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Signal Interface
(Opto Couplers)
Over Current,
Over Temp.,
Cotrol supply
failure
Isolated Power
Supply
Temp. Sensor
C
P
U
Power Chips
LV ASIC
Input signal
conditioning
Gate
Drive
Current sensor(s)
Temp. sensor
the use of bare power chips and application specific control ICs. (4)
Figure 2: HVIC Chip
Improved manufacturability resulting from lower external component
counts.
Unfortunately, in spite of these advantages, the conventional
IPMs generic, general purpose, design does not provide enough
functional integration to meet the demanding cost and size
requirements of some small motor control applications. In these
cases, it is often desirable to increase the level of integration to
include functions such as level shifting, high side power supplies and
current sensing. The ASIPM shown in figure 1b has been developed
to address these requirements. The ASIPM takes the integration a
step farther than conventional IPMs by introducing HVIC (High
Voltage Integrated Circuit) technology. The ASIPMs described in this
paper utilize custom high and low voltage integrated circuits to
provide input signal conditioning, protection logic, analog current
feedback signal processing, level
shifting and gate drive for the
Figure 3: ASIPM Integrated Functions
integrated power semiconductor
devices. A photo of a typical high
Under
Boot
Voltage
voltage integrated circuit (HVIC) is
Strap
Lock-Out
Supply
shown in figure 2.
Control
n
CPU/
DSP
Status
n
ShootThrough
Interlock
Level
Shift
Gate
Drive
SC Prot.
Fault
Status
Feedback
Over
Temp.
U,V,W
TS
Size
Cost
System
Requirements
Form Factor
Functional Value
Development Time
Manufacturability
Inverter
IGBTs & Free Wheel Diodes
Brake
IGBT & Diode
Converter
Diodes
High Performance
General Purpose
Industrial Inverter
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Required
Usually unnecessary in
imbedded inverter applications
Usually unnecessary in
imbedded inverter applications
Current feedback signal is
usually not required
V. ASIPM EXAMPLES
Converter (Rectifier)
Brake
Inverter
Power Circuit
Component
Power Chips
IGBT, FWDi
HVIC
Au Bond Wire
+VCC
Input
Signal
Condition
Level
Shift
HVIC
VVFS
Gate
Drive
& UV
lock
out
VVFB
VP1
VP
+VCC
Input
Signal
Condition
Level
Shift
HVIC
VWF
Gate
Drive
& UV
lock
out
VWF
VP1
WP
VPC
+VCC
Input
Signal
Condition
Level
Shift
HVIC
VN1
UN
VN
WN
FO
CFO
Gate
Drive
& UV
lock
out
Motor
+VCC
Input Signal
Conditioning
Gate
Drive
Protection
Circuit
CIN
VNC
LV-ASIC
RSHUNT
RSF
15V
CSF
(P)
High Voltage
Level Shifters
D
E
PIN
A One-Shot
Pulse Logic
R Q
S
Gate
Drive
(U,V,W)
B
C
+15
Gate
Drive
NIN
(N)
A
B
C
D
E
F
P
P
P
N
N
AMP
IC (A)
Short Circuit
trip level
IC(rated) X 2
VAMP(200%)
Conditions:
VD=15V, Tj= 25C
Protection
Level
Over Current
trip level
VAMP
(V)
3
2
IORMS(rated) x
250% x 2
VAMP(100%)
Typical IC
Waveform
0
0
tW (s)
10
100
200
300
Bus Current (%) Normalized to IORMS(rated) x 2
active low control inputs. Normally, Figure 20: Miniature motor drive using Version 3 ASIPM
these inputs are pulled high to the 5V
logic supply of the MCU with an
external 5.1K resistor. The MCU
commands the IGBT to turn on by
pulling the respective input low.
Hysteresis is provided on all inputs to
prevent oscillations and enhance noise
immunity. The fault signal output is in
an open collector configuration. When
a fault occurs, the fault line pulls low. If
the fault is caused by an SC or OC
condition, the output asserts a fixed
1.8ms pulse. In the case of a UV lock
fault the signal is maintained until the control supply
Table 6: Version 2 ASIPMs
returns to normal. An example of a compact inverter
Peak Output Short Circuit
Inverter
Type
Typical
designed around the version 3 ASIPM is shown in
Protection
Current at
Output
Motor
figure 20.
Rating
(kW)
Current
(ARMS)
CL Warning
(AMPS)
Level (SC)
(Amps)
PS11021
0.2
0.8
5.3
10
PS11022
0.4
1.5
10
20
0.75
3.0
17
38
1.5
5.0
25
40
2.2
7.0
35
60
PS11023
The "Version 2" ASIPM, PS1102X series is
designed for miniature high performance servo and
PS11024
vector drives. In these applications, it is desirable to
PS11025
integrate sophisticated control functions such as a
current limit warning and three phase analog current
feedback. The increased integration simplifies the power
stage and reduces its cost. A simplified power stage also
helps to improve the reliability of complex multi-axis motion
control systems. The version 2 series of ASIPMs consists
of five types designed for 50 to 750W servo drives or 200 to
2200W high performance inverters. Table 6 summarizes the
key characteristics of these devices.
The packaging selected for the version 2 ASIPM is
the same low profile, aluminum base IMS utilized for version
3. A photo of the version 2 ASIPM is shown in figure 21.
A block diagram of the version 2 ASIPM is shown
in figure 22. In order to provide the sophisticated control
functions required for high performance applications, it was
necessary to use a LVASIC for the control and protection of
the low side IGBTs and a HVASIC for the level shift, gate
drive and protection of the high side IGBTs. Like the version 3
ASIPM the version 2 ASIPM has built in boot-strap supply circuits
and P and N side under voltage lock out.
The version 2 ASIPM power circuit consists of six IGBTs
and six fast recovery free wheel diodes forming a three phase
inverter stage. The input rectifier was omitted because many of the
target applications are DC fed inverter modules for multiaxis
systems. For stand alone inverters a separate matching three
phase rectifier module is available. A photo of the matching rectifier
module is shown in figure 23. The braking circuit was not
CBU+
Gate Drive
UV Lock Out
CBV-
CBV+
Gate Drive
UV Lock Out
CBW-
CBW+
Gate Drive
UV Lock Out
Level
Shift
R
230VAC
T
S
Motor
Matching Converter
Module - RM**TN-H
Analog
Current
Signal
Processing
CU CV CW
CL
FO
OT
Control UV Protection
UN
VN W N UP
VP
WP
GND VD
15V
integrated because the requirements of the target applications range from no brake in the case of regulated,
DC fed, multi-axis systems to very large braking devices in systems with heavy regeneration. A circuit
diagram of the power stage is included in figure 22.
In the version 2 ASIPM the low side IGBTs are protected from short circuit conditions by circuits
that monitor the current mirror outputs on the IGBT chips. If the current through the device exceeds the SC
level shown in table 6, the IGBT is immediately but softly turned off. The soft turn off is used to help minimize
transient voltages that can occur during an emergency shut down. The SC level is set at about three times
the IGBTs nominal rating. At this current level the IGBT is in imminent danger of being damaged so an
immediate shut down is warranted. If the short circuit protection is activated the module will assert a fault
output signal. The short circuit protection is automatically reset when the fault timer (tFO expires) and the
control input signal of the IGBT involved returns to the off state.
If the current through any of the low side IGBTs or free wheel diodes exceeds the current limit level
shown in table 6, a warning signal will be asserted on the CL output of the module. At the CL level, the
device is not in imminent danger of being damaged so the power devices are not disabled and normal
inverter operation will continue. The CL signal is a warning that is intended to be used by the system control
to either stop inverter operation or attempt output current regulation depending on the requirements of the
application. The current limit warning is derived from the analog current feedback signals described below.
The version 2 ASIPM has a built in temperature sensor that monitors the base plate temperature
of the module. If the temperature exceeds the OT level specified on the device data sheet, all six IGBTs are
turned off and a fault signal is asserted. The temperature sensor is particularly useful for detecting conditions
such as cooling fan failure, extreme ambient temperatures, improper mounting or heat sink problems.
Normal operation of the module will resume when the base plate cools below the over temperature reset
level. The built in temperature sensor simplifies manufacturing by eliminating the need for mounting and
calibrating external heat sink temperature sensors.
In many high performance applications inverter output current sensors are required for system
control. In order to simplify the power stage design and eliminate the need for hall current sensors, the
version 2 ASIPM integrates three phase current sensing and provides analog feedback signals
proportional to the inverter output currents.
The feedback signals are generated by sampling the low side arm currents and processing them to
create an analog voltage proportional to the output phase currents. The process for deriving these signals is
15V
5.1K
ASIPM
VD
Signal Name
Designation
Description
Control Inputs
Fault Signal
Current Limit
FO
CL
Analog
Current
Feedback
CU, CW, CV
5.1K
CPU/DSP
UP, VP, W P,
UN, VN, W N
FO, CL
10K
CU, CV, CW
0.1nF
GND
Typical
Motor
Rating
(kW)
Inverter
Output
Current
(ARMS)
Peak Output
Current at
CL Warning
(AMPS)
Short Circuit
Protection
Level (SC)
(Amps)
PS11011
0.1
0.8
3.1
6.0
PS11012
0.2
1.5
5.8
12.0
PS11013
0.4
3.0
10.8
24.0
PS11014
0.75
5.0
17.3
43.0
PS11015
1.5
7.0
24.7
53.0
Typical
Motor
Rating
(kW)
Inverter
Output
Current
(ARMS)
Peak Output
Current at
CL Warning
(AMPS)
Short Circuit
Protection
Level (SC)
(Amps)
PS12012
0.2
1.0
3.9
14.4
PS12013
0.4
1.6
5.8
14.4
PS12014
0.75
2.6
11.0
26.8
PS12015
1.5
4.0
15.6
38.0
P2
CBU-
CBU+
Gate Drive SC
Protection
UV Lock Out
CBV-
CBV+
Gate Drive SC
Protection
UV Lock Out
CBW-
CBW+
Gate Drive SC
Protection
UV Lock Out
Level
Shift
R
230VAC
T
S
Motor
Analog Current
Feedback Signal
Processing
CU CV CW
UP
VP
W P UN
VN W N
Br
Over Temp.
Control Power UV
and OV
Protection
5V
15V
The version 1 series consists of five types designed for 100 to 1500W inverters operating from a 240VAC
line. The 1200V series consists of four types designed for 200 to 1500W inverters operating from a
460VAC line. Tables 8 and 9 summarize the key characteristics of these devices.
These devices also utilize the low profile, aluminum base IMS package design. A photo of the
version 1 ASIPM is shown in figure 27 and the 1200V ASIPM is shown in figure 28. A block diagram of
the version 1 ASIPM is shown in figure 29 and a block diagram of the 1200V ASIPM is shown in figure
30. Like version 2 a LVASIC is used for the control and protection of the low side IGBTs and a HVASIC is
used for the level shift, gate drive and protection of the high side IGBTs.
The version 1 ASIPMs power circuit consists of six rectifier diodes forming a three phase bridge,
six IGBTs and six fast recovery free wheel diodes forming a three phase inverter stage and a seventh IGBT
and free wheel diode for dynamic braking. A circuit diagram of the power stage is included in figure 29. An
opening is provided in the positive bus for limiting inrush current. The IGBT chips have current mirror
emitters that are used by the modules internal circuits to provide short circuit protection. The 1200V
ASIPM is the same except that the three phase rectifier is omitted. The power circuit is shown in figure 30. A
separate matching converter module is available for use with the 1200V ASIPM.
The gate drive circuits in the version 1 and 1200V ASIPMs are powered from a single 15V
control power supply and a 5V logic supply. Both power supplies are referenced to a common ground that is
at the negative DC bus potential. All seven IGBTs are independently controlled with logic level input signals
referenced to the 5V supply. The signals are processed by the low voltage ASIC which provides gate drive
for the low side IGBTs and sends control signals to the HVIC for high side gate drive. The HVIC provides
level shifting and gate drive for the high side IGBTs. Built in charge pump circuits supply power for the high
side gate drive circuits eliminating the need for separate isolated power supplies.
In the version 1 and 1200V ASIPMs all six IGBTs are protected from short circuit conditions by
circuits that monitor the current mirror outputs on the IGBT chips. If the current through the device exceeds
the SC level shown in tables 8 and 9, the IGBT is immediately but softly turned off. If the short circuit
protection is activated on a low side IGBT, the module will assert an FO1 fault output signal. The short circuit
protection is automatically reset when the control input signal of the IGBT involved returns to the off state.
CBU+
CBV-
CBV+
CBW-
CBW+
B
Gate Drive SC
Protection
UV Lock Out
Gate Drive SC
Protection
UV Lock Out
Gate Drive SC
Protection
UV Lock Out
PhotoCouplers
R
460VAC
T
S
Motor
V
W
N
Matching Converter
Module - RM**TN-2H
Analog Current
Feedback Signal
Processing
CU CV CW
UP
VP
W P UN
VN W N
Br
OT
Control
Power UV
and OV
Protection
5V
15V
If the current through any of the low side IGBTs or free wheel diodes exceeds the current limit levels
shown in tables 8 and 9, a warning signal will be asserted on the CL output of the module. At the CL level
the power devices are not disabled and normal inverter operation will continue.
If input on signals are asserted for both IGBTs in the same arm as if to cause a shoot through
condition, the module will block the signals, immediately turn off the involved devices, and assert an FO1
fault signal. The shoot through interlock provides an extra level of protection against erroneous input signals
caused by noise or controller malfunctions. Normal operation will resume automatically after both of the
involved input signals have been cycled.
The version 1 and 1200V ASIPMs have built in temperature sensors that monitor the base plate
temperature of the module. If the temperature exceeds the OT level specified on the device data sheet, all
seven IGBTs are turned off and an FO3 signal is asserted.
If the ASIPMs main 15V control supply voltage is under the data sheet specified UV level, over the
specified OV level or if the 5V logic power supply is under
its specified UV level, all six IGBTs will be disabled and an
Figure 31: ASIPM Version 1
FO2 fault signal will be asserted. If any one of the high side
and 1200V Interface Circuit
charge pump supplies drops below its UV level the
ASIPM
+
+
associated IGBT will be turned off. Normal operation will
VDH
5V
15V
resume as soon as the voltages reach the specified reset
VDL
5.1K
5.1K
5.1K
CPU/DSP
UP, VP, W P,
UN, VN, W N,
Br
FO1, FO2,
FO3
CL
CU, CV, CW
0.1nF
Designation
Description
Control Inputs
Fault Signals
Current Limit
Analog
Current
Feedback
CU, CW, CV
10K
GND
levels. Hysteresis is built into the UV and OV trip logic in order to prevent oscillations.
The version 1 and 1200V ASIPMs have 14 microprocessor compatible input and output signals.
All signals are referenced to the 5V logic power supply allowing direct connection to a CPU. Table 10
summarizes the ASIPM's input and output signals. Figure 31 shows a typical external interface circuit.
VI. CONCLUSION
ASIPMs (Application Specific Intelligent Power Modules) consisting of a combination of power
devices, low voltage ASICs and high voltage ASICs are effective for simplifying and miniaturizing the power
section of small motor drives. Maximum system benefit is achieved when the package design and integrated
functions are optimized to meet the requirements of specific applications. This paper has outlined these
system considerations and presented a series of examples demonstrating the effectiveness of this
technology.
VII. REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
G. Majumdar, et al. "A New Generation High Speed Low Loss IGBT Module", ISPSD, May 1992
J Yamashita, et al. "A Study on the Short Circuit Destruction of IGBT's" , ISPSD, May 1993
G. Majumdar, et al. "A New Generation High Performance Intelligent Module" PCIM Europe May
1992
TM
Powerex "IGBTMOD and Intellimod Application and Technical Data Book" Second Edition,
PUB#9DB-200, 1998
E. Motto, et. al. "A New Generation of Intelligent Power Devices for Motor Drive Applications" IEEE
IAS Conference October 1993
E. Motto "Protecting High Current IGBT Modules From Over Current and Short Circuits" HFPC
Conference May ,1995
John Donlon, et. al. "A New Converter/Inverter System for Windpower Generation Utilizing a New
600 Amp, 1200 Volt Intelligent IGBT Power Module" IEEE IAS Conference October 1994
E. Motto, et. al. A New Intelligent Power Module With Microprocessor Compatible Analog Current
Feedback, Control Input, and Status Output Signals, 1996 IEEE IAS Conference Proceedings
Eric R. Motto A New Ultracompact ASIPM with integrated HVASIC 1997 Powersystems World
conference proceedings
G. Majumdar et. al. Novel Intelligent Power Modules for Low-Power Inverters 1998 IEEE PESC
Proceedings
S. Noda et. al. A Novel Super Compact Intelligent Power Module 1997 PCIM Europe conference
proceedings