Highly Integrated and High Efficiency Motor Controller Based on Double Sided Cooling IGBT Module

Paper #:
  • 2017-01-2456

  • 2017-10-08
This paper presents an Integrated Power Module (IPM) and an Integrated Power Unit (IPU) which are based on the IGBT double sided cooling technology. The IPU can be used as the motor control inverter in the electric vehicle. And the IPM used in the IPU is packaged with latest 650V/600A trench field-stop IGBT device and double sided bonding and cooling technology. With the double sided bonding, planar bonding is realized which eliminates the traditional wire bonds. Powers cycling capability and long time reliability of the module have been greatly improved. Integrating with the double sided cooling, a large thermal exchanging area of the dies is achieved. Compared with the traditional single sided cooling module, thermal resistance has been reduced by 23% according to the test. Equipped with the active gate driver technology which utilizing the di/dt control and decoupling of turn-on and turn-off processes, power losses of the IPM have been greatly reduced and optimized. Total power losses in the IPU inverter system have achieved competitor’s datasheet level. The high efficiency (>95%) area of the IPU system can reach up to 80% and with vertical efficiency line in the efficiency map which will benefit longer mileage for the vehicle. According to the test, maximum battery voltage up to 450V and output phase current 450Arms is realized with the IPU system which enlarges the motor working area compared with the traditional 400V/400Arms controller. With the high heat dissipation effects and reduced power losses, IPU system overall structure is optimized and the power density of 22.7kW/L has been realized. It will make the design easier if want to integrate the inverter and motor system together. The designed IPU system based on the double sided cooling IGBT packaging has achieved technical break through which including but not limited to power density, power handling capability, and system efficiency.
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