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I---.
DUT
Fig. 1. Test circuit used for characterizing IGBTs under zero voltage
switching.
Paper IPCSD 94-55, approved by the Industrial Power Converter Committee of the IEEE Industry Applications Society for presentation at the 1993
Industry Applications Society Annual Meeting, Toronto, Ontario, Canada,
October 3-8. Manuscript released for publication July 1 , 1994.
A. Kurnia was with the Department of Electrical and Computer Engineering,
University of Wisconsin, Madison, WI 53706-1691 USA. He is now with AC
Delco Systems, Technology Development, Indianapolis, IN 46256 USA.
H. Cherradi was with the Department of Electrical and Computer Engineering, University of Wisconsin, Madison, WI 53706-1691 USA. He is now with
C.L.M.L./O.N.A., Rabat, Morocco.
D. M. Divan is with the Department of Electrical and Computer Engineering, University of Wisconsin, Madison, WI 53706-1691 USA.
IEEE Log Number 940828 1.
I. INTRODUCTION
HE application of soft switching inverters such as the
resonant dc link inverter is being actively considered by
many manufacturers. With the use of IGBTs, link frequencies
of 30 to 90 kHz seem to be practical at power levels of up
to 200 kW. A long held premise for promoting soft switching
converters has involved device specifications, considered to
be as per manufacturers data sheets. Detailed investigation of
device behavior under soft switching conditions, as opposed to
the more conventional hard switching conditions, has shown
that devices do not behave as per data sheets under both
zero voltage and zero current switching conditions. Particularly, under zero voltage switching conditions, IGBTs have
been shown to demonstrate unanticipated loss mechanisms
which dramatically influence frequency capabilities, and also
unexpectedly influence the choice of converter topology. This
is over and above anticipated second order effects such as
diode reverse recovery, dynamic saturation during tum-on
11. IGBT
Loss MODEL
KURNIA et al.: IMPACT OF IGBT BEHAVIOR ON DESIGN OPTIMIZATION OF SOFT SWITCHING INVERTER TOPOLOGIES
Conduction Los
28 1
in L
I .
- 5
9
4
_Q_
0
For the device that will be considered later in loss calculations,
Le, = 65 nH within the operating range of interest.
Another interesting property reported for IGBT turn-off is a
tail current bump which occurs under low dv/dt conditions,
particularly at high temperatures (see Fig. 4(a)). This seems to
occur as a result of inadequate charge removal from the drift
region [4]. Fig. 4(b) shows experimentally measured turn-off
losses for a second generation FUJI-IGBT under low dv/dt
conditions at 25OC. As expected, a higher temperature results
in higher turn-off losses. By curve-fitting these measured data,
an expression that gives turn-off energy losses for given device
current and snubber capacitance value can be obtained.
Fig. 3(a) also reveals that the device takes a long time to
reach steady state conduction loss condition, and typically
involves a dynamic saturation bump. Under these conditions,
if a snubber capacitor is used across the device (to obtain zero
voltage switching), one can obtain significant turn-on loss due
to snubber dump. Finally, this snubber dump can also set up
very large circulating currents between the snubber capacitor
and the device package possibly overstressing the device. A
detailed discussion of some of these loss mechanisms has been
presented in [1].
10
20
Vce @ IC=1OOA
Vce@Ic=90A
Vce@Ic=80A
Vce @Ic=75A
Vce@Ic=70A
Vce@Ic=60A
Vce@Ic=SOA
Vce@Ic=40A
30
40
di/dt (Alps)
50
I
60
(b)
282
Fig. 5.
Operating at higher frequencies only exacerbates the problem. Taken in conjunction with the widely varying switching
frequency, high-VA ratings of the filter components, and highpeak current stress in the device, it is considered that resonant
pole converters tend to be at a substantial disadvantage, and
will not be considered further. The most promising converters
for moderate power applications of 1-200 kW seem to be the
family of resonant dc link circuits, with the ARCP inverter
a distinct possibility at even higher power levels. This paper
examines first the issue of topology selection based on detailed
device characteristics.
111. RESONANTDC LINKINVERTEROPERATION
20
40
60
80
100
120
I, (A)
(b)
K-1
fl
( K - 1)K
L,
K ( 2 - K)V?
=
LICr
--
dt
Isp
(3)
(4)
KURNIA et al.: IMPACT OF IGBT BEHAVIOR ON DESIGN OPTIMIZATION OF SOFT SWITCHING INVERTER TOPOLOGIES
and
The diode of the clamp circuit conducts during time t,, from
current -Ispto 0 A. Then the clamp current is transferred
to IGBT which also conducts during time t,, until the current
reaches its peak Is,. For the loss calculation, it is assumed that
the load current I, is not allowed to change instantaneously.
The clamp device has a continuous and high dildt whenever it
is conducting, as it clamps KV, across the resonant capacitor
C,. Under such conditions, it has a high-conduction drop
which is proportional to dildt, and a high-circulating current.
This incurs additional losses which are a significant portion
of total inverter loss.
Inverter loss calculations are based on semiconductor losses.
Losses due to high-circulating current are also neglected. The
inverter is assumed to operate in a way such that the load
current I, is not allowed to change instantaneously. For the
worst case scenario, the inverter is driving a resistive load.
The clamp losses consist of conduction and switching loss.
At a constant link frequency, smaller values of resonant inductance L, are indicated for larger resonant capacitors C,. This
results in lower switching losses in the main devices because
of lower dwldt, but increases the switching losses in the clamp
devices since the peak current Is,,in the clamp increases
dramatically. On the other hand, smaller L , induces higher
dildt, and simultaneously higher conduction loss. The various
loss components in the clamp device can be calculated using
the clamp equations and the experimentally measured loss-data
for the kind of device under use. The clamp conduction loss
of IGBT and diode can be evaluated using
tSP
Pcl(con) = f i
(vce
+ Vdiode)Iadt
= fi(k0
+ h I s p + kZI,2,)
(7)
27t
7t
= dfi
(1 - d)fi
(10)
(6)
0
Fig. 6 . Load current and voltage.
(8)
For the worst case scenario, the load current IOand output
voltage V, are assumed to be in phase as shown in Fig. 6.
Under this condition, the fraction of time that each IGBT
conducts K , can be expressed as
1
- -(1
"-2
+ dsin8)dB.
(12)
284
l.7Ke-sat100,k
0'2vd10pk.
(14)
where ko, k1, and k2 are the same as in (7). The turn-on
loss is negligible as the resonant capacitor is not across every
individual main device. The loss due to the internal inductance
in each device is also small and is expressed as
1.0
1.2
1.4
1.6
2.0
1.8
K (Clamp Factor)
(a)
10
I .
'
'
'
' I
' I
'
'
Fig. 7. (a) Clamp conduction and tum-off loss at 25OC using the new loss
mechanisms for three different capacitance values, I., = 600 V, Io,* = 100
A, fl = 60 kHz, IGBT-FUJI 2MBI100L-120. (b) Power loss comparison
of ACRDCL inverter for two different loss models at 25OC, IOpk
= 100 A,
Vs = 600 V, C, = 100 nF, L , = 27.2 pH, IGBT-FUJI 2MBI100L-120.
KURNIA et al.: IMPACT OF IGBT BEHAVIOR ON DESIGN OPTIMIZATION OF SOFT SWITCHING INVERTER TOPOLOGIES
700
285
TABLE I
COMPARATIVE
DATAFOR SO-kVA RDCL-ACTIVELY CLAMPED
(K
= 2.0), WHEREf i = 60 kHz,
= 100 nF, AND L,. = 35
DH, AND HARLISWITCHED
PWM INVERTER
f,w = 10 kHz
FOR V, = 600 V, IGBT-FUJI 2MBI100L120. @i = 25OC.
c,
6004
RDCL RDCL
Clamp Type
2
1.4
Main Devices:
465
61
0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
K (Clamp Factor)
465
61
0 1 0
530
530
Clamp Switch:
n/a
15
33
0.3
I
I n/a
49
n/a
530
n/a
1
n/a
Fig. 8. Power loss for the ACRDCL inverter using the new loss model for
two different temperatures, \% = 600 V, Iopk= 100 A, C,. = 100 nF,fr =
60 kHz, and IGBT-FUJI 2MBI100L-120.
@
TABLE I1
TI = 12SC
lRDCL
5qm
Clamp Type
658
Clamp Switch:
Ida
465
189
0 1
4 ,
465
314
314
0.75
658
1094
15
212
n/a
n/a
n/a
125
n/a
I
~
n/a
n/a
V. CONCLUSION
This paper has presented a detailed examination of the
factors that affect the design of resonant dc link inverters
using IGBTs.
Measured loss data for IGBTs operating under zero voltage
switching conditions have been provided and various loss
mechanisms have been identified. An approach that includes
measured device characteristics in the converter design optimization process has been proposed.
The paper has also addressed the suitability of the resonant
dc link ( R D C L ) inverter in view of better device understanding. It showed that the performance of this family of
converters can be substantially improved by properly choosing
the resonant components for a desired link frequency. Under
such criteria, loss calculation and comparison with the family
286
REFERENCES
[I] A. Kurnia, 0. H. Stielau, G. Venkataramanan, and D. M. Divan, Loss
mechanisms in IGBTs under zero voltage switching, IEEE-PESC
Con$ Rec., 1992, pp. 1011-1018.
[21 B. J. Baliga, Modern Power Devices. New York: Wiley, 1987.
[3] N. Mohan, T. M. Undeland, and W. P. Robbins, Power ElecrronicsConverters, Applications and Design. New York: Wiley, 1989.
[4] A. Petterteig and T. Rogne, IGBT turn-off losses in hard switching and
with capacitive snubber, EPE-MADEP Con$ Rec., pp. 0:203-0:208,
1991.
[5] G. Venkataramanan and D. M. Divan, Comparative evaluation of soft
switching inverters, EPE Con$ Rec., pp. 2013-2:019, 1991.
[6] D. M. Divan and G. L. Skibinski, Zero-switching loss inverters for
high power applications, IEEE-/AS Con$ Rec. pp. 627-634, 1987.
M. Kheraluwala and D. M. Divan, Delta modulation strategies for
resonant link inverters, IEEE-PESC Con$ Rec., pp. 271-278, 1987.
D. M. Divan, G. Venkataramanan and R. W. De Doncker, Design
methodologies for soft switched inverters, IEEE-IAS Con$ Rec., pp.
758-766, 1988.
[91 A. Mertens and D. M. Divan, A high frequency resonant dc link inverter
using IGBTs, IPEC Con$ Rec., pp. 152-160, 1990.