Power Semiconductors Contributing in Energy Management
Power Semiconductors Contributing in Energy Management
[Purpose]
Efforts to curb CO2 emissions are very important to address global warming. Measures are thus actively being taken to save energy, expand renewable energy, including photovoltaic and wind power generation, and introduce electrically driven vehicles, such as hybrid electric vehicles (HEVs) and electric vehicles (EVs). In this situation, expectations are increasingly raised for power semiconductors as key devices for power electronics to use electric energy efficiently and stably. Fuji Electric has developed and commercialized power semiconductors that facilitate downsizing and efficiency improvement of power electronics equipment intended for many fields.
This special issue presents the latest technologies and products of Fuji Electric’s power semiconductors.
All-SiC Modules Equipped with SiC Trench Gate MOSFETs
There are increasing expectations placed on products that utilize SiC modules to achieve higher efficiency,smaller size and larger capacity in power conversion equipment. Fuji Electric has been producing products that incorporate All-SiC modules with a rated capacity of up to 1,200V/100A in a package with a new structure. This package achieves higher performance and higher reliability for SiC modules. In order to expand the rated capacity, Fuji Electric has recently developed a large-capacity package with a new structure. This new package utilizes an All-SiC module with a rated capacity of 1,200V/400A, being equipped with an SiC trench gate MOSFET that achieves both low on-resistance and high-speed switching characteristics.
3.3-kV All-SiC Modules for Electric Distribution Equipment
Fuji Electric has partnered with the New Energy and Industrial Technology Development Organization (NEDO) in a project to develop electric distribution equipment and control systems that contribute to power grid stabilization when distributed energy sources such as solar power generation are massively introduced. For electric distribution equipment, an All-SiC module with a withstand voltage of 3.3 kV has been developed in that purpose. Compared to conventional Si-IGBT modules, it reduces the generated loss of inverters by 64%. As a result, our electric distribution equipment becomes so small and lightweight that they can be mounted to a single utility pole, which was not possible for conventional Si-IGBT modules due to size restrictions.
“PrimePACK™” of 7th-Generation “X Series” 1,700-V IGBT Modules
The demand for large-capacity IGBT modules has been expanding for power conversion systems used in various sectors such as industrial, consumer, automotive and renewable energy. Fuji Electric has developed the “Prime-PACKTM” as the 7th-generation “X Series” IGBT modules. The module reduces power dissipation through characteristic enhancement of semiconductor chip and significantly reduces thermal resistance by using a newly developed high thermal conductive insulating substrate. Furthermore, by improving the capacity of ΔTvj power cycle and the heat resistance of insulating silicone gel, the module has increased the guaranteed continuous operating temperature from 150°C to 175°C. With these technical development, Fuji Electric has achieved a product with a maximum rated current of 1,800A using newly developed technologies.
Fuji Electric has been developing the “HPnC” high-current power module to be used with electric railcars and photovoltaic and wind power generation facilities. The chip uses 7th-generation “X Series” technology, enabling it to achieve lower power loss. The package employs an aluminum nitride (AlN) insulating substrate that utilizes a high heat-dissipating member, as well as base materials consisting of magnesium and silicon carbide composite materials (MgSiC). Adopting a laminated structure for the enclosure of the terminal makes the internal inductance decrease to 10 nH. Furthermore, Ultrasonic terminal welding is used to comply with the RoHS directive. With these technologies, the module achieves a high current density, which is 12% greater than the conventional HPM.
7th-Generation “X Series” RC-IGBT Module Line-Up for Industrial Applications
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YAMANO, Akio; TAKASAKI, Aiko; ICHIKAWA, Hiroaki
In order to meet the market demand of the smaller size, lower power dissipation and higher reliability for IGBT modules, Fuji Electric has developed a reverse conduction insulated gate bipolar transistor (RC-IGBT) that integrates an IGBT and a FWD on a single chip. We have also developed the “Dual XT” to expand the line-up of the 7th-generation “X Series” RC-IGBT module for industrial applications that has a rated voltage of 1,200V. While the “Dual XT” 6th-generation “V Series” IGBT module for industrial applications had a maximum rated current of 600A, the new module has an expanded rated current of 1,000A. Compared with the conventional product, which uses the same package, the new product greatly improves the junction temperature and junction temperature rise of the chip during actual operation. This module will contribute to further increase of the output and extension of service life of the power converters.
“M660” High-Power IGBT Module for Automotive Applications
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OSAWA, Akihiro; HIGUCHI, Keiichi; NAKANO, Hayato
IGBT modules for automotive applications need to have low power loss to efficiently use battery power. They are also required to achieve small size and lighter weight while having high power. In response to these market demands, Fuji Electric has developed the “M660” direct water-cooled power module. This module adopts a lead frame structure, instead of wire bonding, which was conventionally used for internal wiring. It also employs the cooling structure that integrates a water jacket with reverse-conducting insulated gate bipolar transistors (RC-IGBTs) that have improved characteristics. With these structures, the M660 achieves the rated capacity of 750V/1,200A, which is the world’s highest power as a general-purpose 6-in-1 IGBT module.
There is increasing demand for reducing the environmental load of automobiles. Automotive pressure sensors, which are indispensable for control systems for high efficient engines and cleaner exhaust gas, are required to achieve high-temperature operation, corrosion resistance, electrification resistance, and miniaturization. In order to meet these demands, the 6.5th-generation automotive pressure sensors have been developed. They inherit from the 6th-generation series while providing several enhancements, such as improved electrification resistance and corrosion resistance to exhaust gas and vaporized fuel, as well as a smaller size and improved reliability of sensor accuracy. They optimize temperature characteristic to guarantee operation at 150°C and add a clamp function to prevent erroneous detection by separating the diagnostic voltage range from the normal output voltage range.
“FA8A80 Series” 650-V PWM Power Supply Control ICs
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HIASA, Nobuyuki; ENDO, Yuta; KARINO, Taichi
Switching power supplies for electronic devices, which are increasingly being required to save energy and reduce the number of parts usage, need to achieve high efficiency, low standby power, and reduction in the number of parts. Fuji Electric has developed the “FA8A80 Series” 650-V PWM power supply control ICs, which allows power supplies to achieve compact size and improve safety, as well as high efficiency and low stand-by power, which are inherited from the “FA8A60 Series.” The maximum applied voltage for the high-voltage input terminals has increased to 650 V from the previous withstand voltage of 500V. Furthermore, the series has also achieved greater surge resistance. Their protection functions have the same characteristics as conventional products, facilitating to use existing design resources to promote labor savings in power supply design.
“Super J MOS S2 Series” and “Super J MOS S2FD Series” for DFN 8 × 8 Packages
Fuji Electric has launched the DFN 8 × 8 package line-up of the “Super J MOS S2 Series” and “Super J MOS S2FD Series” 2nd-generation low power loss SJ-MOSFETs having a super-junction structure. This surface mount package is smaller and thinner than the previous D2-PACK package. The DFN 8 × 8 package doesn’t have a lead terminal, but all electrode pads are arranged on its back surface. Compared with the D2-PACK, the mounting area has been reduced by 58% and the package height to 0.85mm, thus making high-density mounting possible. It also comes equipped with a sub-source terminal for speeding up switching operations.
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.