Power Semiconductors Contributing in Energy Management
Power Semiconductors Contributing in Energy Management
[Purpose]
High-efficiency energy usage has become an extremely important factor in achieving a low-carbon society. In particular, electric energy has become indispensable in numerous fields such as automobile, industrial machinery, social infrastructure and consumer electronics, and as such, there is much expectation that advances in power electronics technology will enable the high-efficiency usage of electric energy. Fuji Electric has been developing easy-to-use power semiconductors that are characterized by their high energy conversion efficiency and low noise as key devices in the field of power electronics technology.
In this special issue, we will introduce the latest technologies and products of Fuji Electric’s power semiconductors.
We applied the All-SiC (silicon carbide) module with new package structure to mega solar power conditioning sub-system (PCS), achieving 98.8% energy conversion efficiency and resulting in energy conservation. Key technologies are 3-dimensional wiring using Cu pins with power board instead of conventional Al wiring and full-mold structure using the thermosetting epoxy resin. These technologies lead to small package size, low inductance, and high reliability. We have optimized the package design to bring out the intrinsic performances of SiC device. Resin flow analysis and its visualization methods are carried out to design molding process, resulting in the full mold structure with free air void.
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1,700-V Withstand Voltage SiC Hybrid Module
ONEZAWA, Takumi; KITAMURA, Shoji; ISO, Akira
Fuji Electric has developed a SiC hybrid module with a 1,700-V withstand voltage. It is designed for use in the traction market as a power device that can be utilized in inverters that contribute to energy savings. This module is equipped with 6th-generation IGBT chips and applies SiC-SBD chips to its FWDs. It has a product rating of 1,700 V/1,200 A (2 in 1) and has 2 specifications: standard specifications that make much of power dissipation, and low VCE(sat) specifications suitable for low switching frequencies. The standard specifications reduce loss by 18% compared with conventional Si modules. Furthermore, the low VCE(sat) specifications achieve 6% loss reduction compared with the standard specifications at low switching frequency condition.
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3,300-V Withstand Voltage SiC Hybrid Module Technology
KANEKO, Satoshi; KANAI, Naoyuki; TSUJI, Takashi
There has been increasing demand for electronics to achieve not only energy savings, but also be more compact, lightweight and improved performance such as high output. Fuji Electric is seeking to meet these demands by pursuing the development of a SiC hybrid module with a 3,300-V withstand voltage. By adopting the SiC-SBDs that we developed in partnership with the joint research body Tsukuba Power-Electronics Constellation (TPEC), we have been able to reduce generated loss by 24% compared with current Si modules. In addition, we have also utilized Sn-Sb solder to ensure high reliability and have been able to improve continuous operation temperature by 25 °C. Moreover, we made use of the reducing effect of generated loss to achieve improvements in power density while also reducing the footprint size by approximately 30%.
In recent years, the IGBT module market has been seeing increasing demand for compact modules with low loss and high reliability. In order to meet these demands, we have developed the 7th-Generation “X Series” IGBT Module. By significantly reducing the loss of IGBT and FWD chips and developing a package characterized by its high heat dissipation, high heat resistance and high reliability, we have reduced the module’s footprint by approximately 36% and power loss by approximately 10% and achieved long-term reliability. Furthermore, by enhancing its withstanding and characteristics during high-temperature operation, we increased the maximum temperature for continuous operation to 175 °C, from the conventional temperature of 150 °C. These enhancements have enabled the module to significantly increase output current, and this further increase the power density and miniaturizes the size of power converters.
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2nd-Generation Small IPM
ARAKI, Ryu; SHIRAKAWA, Toru; KOGAWA, Hiroki
Fuji Electric has been developing small intelligent power modules (IPMs) that integrate into a single package the power devices and control IC needed in the system construction of motor drives. We have now developed a 2nd-generation small IPM based on 7th-generation IGBT technology to achieve even more energy savings. The module reduces the loss by 10% or more in the intermediate load region, such as in the case of a 5.6-kW air conditioner, and by 20% or more in the rated and maximum load region compared with the 1st-generation module. In addition, temperature rise in the soldering on the circuit board has also been reduced by approximately 20 °C compared with the 1st-generation module. Overall, the module achieves enhanced energy savings, expands output current, and increase reliability during circuit board mounting and a greater degree of freedom during system design.
A high voltage integrated circuit (HVIC), which is a gate driver IC with a high breakdown voltage, is one of the key devices required in enhancing the functionality of intelligent power modules (IPMs). Fuji Electric has developed HVIC technology characterized by its advanced functionality, compactness, high reliability, and guaranteed industrial use at 600 V/1,200 V for small- and medium-capacity IPM. By reducing the circuit area and adopting high breakdown voltage technology and enhanced noise resistant level-shift circuit technology, we have reduced the chip size by 20% while improving the breakdown voltage and reliability. In addition, we have achieved over-current and overheat protection circuit technology for upper-arm IGBT, as well as level-down functionality for alarm signals.
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3rd-Generation Direct Liquid Cooling Power Module for Automotive Applications
Fuji Electric has developed a 3rd-generation direct liquid cooling power module for hybrid and electric vehicles. The power module has a rated capacity of 750 V/800 A, which is designed for motor capacity of 100 kW. The market for automotive application based power modules has been requiring increased efficiency and module miniaturization. To meet these demands, we have improved exothermicity by adopting a water jacket for integrating the cooling fins and cover while also increasing the reliability of the solder, thus enabling the module to achieve continuous operation at 175 °C. Furthermore, we have miniaturized the power module by adopting an RC-IGBT that integrates IGBT and FWD.
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Packaging Technology of 3rd-Generation Power Module for Automotive Applications
GOHARA, Hiromichi; TAMAI, Yuta; YAMADA, Takafumi
The development and popularization of hybrid and electric vehicles has been accelerating in recent years. These new vehicles demand miniaturized, light-weight and higher-output power module in order to improve fuel efficiency. Fuji Electric has developed high heat dissipating cooling unit for direct water-cooled structures, an ultrasonic bonding technology for electrodes and copper terminal, and new long-life solder that applies both precipitation strengthening and solid-solution strengthening. By applying these technologies, the 3rd-generation power modules for automotive applications that utilize RC-IGBT dies achieve greater reliability, about 30% smaller footprint and thinner structure compared to the previous generation.
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RC-IGBT for Automotive Applications
YOSHIDA, Soichi; NOGUCHI, Seiji; MUKAI, Koji
The number of hybrid electric vehicles and electric vehicles in use on the road has been increasing as a measure to reduce CO2emissions in order to protect the environment from phenomena such as global warming. In order to improve fuel efficiency for these types of vehicles, they need to reduce loss in mounted semiconductor devices, while also decreasing the size of the inverter. To meet these needs, Fuji Electric has been working to develop an RC-IGBT that integrates an IGBT and FWD into one chip. Moreover, we have optimized trench gate spacing, a field stop layer and lifetime control for the RC-IGBT for automotive applications. As a result, the inverter achieves an about 20% reduction in generated loss during the operation compared to using conventional RC-IGBTs for automotive applications.
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Relative Pressure Sensor for Automobile Fuel Tanks
KATO, Hirofumi; ASHINO, Kimihiro; SATO, Eisuke
In recent years, there has been increasing regulation to reduce the environmental burden of automobiles. One example of such regulation is the requirement to detect fuel leaks in the United States. Fuji Electric has developed a relative pressure sensor for automobile fuel tanks capable of being directly mounted to a pipe inside the engine room. The sensor is used for controlling vaporized fuel exhaust suppression devices that recover vaporized fuel to incinerate it in the cylinder. Based on our 6th-generation compact pressure sensor technology, we have successfully improved resistance to vaporized fuel, enhanced protective functions and reinforced EMC to both ensure durability and achieve high-precision detection.
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PWM Power Supply Control IC “FA8B00 Series” Capable of Handling Peak Loads
MATSUMOTO, Shinji; YAMANE, Hiroki; YABUZAKI, Jun
In recent years, the notebook computer and inkjet printer market requires increasing the maximum output power for new CPUs and motor drive loads. To meet these requirements, Fuji Electric has developed the “FA8B00 Series” of pulse width modulation (PWM) power supply control IC capable of handling Peak loads. This IC can increase the switching frequency up to 130 kHz in accordance with rise in FB terminal voltage, allowing it to increase the maximum output power of a power supply without increasing the volume of a transformer. Furthermore, the IC comes equipped with an expansion function for switching frequency jitter that enables it to achieve low EMI noise characteristics even against varying loads.
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2nd-Generation Low-Loss SJ-MOSFET “Super J MOS S2 Series”
In order to use energy efficiently, there has been increasing demand for enhanced efficiency in power conversion equipment, and power metal-oxide-semiconductor field-effect transistors (MOSFETs) that are equipped with it have been required to be compact, low loss and low noise. Fuji Electric has developed the easy-to-use 2nd-generation low-loss SJ-MOSFET “Super J MOS S2 Series” that reduces on-resistance Ron·A, which is standardized by unit area, and improves the trade-off characteristic between turn-off switching loss Eoff and the VDS surge at turn-off switching. The adoption of this product is expected to improve the efficiency of power conversion equipment.
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High-Speed Discrete IGBT “High-Speed W-Series”
HARA, Yukihito; NAITO, Tatsuya; KATO, Yoshiharu
Since power conversion efficiency is an important factor for uninterruptible power systems (UPSs) and power conditioning sub-systems (PCSs) for photovoltaic power generation, switching devices used in the equipment are required to reduce the power loss. For compact inverter welding machines, utilized devices are required to have lowloss characteristics and high-speed switching to make conveyance easier. The high-speed discrete insulated-gate bipolar transistor (IGBT) that we have developed and released reduces parasitic capacitance in active parts and optimizes the field stop layer, thereby achieving a 10% reduction in loss for 650-V products and a 19% reduction in loss for 1,200-V products when compared to the conventional product.
A long standing customer that tested several competitors’ products over a decade ago, chose a Fuji Electric product that not only meets their application criteria, but exceeded their expectations regarding: performance, quality and reliability for their commercial mixer product lines.
As their standard of choice, our AC Drives continue to surpass expectations as our product models offer the versatility and flexibility required for any demanding environment. Fuji Electric AC Drives prove to be technically superior compared to other products offered in the market. Our compact design, 3-year warranty, and exceptional torque features is ideal for many recipe requirements that make Fuji Electric their sole supplier for all of their AC drives needs.
Our products are designed to operate in 50 deg C ambient under full load conditions with no derating factor. The VFDs also maintains a UL rating under single phase power input. Fuji Electric’s ECO-DY model has a standard feature of a simultaneous control of Pump pressure and water table level control. This feature will control a pump’s output pressure and automatically switch to water table level control when the level sensor goes below an adjustable threshold. This prevents costly dry run damage to the submersible pump.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed for Agriculture Irrigation control. For this case, the ECO-DY model achieves the control by switching between two PID loops. Throughout this process, the first loop, PID1, will control the output pipe pressure. The second loop, PID2, controls the water table level. There is a sensor threshold and time that controls the switching between PID1 or PID2. One of the PID sensors will need to be a 0-10v signal and the second will need to be a 4-20ma input.
Fuji Electric VFDs are a tough, rugged and designed to operate in the harsh conditions of the oil field. Our VFDs are used in thousands of Oil field pump jack applications. For this Oil Field application, they run in 50 deg C ambient at full power without derating.
In this application, our VFDs provided the standard capability to overcome the regeneration portion of the pump jack cycle without needing braking resistors. Our VFD accurately senses the regenerative energy created by the beam pump and precisely increases the speed to eliminate the need for a braking resistor.
Peter Pugger is the world’s leading manufacturer of mixing extruders (pugmills). With the growing demand to mix and extrude new and innovative products, Peter Pugger machines require versatility and efficiency as it relates to motor control, speed control, soft start/stop and remote capability. The utilization of Fuji Electric's FRENIC-Mini and FRENIC-ACE drives has allowed their systems to maintain product quality, durability and performance. The durability of our Fuji Electric drives and the three-year warranty has established our drives as the drive of choice for all of our units. With thousands of machines worldwide, Fuji Electric’s dependability has played a key role in their success.
H2O Technologies is a high quality, highly innovative OEM Control Panels fabricator that specializes in the engineering, designing and building of Bypass Control Panels for hydraulic pump related industries that construct fountains, waterfalls and municipal pools. Fuji Electric’s FRENIC -Eco and EcoPAK Bypass Panels quickly became H2OTechnologies’ exclusive offering due to its high quality, product adaptability, and superb technical & support staff. “We have discovered a hidden gem working with Fuji Electric; it’s their ability to take us back to better days, when there was less bureaucracy, where management decisions and issues resolution were local and only a phone call away. That is a “game-changer” that sets them far apart from almost every other large organization”, exclaims Greg Sills, PPX Central’s President & CEO.
Fuji Regenerative Blowers are used to provide Air agitation for Plating, Cleaning and Rinse Tanks. They can provide high amounts of air at low pressures. They offer the advantages of clean, oil-free air that does not deliver any contaminants to foul or spoil the tank fluid. Fuji Regenerative Blowers offer a form of agitation without any moving parts in the bath. Blowers require no lubrication and that means no contaminated chemical baths. Fuji Blowers are dependable and reliable devices with no wearing, rubbing or sliding components.
Fuji Electric Power Semiconductors are used in Wind Turbines of major Wind Turbine Manufacturers. The PrimePACK™ 3+ improves power conversion efficiency to reduce power loss and increase output power. Amid the beautiful and expansive natural landscape of northern Denmark, you can see lines of wind turbines. These wind turbines use our large-capacity IGBT module PrimePACK™ 3+. In this wind power generation, the force of wind spins the blades of the wind turbine, which in turn rotates the generator to generate electricity. In order to feed this electricity into transmission lines, the voltage and frequency must be changed, and that power conversion is where our power semiconductors play a vital role.
Fuji Electric VFDs are designed to handle harsh outdoor conditions needed to run Electric Submersible pumps (ESPs) in the Oil Field. They operate in 50 deg C ambient under full load conditions with no derating factor. VFDs also maintain a UL rating under single phase power input.
For ESPs, Fuji Electric’s FRENIC-Mega is packaged in a Nema 3R enclosure along with a sine wave filter that feeds a step up transformer to create the high voltage needed for the special ESP motor. The ESP motor is sometimes thousands of feet down in the well bore. Some ESP motors are induction style while others are permanent magnet style. The Fuji Electric FRENIC-Mega works on both types of ESPs. Fuji Electric's VFD has a special feature that allows motor base voltage at speed to be adjusted while monitoring current for maximum operating efficiency thus saving valuable electrical power operation costs.
Significant levels of refrigerants and heating are needed to slow down spoilage and maintain preharvest freshness and flavor of ripe fruit and vegetables. Fuji Electric Variable Frequency Drives (VFD) make it possible to quickly provide the necessary cooling or heating to maintain a uniform temperature, humidity, air-circulation or fresh air requirements in cold storage while at the same time the energy consumption is reduced to a minimum. In standard system designs, electric motors are intended to operate at a fixed speed. This speed is determined by the frequency of the power supply and the motor design (number of poles).
The shaft load on the motor is determined by the product of shaft speed and torque. With a fixed speed, motor power is determined by the torque of the load. With a change in speed the motor load will not only benefit from the speed reduction, but also any reduction in torque with speed. Two types of motor load exist; constant torque and variable torque.
VFDs give better control and more efficiency for compressors, fans and pumps:
VFD speed control will reduce the power penalty associated with slide valve, poppet valve or throttling capacity control. On compressors with no capacity control speed control will eliminate other poor control strategies.
VFD speed control provides dramatic fan power reductions at reduced speed. This also translates into reduced motor heat loads in refrigerated spaces.
VFD speed control provides dramatic fan power saving relative to fan cycling
For maintenance of AC Drives, it is best to institute a schedule of routine maintenance which includes cleaning of the drives and their heatsinks. This prevents overheating and also prevents other debris from being lodged inside the drive!
Scheduling a Freight Pick Up
A customer was given incorrect information for scheduling a freight pick up and the terms for shipping the item. The shipment was delayed and stuck in a freight branch location. This led our team to coordinate communications between several stakeholders (Customer, Logistics Company, End User, and the freight company shipping the order). Information had to be confirmed for accuracy and ease of understanding to avoid confusion or delays. Our team at Fuji Electric was able to keep the customer informed of status regularly and get the info needed in order to resolve the issue and get the order completed.
Meeting Production Schedules
Due to material challenges, in order to meet our customer's production schedule, our team members participate in weekly meetings, provide status and shipping updates, and facilitate direct shipments from our factories. It requires daily attention and time management skills to keep track of multiple avenues to achieve delivery. However, there is a great sense of satisfaction knowing we are part of a team doing everything possible to meet their expectations!
Critical Need of Our Parts
An auto supplier was in critical need of parts or they go line down. Our team called members from Fuji Electric Japan's shipping team and got them to move an ocean orders to air drop ship to customer. No lost downtime!
Did you also know Fuji Electric Corp. of America (FECOA) was established in 1970? Fuji Electric Corp. of America is happy to celebrate over 50 years in the United States! Fuji Electric now aims to become a leading-edge company in “energy and the environment” by building upon our core platform of five technology fields which unlock the potential of electricity—energy, industrial systems, social systems, power electronics, and electronic devices.
Industrial Laundry Solutions
Fuji Electric’s FRENIC-Ace model, Variable Frequency Drives (VFDs) are commonly used in commercial laundry equipment for their ability to control the speed of electric motors. In the context of commercial laundry, VFDs are often employed in various machines and systems to enhance efficiency, reduce energy consumption, and provide better control over operations. Here are some ways VFDs are utilized in commercial laundry equipment.
Motor Control: Can regulate the speed of electric motors in washers, dryers, extractors, and other laundry equipment. By adjusting the motor speed according to the load and operational requirements, VFDs help optimize energy consumption and extend the lifespan of the equipment.
Energy Efficiency: Enable soft starts and stops, reducing the energy demand during motor acceleration. They also allow for precise control of motor speed, preventing unnecessary energy consumption when full speed is not required. This contributes to energy savings and overall operational efficiency.
Customized Washing Cycles: In laundry equipment, different fabrics and loads may require varying levels of agitation, spin speed, or drying time. VFDs provide the flexibility to customize washing cycles by adjusting motor speeds, ensuring that each load is treated appropriately.
Load Balancing: Used to balance loads in commercial laundry systems. In situations where multiple machines are connected to a common power supply, VFDs help distribute the load evenly, preventing overloads and optimizing the use of available power.
Maintenance Benefits: By controlling motor speed and providing real-time performance data, VFDs can contribute to predictive maintenance strategies. Monitoring motor parameters allows for early detection of issues, reducing downtime and preventing costly equipment failures.
Environmental Compliance: The ability of VFDs to control motor speed based on demand aligns with energy efficiency requirements and environmental regulations. Using VFDs in commercial laundry equipment helps businesses meet sustainability goals and adhere to energy efficiency standards.
In summary, Variable Frequency Drives play a crucial role in enhancing the performance, energy efficiency, and operational flexibility of commercial laundry equipment. They contribute to cost savings, reduce environmental impact, and improve the overall reliability of laundry systems.