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To meet the demand for high-power switching solutions, many rely on power modules. Electric vehicles like Tesla are a great example. Xiao Bei PCB design service. Professional, focused. Careful service. The size of power modules may be small, but their reliability is a motivating factor for their evaluation. They are not considered one of the main technologies for useless power switching. This article will introduce what power modules are, how they work, and their advantages. Related technologies, such as IGBT and MOSFET, are also discussed here.
Latest Technologies Featuring Power Modules
Power modules are advancing in various aspects and product types. They are best suited for higher voltage applications and can be used in powerful power switching devices. In TI (Texas Instruments) terminology, a power module contains a DC-DC converter. It integrates the controller and power, FET, and inductors into one package. Typically, the unit will include more than these three components. This includes gate drivers, sensing, and protection features. The core function is to switch motor power. Another area entering the spotlight is electric shifting and servo drives. Some power modules integrate features and intelligence far beyond these basic functions. But at least that’s what power modules are.
Defining Power Modules from Three Perspectives:
From an electrical perspective, power modules are busy when physical integration is tight. They reduce parasitic components in the interconnections of power semiconductor devices. From a thermal perspective, power modules have thermal conductive base plates. This can be bolted to a heat sink or cold plate to eliminate heat loss. From a mechanical perspective, it provides strong mechanical packaging for the components. In summary, power modules are electromechanical devices. They are optimized for power converter operations. Power modules are typically used at higher power levels. Due to their robust mechanical structure, they can simplify the design of power converters. Additionally, they ensure normal operation from electrical and thermal perspectives. However, it is essential to follow the module datasheet specifications and guidelines. IGBT and MOSFET Typically, power modules consist of transistors and diodes. Some combine transistors into used configurations, such as half-bridge configurations and H-bridge configurations that allow you to switch the current direction through the motor from a single voltage power supply. MOSFET and IGBT are some of the most common switching elements. IGBT IGBT stands for Insulated Gate Bipolar Transistor. It is a three-terminal power semiconductor device. It acts as an electronic switch, characterized by high efficiency and fast switching. Additionally, it combines the simple gate drive characteristics of MOSFETs with high current and low saturation voltage. It is most suitable for medium to high power applications. For example, from air conditioning and sound systems to trains and electric vehicles. In contrast, large IGBT modules usually consist of many devices operating in parallel. IGBTs are suitable for high voltage, high current, and low switching frequency applications. Field Effect Transistor MOSFET stands for Metal Oxide Semiconductor Field Effect Transistor. It handles significant power levels. MOSFETs have the advantage of fast switching speeds. Unlike their “bipolar” counterparts, they also have good efficiency at low voltages. And due to their isolated gate, they are easy to drive. Power MOSFETs are often used in low voltage applications (less than 200V). Other uses include: DC-DC converters, low voltage motor controllers. MOSFETs are suitable for low voltage, low current, and high switching frequency applications. It can also operate in the opposite direction. But this can be adjusted using a freewheeling diode with IGBT—provided the application is more suitable for IGBT. Smart Power Modules Power modules are continuously evolving to better address engineering challenges. Most importantly, they simplify their use. Smart power modules are one of the latest developments in power module technology. They contain an IGBT with additional control and protection circuits. The control circuit provides the driving circuit for switching bipolar transistors. Then, there is simpler gate drive logic for turning on and off. The protection circuit of smart power modules can prevent issues such as: high temperature, excessive current, short circuits, undervoltage conditions. The components in power modules are packaged in plastic with a metal base plate. This allows for adequate cooling when needed under high power conditions. In the past, power modules used screw contacts. Now, pin and crimp contacts can be used. These contacts allow for high current and high voltage usage without soldering. This simplifies installation, removal, and replacement. Applications of Power Modules The applications of power modules are common in electric vehicles and motor controllers. Other uses include: AC motor drives, front-end appliances, battery charging, cathodic protection converters, conveyor belts, DC choppers, electroplating, elevator control, half-bridge, heater control, HVAC control, inverters, medical electronics, motor control, AC motor control, DC motor starters, power factor correction, reverse polarity protection switches, three-phase inverters, traction transport, uninterruptible power supply systems, welding. Most high-power switching applications can also use power modules. Advantages of Power Modules Advances in high-frequency soft-switching technology. Semiconductor processes and packaging technology. Power density is increasing. Conversion efficiency is also improving. And the application is simpler than ever. Besides, power modules have even more features! 1. Simple and Reliable Design There are various types of power modules available in the market. There are AC-DC, DC-DC, and high voltage types, to name a few. Regardless of the type, the design is more compact due to the high integration circuits within the module. Depending on the supplier, they may offer specialized technical support and system solutions. Some can even provide peripheral circuits and parameter curves for the modules. 2. High Reliability Power modules use automated processes to ensure quality and reliability. They are designed, developed, and tested for perfect mass production under strict standards. 3. High Power, High Density, High Efficiency Modules use multilayer PCB aluminum substrates. This has high power density and small size, saving space occupied by the system. Currently, a 1/4 brick DC-DC module can reach up to 1000W. This level is somewhat challenging to achieve with discrete solutions. 4. Easy to Maintain If a failure occurs, other modules can be replaced to restore system functionality. Suppose you need to change the scheme midway through the design. You only need to change the modules inside without altering the overall power supply circuit. 5. Time and Cost Saving Power modules have various input and output options. They can be repeatedly installed or cross-installed to form modular combinations. This achieves multi-input multi-output. Compared to discrete power solutions, debugging is simpler and safer. In return, this simplifies design applications and shortens development time.