IGBT7 Power Modules – Engineered to Provide Powerful, Precise and High-Performance Solutions for Industrial Motor Drives

Imagine a massive ship navigating through turbulent seas. The ship’s engine room is its heart, responsible for converting fuel into the power that propels the vessel forward. If the engine is outdated or inefficient, the ship struggles, burning more fuel and risking breakdowns. In the world of industrial automation, processing industries and commercial and agricultural vehicles, the "engine room" is the motor drive system, and at its core lies the IGBT power module. Just as a modern, high-efficiency engine can transform a ship’s performance, our IGBT7 power modules are revolutionizing the way motor drives operate, delivering unprecedented efficiency, reliability and control.

In this blog post, you’ll discover how our seventh generation Insulated-Gate Bipolar Transistor (IGBT7) power modules are setting new benchmarks for motor drive applications. We’ll explore the technology behind these modules, the key benefits they offer and how they’re being used to solve real-world challenges in industrial motor drive applications. By the end, you’ll understand why IGBT7 modules are a game-changer and how you can leverage them to elevate your own motor drive designs.

The demand for smarter, more efficient and more reliable motor drives has never been higher. Over the past decade, industries have shifted toward automation, robotics, electrification and sustainability while respecting safety, high reliability and cost optimization. All these trends require motor drives that can handle higher power, operate more efficiently and withstand harsh environments.

Historically, power modules have been the linchpin of motor drive systems, dictating how effectively electrical energy is converted and controlled. Early generations of IGBT modules provided a leap in performance as they evolved from PT (Punch Through) to NPT (non-punch though) and gradually became more efficient.

But as applications have grown more demanding, the need for even greater power density, reliability, design flexibility and faster time to market at lower cost has become clear. Enter our IGBT7 power modules—a culmination of years of innovation, designed to meet the needs of todays and tomorrow’s motor drive applications with power, precision and performance.

Industrial motor drives account for more than 40% of the world’s total electricity consumption and over 70% of total global industrial electricity usage.

A standard industrial motor drive typically consists of 3-Phase rectifier, Brake chopper and 3-Phase inverter which could be 2 level or multilevel. The LT (< 1000Vac 3-Phase) drive has output voltages between 3-Phase 380V to 690V with nodes such as 415V, 440V and 480V depending on the type of motor and applications. Switching frequency is generally low to medium with around 2KHz for > 100kW and 4KHz for < 100kW though the range may vary.

The key requirements revolve around power handling, reliability, safety, ease of use and better price/performance ratio. The range varies from sub 100kW up to 1250KW.

Fig : typical circuit for Industrial 3-Phase motor drive

The drive could be further classified into normal duty drives and heavy-duty drives depending on the nature of applications.

High Efficiency and Power Density

Our IGBT7 modules have up to 15 to 20% lower V_CE(sat) Vs previous generations, which translates into 15 to 20% lower Conduction losses and in turn better efficiency.

Superior Thermal Stability and Overload Capacity

IGBT7 modules are built to withstand 8µS short circuit and overload capacity at junction temperatures up to 175°C. Enhanced freewheeling diode softness ensures robust performance even under fluctuating loads.

Most of the industrial automation applications have less than 60 seconds of overload with a maximum 20% duty cycle. The extent of typical overall is as given below and can vary from 110% for light duty up to 150% for heavy duty torque applications. During these overloads IGBT7 module can withstand up to 175°C junctional temperature avoiding need for overdesign, paralleling and or higher rated modules. This results in high reliability and durability with a better cost/performance ratio.

Precision With dv/dt Control for Motor Control Reliability and Safety

Inverters used to drive the motor use Pulse-Width Modulation (PWM) signals and higher pulse rise time of the switches results in high dv/dt, which is further exacerbated by the long cables used in the motor drive application from the inverter to the motor, resulting in higher peak voltages right at the motor terminals. These dangerously high voltage spikes due to rising time can result in arching and eventually insulation failure. This is why motor manufacturers strongly recommend not exceeding the dv/dt (ideal range between 2 to 8 kV/µs and median at 5 kV/µs) at the inverter terminal in the worst-case scenario for 3-phase motors of typical 380/415/440 VAC. There is a strong reason why motor drivers operate at lower to medium frequencies 1 to 4 KHZ.

IGBT7 can use a gate resistor for precise dv/dt control as Rg value needs to be optimized to achieve the desired dv/dt < 5 kV/µs. This feature is of immense benefit to ensure the safety and reliability of the end applications and mitigate the risk with proper designing of converter using IGBT7 modules. IGBT7 achieves this with tremendous ease and simplicity.

High Voltage and Current Handling

With support for voltages up to 1700V and currents up to 900A, our IGBT7 modules are ideal for mid- to high-power applications. This capability ensures that even the largest industrial motors can be controlled safaely and efficiently.

Ease of Use and Integration

We offer IGBT7 modules in a variety of topologies and package options, making them easy to integrate into both new and existing designs. Simple gate driving requirements and flexible configurations help reduce development time and system complexity. Additionally, IGBT modules can be used along with dsPIC® microcontrollers, choosing an appropriate one to add more value with Microchip offerings.

Fig: unleash full capability of microchip with MCU and Power Modules

Cost-Effective and Scalable Solutions

Thanks to widespread adoption and economies of scale, IGBT7 modules are a cost-effective choice for manufacturers. With over 40+ variants in IGBT7, 350+ in entire IGBT portfolio across generations from IGBT3 to IGBT7 and the ability to customize solutions, Microchip helps you find a suitable fit for your specific needs.

Real-World Applications

• Industrial Motor Drives: 
  • Industrial pumps and fans
  • Compressed Air Systems
  • Process Automation
  • Aviation, Marine and Defense
  • Fork-Lifts, Cranes, Commercial /Industrial elevators

If you’re ready to enhance your motor drive applications with the latest in power module technology, now is the time to explore our IGBT7 power modules. Whether you’re designing Industrial fans or pumps, process automation or cranes, these modules offer the performance, reliability and scalability you need.

Want More?

For more information, technical resources or to discuss your specific application needs, visit the Microchip IGBT Power Modules page