 billion, to International Rectifier. In the IGBT segment, Mitsubishi Electric overwhelms, well in front of Infineon. Be that as it may, Infineon's consolidated incomes in both areas was sufficient to keep up its lead in the general force semiconductor market, as indicated by the new report, Next-Generation Power Semiconductors: Markets Materials, Advancements as of late distributed by The Information Network.

As per the report, the IGBT segment will see the most grounded development inside the force semiconductor market, with a determined normal yearly development of 4.9 percent, going from $3.1 billion in 2012 to $4.0 billion in 2017. Power MOSFETs are no sleepers either, holding the biggest piece of the pie in 2013, because of its quick exchanging speed, close immaculate entryway impedance, quick exchanging speed, magnificent solidness, and a moderately low on-state resistance.

The Information System ventures 3.3 percent normal yearly development of the MOSFET market, from $5.4 billion in 2012 to $6.3 billion in 201As per the report, the IGBT segment will see the most grounded development inside the force semiconductor market, with a determined normal yearly development of 4.9 percent, going from $3.1 billion in 2012 to $4.0 billion in 2017.

Power MOSFETs are no sleepers either, holding the biggest piece of the pie in 2013, because of its quick exchanging speed, close immaculate entryway impedance, quick exchanging speed, magnificent solidness, and a moderately low on-state resistance.

The Information System ventures 3.3 percent normal yearly development of the MOSFET market, from $5.4 billion in 2012 to $6.3 billion in 2017.

The business sector scene is because of progress, be that as it may, subsequent to Infineon has gained Universal Rectifier. The joined organizations will hold more than a 27 percent offer of the force semiconductor market in 2014, which is well in front of the following biggest contender, Fairchild Semiconductor, who holds not exactly a 10 percent offer, and Mitsubishi Electric, with not exactly a 9 percent offer.

IPOSIM - The Infineon Power Simulation Program for Loss and Thermal Calculation of Infineon Power Modules and Disk Devices

Infineon owns a  power simulation program that will support you while selecting the right Infineon bipolar modules or disk devices for your rectifier such as (B2, B6, M3.2 and M69 or AC switch (W1C and W3C) applications as well as suited IGBT modules for your inverter needs these could be: single, 3 phase and 2 levels , or even DC converter applications.

This program performs a calculation of switching and conductions losses for all components, keeping an account of the conduction and switching losses as well as thermal ratings, different control algorithms can be applied if it requires to, thermal conditions can be adapted by user defined or predefined heat sinks.

The results will be shown in tabular and graphic representation  and can be saved for later revision or printed as a pdf file.

IPOSIM is just as easy  to use as it sounds  and enables the user to choose the correct Infineon device for their very own need.

This makes Infineon a pioneer in improvements in the IGBT area.

Switching Behavior of Paralleling IGBTs

The paralleling behavior for  IGBTs deserves of an special attention that has to be given to the drive circuit, this is due to the variation of the gate threshold voltage of the different chips, simply connecting the gates is not adequate. As they are not just a  few of them but several, Instead, each gate has to be driven by its own gate resistor in order to ensure that the chip with the lowest threshold voltage does not clamp the voltage for the others and carry all the current.

The layout of the emitter circuit has to be very symmetrical in order to minimize differences in emitter inductances and resistances. Even minor, unavoidable differences in the emitter inductances and resistances will generate compensation currents between the gate drive emitter connections. It is recommended to use a resistor in the range of at least 0.5 Ohm, but not to exceed approximately 1/3 of the total gate resistance.

IGBT in Electric and Hybrid Electric Vehicles

One of the rapidly growing and diversified industries is the automotive manufacturing, which is the largest with a broad extent in consumer preferences for model, easement and innovation. Everyone will profess that severe urban pollution is occurred by the gasoline powered vehicles when these consume dwindling fossil fuel resources. Expansion of electric and hybrid-electric vehicles is the most effective solution of this problem. We have to face serious technological challenges to achieve the worldwide goal to lessen the CO₂ discharge and fuel consumption with pioneering endeavors in evolving electric vehicles (EVs) and hybrid electric vehicles (HEVs).

Motor drives based on IGBT have been used in all hybrid-electric and electric cars introduced into the market until now. IGBTs play the major role in new powertrain generations like EVs and HEVs to drive the electric motor or gather the energy. IGBTs are vulnerable to heating issues because they run at very high frequencies and under high power. Thermal characterization helps to optimize the IGBTs layout, structure and mounting to optimize its performance.

All hybrid-electric and electric cars that have been introduced into the market so far have relied up on IGBT-based motor drives. In new powertrain generations such as EVs and HEVs, IGBTs play the key role in order to drive the electric motor or store the energy. IGBTs run at very high frequencies and under high power which makes them vulnerable to thermal problems. After all we can say, the availableness of IGBTs has been diametrical to the advancement of the hybrid vehicles and to the expansion of the charging substructure for the electric vehicles. IGBTs will continue playing a very important part in the availability of cost deducting technology for the entire hybrid and electric vehicle business.

Usage of IGBT in CNC Machines

The simple definition of plasma cutting is cutting steel and other metals of different thicknesses (or sometimes other materials) using a plasma torch. When doing this, an inactive gas (in some cases, compressed air) is turned into plasma by blowing it at extreme speed out of a nozzle; at the same time an electrical arc is forged through that gas from the nozzle to the metal being cut. The plasma is sufficiently heated to melt the metal in the process of cutting.

The Insulated Gate Bipolar Transistor (IGBT) versus the Metal Oxide Semiconductor Field Effect Transistor (MOSFET) has been a controversial subject ever since the IGBT technology came into being in the 1980's. CNC plasma cutting machines were initially using MOSFETs as transistor. But the usage of IGBTs (Insulated Gate Bipolar Transistor) is now grown notably in this field. IGBTs are deployed in plasma cutting technology to provide more commercial plasma cutting equipment. With assimilated MOSFETs, if one of the transistors actuates out of time, it can cause collapse of one quarter of the inverter. A later discovery, IGBTs, is not as subject to this failure mode. IGBT technology for welding applications has certainly proved to more effectively handle the rigorous demands the high duty cycle welders as it offers higher voltage capacities and heat tolerances than the earlier MOSFET.

CNC machines with IGBTs are swift. Preheating is not needed, so the torch can start cutting without delay. With speeds up to 500 IPM, it can contend with laser cutters based on the type of part. These cutters are multipurpose, competent for piercing, complicated cutting and beveling in one process. These can effectively cut any electrically conductive metal up to 6" thick. Accurate cutting is one of the characteristics of CNC plasma cutters. These machines are paired with highly advanced software and high precision components; the want for costly secondary operations is dispelled. The torch head is computer controlled and can do clean, sharp cuts. Solid integration between the cutting torch and software results in excellent manufacture, high cut quality, fewer dross and high superiority edges. An IGBT based CNC engine may appear complicated, the CNC (computer numerically controlled) software takes most of the guess work out of cutting. With an ultra modern package, even a first time worker is doughty of creating amazing outcome. The machines are safe too, almost all systems offer a downdraft or exhaust system to pull out the smoke away from the operator.

The IGBT plasma cutters are better suited for professional environments. These take up a different method to start the pilot arc. Many IGBT plasma metal cutters often deploy high frequency starting technology, high voltage circuit just for the starting process while others use Pilot Arc starting technology, where the torch enables a constant arc without touching the workpiece.

CNC plasma cutting sector has been improved notably in recent years. In the past, CNC machine’s cutting tables were horizontal, but nowadays vertical CNC plasma cutting machines are available providing enhanced flexibility, swift operation and utmost safety.

Applications of IGBT

Now-a-days the IGBT (Insulated Gate BipolarTransistor) is extensively applied in the transportation, renewable power generation, consumer, aircraft, medical, industrial and financial sectors all worldwide. As a result, billions of people from around the globe are enjoying enhanced comfort, convenience, and quality of life. IGBTs are known for their fantastic efficiency and speedy switching characteristics. These qualities make IGBTs very suitable for applications where saving energy and protecting the environment are very important. IGBTs are being used in almost all sectors of our economy because there isn’t any exact alternative available which can be used in place IGBT and can offer same advantages.

Over the last 20 years, the cumulative influence of the advanced capability of IGBT-powered applications has been an aggregate worth savings of $ 2.7 Trillion for U.S. consumers and $ 15.8 Trillion for consumers all over the world. On the other hand, the developed efficiency generated by IGBT-powered applications has propagated a cumulative lessening in carbon dioxide emissions by 35 Trillion pounds in the United States and 78 Trillion pounds worldwide during the last 20 years. So, the IGBT has already had a key impact to make a sustainable world-wide society with advanced living standards along with alleviating the environmental impact.

After its conception in the early 1980s, the applications for IGBTs have been incessantly spreading. It has already had a great impact on: the transportation sector, the consumer sector, automation sector, industrial sector, medical sector, aerospace sector, marine sector, defense sector; financial sector, power transmission and distribution sector, renewable energy power generation sector and many other sectors of the economy.

What would happen if all the IGBT were removed from the applications that they serve today?” The answer is quite revealing: Our new solar and wind based renewable energy sources would not be able to deliver power to the grid because the inverters would stop functioning. Our gasoline power cars would stop running because the electronic ignition systems would no longer function. Our hybrid electric and electric cars would stop running because the inverters used to deliver power from the batteries to the motors would no longer function. Our electric mass-transit systems would come to a standstill because the inverters used to deliver power from the power-grid to the motors would no longer function. Our air-conditioning systems in homes and offices would stop working because the inverters used to deliver power from the utility company to the heat-pumps and compressors would no longer function. Our refrigerators and vending machines would no longer function making the delivery and storage of perishable products impossible. Our factories would come to a grinding halt because the numerical controls use to run the robots would cease to function. Our new low-energy compact fluorescent bulbs would stop functioning limiting our activities to the daytime. Our portable defibrillators recently deployed in emergency vehicles, on-board airplanes, and in office buildings would no longer be operational putting over 100,000 people at the risk of death from cardiac failure.

In one statement, the quality of life in our society would be greatly deteriorated if the IGBT is no longer available. It’s a blessing of modern science.

Applications of Infineon IGBT - FZ1600R12KF4 Best IGBT for Motor Drives

Let FZ1600R12KF4 charge up your motor drives! Order yours now at http://www.USComponent.com/buy/eupec-infineon/fz1600r12kf4/ and be the first among your competitors.

Capable of generating power up to 1200V and 1600A with a light weight of 2.20lbs, Infineon IGBT FZ1600R12KF4 is a perfect fit for various motor drives. Its easy construction aspect even makes its usage more convenient to users compared to the conventional semiconductors.

Eupec Infineon FZ1600R12KF4 has a high surge current reaching up to 2500A or 60Hz. It’s a non-isolated type composed of a mounting base serving as an anode terminal, making it suitable for low voltage with 3-phase rectifier applications.

This lead-free IGBT transistor module is so powerful and durable that it can last and maintain its efficiency for many years. Highly versatile, FZ1600R12KF4 can be used on other applications, such as DC motor controls, AC motor controls and uninterruptible power supply (UPS) devices.

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