Using IGBT4 Modules to realize High Power Density Design of Wind Power ConvertersOct. 2010 Power SeminarWind Power and Infineon Solution22.05.2007For internal use onlyPage 2Double Feed Induction Generator22.05.2007For internal use onlyPage 3Direct-Drive Synchronous Generator22.05.2007For internal use onlyPage 4Direct-Drive Synchronous Generator22.05.2007For internal use onlyPage 5Requirement of IGBT modules for wind converter20 years design-lifetime for power semiconductors ¬ calculation based on load cycles given by customers based on their specific power conversion system. Clearance and creepage distances higher than for industry inverters needed in case no splash water protected cabinet is used. ¬ for high humidity and salt content in the air Low losses Low thermal resistances Availability of DC-link voltage ¬ Package, internal stray inductance. RBSOA22.05.2007For internal use onlyPage 6IGBT Module SolutionIHMPrimePackTMEconoDualTM3EconoPackTM+22.05.2007For internal use onlyPage 7Module Solution22.05.2007For internal use onlyPage 8Overview of IGBT in Wind PowerA3600240018003600 A -400 A16002400 A -300 A12001000A1000800450A 650A 450 A -150 A Parallel to 1350A 450 A -150 A600AlSiC KF6C_B2 KF6C400SixPACK HalfbridgeKE3 KE4 ME3 ME4AlSiC KE3_B230022.05.2007For internal use onlyPage 9IGBT modules ->Double Feed Wind SystemWind Power 1.25MW IGBT Module EconoDUAL3 Rotor side FF450R17ME4 Paralleling / per arm 2pcs Grid side FF450R17ME4 FS450R17ME4 FF650R17IE4 FF450R17ME4 FF650R17IE4 FZ1600R17HP4 FZ1600R17KE3 FF1000R17IE4 Paralleling /Per arm N N N 3pcs 2pcs N Cooling WaterPrimePACK2/3 1.5MW EconoDUAL3 PrimePACK2/3 IHM B IHM A 2.0MW PrimePACK3FF1000R17IE4 FF450R17ME4 FF1000R17IE4 FZ1600R17HP4 FZ1600R17KE3 FF1000R17IE4N 3pcs 2pcs NWater Water Air-forced Air-forced3pcs 2pcs N 4pcs2pcs 2pcs N 4pcsAir-forced Water Air-forced WaterIHM B EconoDUAL3FZ2400R17HP4 FF450R17ME4FZ1600R17HP4 FF450R17ME4*Remark: 1) The proposal is based on the simulation conditions below as well as the general case experiences. Vdc=1100V, Vin=690V, fo=0~15Hz, fs=2kHz @ rotor side, fo=50Hz, fs=3kHz @ grid side, OL=120%. 2) The usage of the different IGBT solutions are mostly influenced by the real cooling system. Therefore, the disclaimer rule should be complied.22.05.2007 For internal use only Page 10IGBT modules ->Full Power Wind SystemWind Power 1.5MW IGBT Module PrimePACK3 IHM A 2.0MW PrimePACK3 IHM B Rotor side FF1000R17IE4 FF1200R17KE3 FF1000R17IE4 FZ2400R17HP4_ B29 Paralleling/ per arm 3pcs 2pcs 3pcs 2pcs Grid side FF1000R17IE4 FF1200R17KE3 FF1000R17IE4 FZ2400R17HP4 _B29 Paralleling /Per arm 3pcs 2pcs 3pcs 2pcs Cooling Water Water Water Water22.05.2007For internal use onlyPage 11PrimePACK™Highest creepage and clearance distance Housing material with CTI>400 Designed for over voltage class 2 Very low inductive module design Optimized chip position for better heat spreading. Complete portfolio available for 1700V. Easy for paralleling of several modules Optimized driver board design possible22.05.2007For internal use onlyPage 12Product Range22.05.2007For internal use onlyPage 13PrimePACK™Internal Bus BarLow Module Stray Inductance* Welding instead of soldering increasing mechanical robustness Optimized CostPrimePACKTM2: Internal Layout* PrimePACK™2: ~ 18 nH * PrimePACK™3: ~ 10 nH22.05.2007For internal use onlyPage 14PrimePACK™ RthchIncreased mounting screws dedicated for each DCBXXXXXDiode IGBTXXXXXResult in: Low Thermal Resistance RthCH (Case-Heatsink)22.05.2007For internal use onlyPage 15PrimePACK™Creepance 33mm Clearance 19mm CTI > 400High Creepance & Clearance Distance for Highly Contaminated Environment Meets Safety Standard: up to 3300V Impulse Voltage (Over Voltage Class 2, Pollution Degree 3)22.05.2007For internal use onlyPage 16IHM B family with IGBT41200V/1700VNEWNEWFZ Single switch3600 INOM 3600AR17 UCE 1700 VH IHM B housingP4 High Power IGBT4_B2 Traction versionNew IHM B housing22.05.2007 For internal use onlyNew IGBT4 chipPage 17Housing CompatibilityIHM A housingIHM B housingBoth housing types are 100% mechanically compatible concerning footprint - 130x140 mm housing - 140x190 mm housing mounting positions - to the heat sink - to the bus bar - to the PCB22.05.2007 For internal use only Page 18IHM B Version - “ industrial” and “traction”Applications: Module features: Base plate: Substrate: Power Cycling: Thermal Cycling: Isolation:[RMS, 50Hz, 1 Min.]TractionIndustryAlSiC Optimised Optimised Optimised 4 kV Σ = Higher ReliabilityCu Al2O3 Standard Standard 3,4 kV Σ = Cost Efficiency22.05.2007For internal use onlyPage 19Products Range (1700V)“Copper base plate” “AlSiC base plate”22.05.2007For internal use onlyPage 20PrimePACK3 –high power density FF1400R17I P41400A / 1700VFF1000R17I E41000A / 1700V1400A/IP4 Vcesat=2.1V @Tvj=125oC 2.2V @Tvj=150oC (Eon+Eoff) /Inom =0.804mJ/A Rthjc=0.0155K/W 0.80361000A/IE4 Vcesat =2.35V @Tvj=125oC 2.45V @Tvj=150oC (Eon+Eoff)/Inom=0.681mJ/A Rthjc=0.024K/WOutput currentOutput currentAir forced vs. PipelinePipe line vs. Liquid。