IGBT Motor Drives in the Hybrid & Electric Vehicles

The automotive industry, the largest in the world, is fast-growing and diverse, with a wide range of customer preferences for design, comfort, and technology. It is well recognized that gasoline power vehicles produce significant urban pollution while consuming a dwindling fossil fuel resource. A solution to this problem is the deployment of electric and hybrid-electric vehicles. The global goals to reduce emissions and fuel consumption, with pioneering efforts in developing electric vehicles (EVs) and hybrid electric vehicles (HEVs), bring significant technology challenges. 

All hybrid-electric and electric cars that have been introduced into the market so far have relied upon IGBT-based motor drives. In new powertrain generations such as EVs and HEVs, IGBTs play a 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. Thermal characterization helps to optimize the IGBTs layout, structure and mounting to optimize its performance. After all, we can say, the availableness of IGBTs has been diametrical to the advancement of hybrid vehicles and to the expansion of the charging substructure for electric vehicles. IGBTs will carry on playing a significant part in the availableness of expense reducing technology for the whole hybrid and electric vehicle business.

Rotor position sensor system for brushless motor control in IGBTS

Brushless motors are frequently used in (H) EV applications. These highly efficient motors are based on fast and precise rotor position sensors for switching, since these sensor parameters have a significant impact on starting behavior, dynamics, torque undulation, and efficiency. There are different principles to detect the position of the rotor: electromechanical (inductive) and magnetic resolution. Sensor systems based on solving the problems of transistors have some limitations (analog output, complex circuit, high system costs, space limitations, sensitivity to lost fields and positioning tolerances, etc.). 

The 32-bit AURIX microcontroller family, With its delta-sigma ADC to perform carrier signal generation and software-based coding, it already helps save the external resolution IC and, therefore, the system cost by 20%. On the other hand, magneto-resistant angle sensors (xMR) with AMR (Anisotropic-Magneto-Resistance) or GMR (Giant-Magneto-Resistance) technology offer high precision accuracy, combined with low sensitivity to the tolerances of position.

FZ1600R12KF4 Best IGBT for Motor Drives

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.

https://www.youtube.com/watch?v=cvnefN9zDXo

Use of IGBTs in Tesla Roadster

Tesla Roadster is the first high-performance electric car in the world. It is very speedy, unprecedented; handles like a dream and goes like a bullet. But it doesn’t consume a single drop of gasoline and practically noiseless. Traditional gasoline-powered car contain hundreds of moving parts. But the Roadster is powered by just four main systems. These are: The Energy Storage System (ESS), The Power Electronics Module (PEM), an electric motor and a sequential manual transmission. We will talk about the power electronics module below. The Roadster battery, as with all batteries, stores electricity at a DC voltage. The motor uses energy in the form of an AC voltage. The Power Electronics Module functions as a bridge for energy between the charge port, battery, and motor. Every electron ever used in a Roadster, from the motor drive to the dome light, flows through the Power Electronics Module. It is a power inverter and charging system that converts AC voltage from the grid at between 90V and 265V, into DC voltages between 250V and 425V using 72 insulated gate bipolar transistors (IGBTs). This lead a significant increase in power output likened to first-generation electric cars. Under peak acceleration, the batteries can provide 200 kW of energy -- sufficient to power 2,000 incandescent light bulbs. Along with controlling charge and discharge rates, the Power Electronics Module controls voltage levels, the motor RPM (revolutions per minute), torque and the regenerative braking system.

FZ1200R12KF5 - Perfect IGBT for Motor Control

FZ1200R12KF5 is a TRANS IGBT (Insulated Gate Bipolar Transistor) module N-CH 1200V 78A 7Half-Bridge. This module is manufactured by Infineon Technologies, Germany previously familiar as Eupec who is one of the prime manufacturers and suppliers of semiconductors and system solutions. The best applications of FZ1200R12KF5 are DC motor control, NC equipment, AC motor control, contactless switches, electric furnace temperature control, light dimmers & welders. In case of power & energy, efficiency, mobility and security are three basic needs of this modern society. Infineon has sorted their product lineup by considering these facts. FZ1200R12KF5 is an IGBT device that combines the voltage characteristics of a biopolar transistor (collector – emitter) and the drive characteristics of a MOSFET.

Prior to 1990s, the only available power semiconductor switching device was silicon GTO which had the power manipulation capability compatible for motor control applications. In the 1990s, the ratings of IGBTs had adequately advanced, to exceed one Mega-Watt allowing penetration of the IGBT into this traction market. The availability of the IGBT allowed significant improvements in the motor drive technology due to elimination of snubber circuits and an increase in the operating frequency of the inverter circuit used to deliver power to the motors. FZ1200R12KF5 is an IGBT device from Infineon which is used frequently for electric motor control.

The Motor Control Unit (MCU) is the vital part of a 100% electric-powered vehicle as it handles and regulates the electrical power supply to the electric motor to generate the necessary level of torque to power the vehicle by converting the battery packs DC voltage into three-phase AC. Inversely, the MCU is responsible for managing the electrical energy that is generated by the regenerative braking system and is fed back into the lithium-ion battery pack.

The crucial electrical components accommodated within the Motor Control Unit are a smoothing condenser to help stabilize the DC current, several FZ1200R12KF5 convert the DC electrical current into AC, a heat sink to provide cooling/heat dissipation and a control board that supervises the electric motor. The control board is located in a separate area within the MCU from the smoothing condenser, the IGBTs and the heat sink to protect it from the heat generated by these components.

Infineon Technologies has developed voltage-source inverters for AC motor drive systems with IGBT based inverters serving applications under 3,600kVA and GTO thyristor inverters for higher power levels. Because steel manufacturing lines use so many variable-speed motors, size reductions in the motor drive units can contribute to substantial savings in factory floor space that reduce investment costs. High-power-factor converters are another focus of technology development since these converters produce less reactive power and introduce lower levels of power line harmonics. FZ1200R12KF5 is an IGBT device being used in the inverters for such AC/DC motor drive systems.

http://www.uscomponent.com has been selling IGBT power transistor module including FZ1200R12KF5 since 2001. We have a dedicated quality control team unlike any supplier which always tries their best in order to maintain a quality. We sell original and new parts electronic parts only. Please visit our website for stock check or tech support.

FZ1200R12KF5 - A Perfect IGBT For Motor Control

FZ1200R12KF5 is a TRANS IGBT (Insulated Gate Bipolar Transistor) module N-CH 1200V 78A 7Half-Bridge. This module is manufactured by Infineon Technologies, Germany previously familiar as Eupec who is one of the prime manufacturers and suppliers of semiconductors and system solutions. The best applications of FZ1200R12KF5 are DC motor control, NC equipment, AC motor control, contactless switches, electric furnace temperature control, light dimmers & welders. In case of power & energy, efficiency, mobility and security are three basic needs of this modern society. Infineon has sorted their product lineup by considering these facts. FZ1200R12KF5 is an IGBT device that combines the voltage characteristics of a biopolar transistor (collector – emitter) and the drive characteristics of a MOSFET.

Prior to 1990s, the only available power semiconductor switching device was silicon GTO which had the power manipulation capability compatible for motor control applications. In the 1990s, the ratings of IGBTs had adequately advanced, to exceed one Mega-Watt allowing penetration of the IGBT into this traction market. The availability of the IGBT allowed significant improvements in the motor drive technology due to elimination of snubber circuits and an increase in the operating frequency of the inverter circuit used to deliver power to the motors. FZ1200R12KF5 is an IGBT device from Infineon which is used frequently for electric motor control.

The Motor Control Unit (MCU) is the vital part of a 100% electric-powered vehicle as it handles and regulates the electrical power supply to the electric motor to generate the necessary level of torque to power the vehicle by converting the battery packs DC voltage into three-phase AC. Inversely, the MCU is responsible for managing the electrical energy that is generated by the regenerative braking system and is fed back into the lithium-ion battery pack.

The crucial electrical components accommodated within the Motor Control Unit are a smoothing condenser to help stabilize the DC current, several FZ1200R12KF5 convert the DC electrical current into AC, a heat sink to provide cooling/heat dissipation and a control board that supervises the electric motor. The control board is located in a separate area within the MCU from the smoothing condenser, the IGBTs and the heat sink to protect it from the heat generated by these components.

Infineon Technologies has developed voltage-source inverters for AC motor drive systems with IGBT based inverters serving applications under 3,600kVA and GTO thyristor inverters for higher power levels. Because steel manufacturing lines use so many variable-speed motors, size reductions in the motor drive units can contribute to substantial savings in factory floor space that reduce investment costs. High-power-factor converters are another focus of technology development since these converters produce less reactive power and introduce lower levels of power line harmonics. FZ1200R12KF5 is an IGBT device being used in the inverters for such AC/DC motor drive systems.

http://uscomponent.com has been selling IGBT power transistor module including FZ1200R12KF5 since 2001. We have a dedicated quality control team unlike any supplier which always tries their best in order to maintain a quality. We sell original and new parts electronic parts only. Please visit our website for stock check or tech support.

Sistema de sensores de posición del rotor para el control del motor sin escobillas en IGBTS

Los motores sin escobillas se utilizan frecuentemente en aplicaciones (H) EV. Estos motores altamente eficientes se basan en sensores de posición del rotor rápidos y precisos para conmutación, ya que estos parámetros del sensor tienen un impacto significativo en el comportamiento de arranque, la dinámica, la ondulación del par y la eficiencia. Existen diferentes principios para detectar la posición del rotor: resolución electromecánica (inductiva) y magnética. Los sistemas de sensores basados en resolver las problematicas de los transitores tienen algunas limitaciones (salida analógica, circuito complejo, altos costes del sistema, limitaciones de espacio, sensibilidad a campos perdidos y tolerancias de posicionamiento, etc.).

La familia de microcontroladores AURIX de 32 bits, con su ADC delta-sigma para realizar la generación de señales portadoras y la codificación basada en software, ya ayuda a ahorrar el IC de resolución externa y, por lo tanto, el coste del sistema en un 20%. Por otro lado, los sensores de ángulo resistente a magneto (xMR) con tecnología AMR (Anisotropic-Magneto-Resistance) o GMR (Giant-Magneto-Resistance) ofrecen una precisión de alta precisión, combinada con una baja sensibilidad frente a las tolerancias de posición.