Fuji Electric Corporation (Headquarters: Shinagawa-ku, Tokyo, President: Tsuhiro Kitazawa) is pleased to announce that it has started mass production of the HPnC*2, a large-capacity IGBT*1 module for the seventh-generation X-Series, for the railway market.
1. Background
In recent years, railways have been attracting attention as an energy-efficient and eco-friendly means of transportation to prevent global warming, but since vehicles consume a lot of electricity, they are faced with the challenge of making vehicles smaller and lighter, and how to reduce energy consumption. Power semiconductors (IGBT modules) are electronic components that convert alternating current and direct current through high-speed switches (power-off and power-on) installed in the main inverter unit of the drive system of railway vehicles and auxiliary power supply devices that supply power to air conditioning systems and interior lighting.
We have developed and started mass production of the HPnC large-capacity IGBT module that reduces power consumption. The electrified railway market is expected to grow at an average annual rate of 6% in the future, and the market size is expected to reach 500 to 60 billion yen*3 by 2023.
Company forecasts
2. Product features
(1) Reduce power consumption and achieve energy saving
This product is equipped with our latest 7th generation IGBT components, which have industry-leading low-loss performance. In addition, this product reduces losses by 76% by reducing the internal inductance that restricts high-speed switching by optimizing the package structure compared to the previous model. The operating power consumption of the inverter equipped with this product is approximately 8.6% lower than that of the conventional product ("HPM" produced by our company), and in combination with the characteristics of (2) below (enhanced heat dissipation), this product is able to more effectively suppress heat generation, and achieves a 19% reduction in size and 13% weight reduction compared to the previous model.
(2) Improve the material of the heat dissipation base plate to improve reliability
One of the main causes of IGBT module failure is the deterioration of the connection inside the module due to stress caused by changes in operating temperature. To achieve this, the material of the heat dissipation base plate of the module was replaced by a composite material of aluminum and silicon carbide (AlSiC) with better thermal conductivity of magnesium and silicon carbide (MgSiC), which has better thermal conductivity, and the heat dissipation performance is enhanced, and temperature changes are suppressed. In addition, while the conventional model uses solder to connect the insulating substrate to the energized terminals, the new model uses ultrasonic welding*4 to reduce the failure rate of the product.
*4: This method uses ultrasonic vibration to directly connect the object.
(3) It is convenient for power semiconductors to be connected in parallel
In the old model, the circuit was composed of a three-layer busbar (energized conductor) stacked structure, which becomes very complex when the power semiconductors are used in parallel (see figure). The arrangement of the terminals has been optimized, and the three-layer busbar can be uniformly arranged in the same direction, making it easy to connect power semiconductors in parallel (multiple parallels) and making it easier to assemble various inverters.
3. Main specifications
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