High Power IGBT Inverter Design

Marius Rosu PhD, EM Product Manager Scott Stanton, Technical Director Leon Voss PhD, Senior AE Vincent Delafosse, Senior AE
2009 ANSYS, Inc. All rights reserved.

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Objectives
ANSYS Multiphysics Inverter Design Flow High Power System Design Concept
IGBT Electro-Thermal Model
Average Dynamic

IGBT Package Thermal Model

Extracted from CFD

IGBT Package Mechanical Stress Analysis

Thermal Stress Electromagnetic Forces

EMC/EMI Analysis
Parameter Extraction: R, L, C, G Radiated Emissions Full Wave Effects
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Outline
ANSYS Icepack Ansoft SIMPLORER Ansoft Q3D ANSYS Mechanical Ansoft SimplorerHFSS Ansoft
+
W

ECELink

IA
A
EQU

+
sourceA1 Magnet01

Ixa := Ixb := IB.I Ixc := IC.I Ix := Ixa + Iya

sourceA2

Magnet02

IB
A

sourceB1

Iyb := IB.I E Iyc := IC.I Iy := Iya + Im := sqrt(Ix^ delta := at

D

sourceB2

IC
A

sourceC1

ECE - LINK

sourceC2
FEA

ICA:

ANGRA +
GAIN

57.3
EQUBL

CONST

-30+PWM_P

EQUBL

CONST

-60+PWM_P

EQUBL

CONST

-90+PWM_P

EQUBL

CONST

-120+PWM_P

EQUBL

CONST

-150+PWM_P

EQUBL

2009 ANSYS, Inc. All rights reserved.

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High Power Inverter System

Multiphysics Design Concept
ANSYS Icepack Ansoft SIMPLORER

Model Order Reduction

Current profile

Ansoft SIMPLORER Ansoft Maxwell/RMxprt Model Order Reduction

Temperature profile

ANSYS Mechanical Model Order Reduction

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IGBT Family

Electro-Thermal Model
Average IGBT Model
A DC core
DC core

Dynamic IGBT Model

A C E F

Energy calculation

Capacities C(V), C(I) parasitics L, R, C controlled sources Full parameter excess Thermal network

Thermal network

Maximum simulation speed:

Accurate static behaviour Accurate thermal response No voltage and current transients Suitable for system design analysis

Maximum simulation accuracy:

5

Sophisticated semiconductor based model Accurate static, dynamic and thermal behaviour Accurate gate voltage and current waveforms Suitable for drive optimization, EMI/EMC
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IGBT Device Generation

Characterization Tool
Transfer characteristic curve from datasheet Fitted curve vs. measured data

Extraction of the IGBT Electro-Thermal Parameters

Measured Data

Fitted Curve

Extracted parameter values

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The Average IGBT Model

Three main parts static core thermal network energy calculation section Parameters extracted through characteristic curves

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The Average IGBT Model (2)

Switching V and I waveforms are square Switching losses are calculated at each switching period Turn-ON/OFF power pulses are injected into thermal network Amplitude of the rectangular power pulses are calculated

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PON/POFF Switching Power EON/EOFF Energy losses PDC Conduction power dissipation; TON/TOFF Power injection pulse durations Vce,sat Saturation collector-emitter voltage
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The Dynamic IGBT Model

Dynamic IGBT shares the same static the Average model The switching energy of the Dynamic IGBT model is the direct integration of the switching voltage and current

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The Dynamic IGBT Model (2)

Dynamic IGBT accurately captures the switching waveforms Suitable for EMI/EMC analysis

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IGBT Package

Thermal Model: Technical Background

ANSYS Icepack

Temperature rise at any point in the system is the sum of the independently derived temperature increase attributable to each heat source in the system Assumptions:
Temperature assumed to be a linear function of heat sources This requires that the fluid flow is constant (for each study) and density and all properties are constants
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IGBT Package (2)

Thermal Model: Technical Background Each matrix element is a complete thermal 1n ( t ) transient response curve 2 n ( t ) [h1( t ) h2 ( t ) L h n ( t )]T M nn ( t )

T1 ( t ) 11 ( t ) 12 ( t ) T2 ( t ) 21( t ) 22 ( t ) = M M M Tn ( t ) n1 ( t ) n 2 ( t )

L L O L

Foster network

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IGBT Package Thermal Model

Implementation

T T Tref = Z th ( t ) = P P
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IGBT Package Thermal Model

Validation Simple 4-node system Air at a constant speed of 1 m/s
4 3

2 1
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IGBT Package Thermal Model

Blue-measurement data Red-fitted results

Node 1 self-heating

Node 1 Due to Source 2

Node 1 Due to Source 4

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Node 1 Due to Source 3

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IGBT Package Thermal Model

Validation

Temperature at Node 1 with constant heat flux applied at all 4 nodes Temperature at Node 1 with time-variant heat flux
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IGBT Inverter Design

High Power System Analysis Ansoft SIMPLORER V8.1

DC Current Profile
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17

Line Current Profile

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IGBT Inverter Design

Mechanical Stress Analysis Ansoft Maxwell V13.0 coupled with ANSYS Mechanical R12.1

Mapping Power Loss

Thermal-Structural

Input DC Current Profile

Input Line Current Profile

18

Mapping Electromagnetic Force

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IGBT Inverter Design (2)

Mechanical Stress Analysis

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EMI/EMC

Electrical Parasitics Extraction

Extract the resistance, inductance, capacitance and conductance (RLCG) parameters of the entire package
Frequency can have a significant impact on the design performance

Ansoft Q3D

Low Frequency
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High Frequency
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EMI/EMC

Electrical Parasitics Extraction

Extracting parameters is straightforward as the nets are automatically assigned

Positive Bar Negative Bar

Phase A Phase B Phase C

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EMI/EMC

IGBT Mesh and Field Result

Current Distribution

The structure is meshed using automatic and adaptive meshing

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EMI/EMC

Parasitics Extraction
How do we set up the frequency sweep?
Nyquist sampling: To capture a time step of Ts, obtain frequency domain information up to:

Fmax

1 = 2 ts

For a time domain waveform with a risetime of 80 ns, in order to capture the ringing in the time domain, we would want to capture at least 4 samples during this risetime. This implies a sampling time of 20 ns

We need to solve up to 50 MHz (= 1/20ns)

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EMI/EMC

Parasitics Extraction
The simulation outputs consist of the RLC matrices for different frequencies

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System Integration
Circuit Design based on Parametrized IGBT and Frequency Dependent Model

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System Integration (2)

+
W

ECELink1

IA
A
EQU

+
sourceA1 Magnet01

EA

Ixa := Ixb := IB.I * Ixc := IC.I * Ix := Ixa + Iya :

sourceA2

Magnet02

IB
A

sourceB1

Iyb := IB.I * E Iyc := IC.I * Iy := Iya + I Im := sqrt(Ix^2 + delta := ata

D D

sourceB2

IC
A

sourceC1

EC

ECE - LINK
2DGraphSel1 60.00 50.00 NIGBT71.IC

sourceC2
FEA

ICA:

ANGRAD +
GAIN

EQUBL

57.3 2DGraphCon1
CONST

474.00m 400.00m
EQUBL

-30+PWM_PER

25.00

CONST

-60+PWM_PER

FFT
200.00m 0

EQUBL

GS_I...
CONST

-90+PWM_PER

0 -22.50 0 100.00m 240.00m

EQUBL

CONST

-120+PWM_PER

EQUBL

100.00
EQUBL

1.00k 3.00k 10.00k

100.00k 1.00Meg
CONST

-150+PWM_PER

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Extract Power Loss

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Full Wave Effect

2DGraphCon1 474.00m 400.00m

Ansoft HFSS
GS_I...

200.00m

0 100.00 1.00k 3.00k 10.00k 100.00k 1.00Meg

Multiplied magE plots Multiplied magE plots by Simplorer by Simplorer

Emission Test

Freq. res.

MagE@10m by specified inputs

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Normalized S para.

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The Virtual Test

The Whole Car Body

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Conclusion
ANSYS Icepack Ansoft SIMPLORER Ansoft Q3D ANSYS Mechanical Ansoft SimplorerHFSS Ansoft
+
W

ECELink

IA
A
EQU

+
sourceA1 Magnet01

Ixa := Ixb := IB.I Ixc := IC.I Ix := Ixa + Iya

sourceA2

Magnet02

IB
A

sourceB1

Iyb := IB.I E Iyc := IC.I Iy := Iya + Im := sqrt(Ix^ delta := at

D

sourceB2

IC
A

sourceC1

ECE - LINK

sourceC2
FEA

ICA:

ANGRA +
GAIN

57.3
EQUBL

CONST

-30+PWM_P

EQUBL

CONST

-60+PWM_P

EQUBL

CONST

-90+PWM_P

EQUBL

CONST

-120+PWM_P

EQUBL

CONST

-150+PWM_P

EQUBL

2009 ANSYS, Inc. All rights reserved.

29

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