Design of metal substrate PFC motor drive "An investigation of thermal performance of IMS with WBG devices"
Author
Simonsen, Thomas Skovsgaard
Term
4. term
Education
Publication year
2023
Abstract
This thesis investigates whether insulated metal substrates (IMS) can meet the thermal requirements of a compact, low-cost PFC motor drive built with wide-bandgap (WBG) devices such as GaN and SiC. The motivation is the need for higher efficiency, higher power density, and improved thermal management in modern power electronics. The work reviews PFC converter topologies (including bridgeless options), compares semiconductor technologies, and examines PCB layout trade-offs between electrical and thermal performance. Converter and component parameters are identified, and system-level models and simulations are developed for both the PFC stage and a subsequent three-phase inverter for motor operation. IMS-based PCBs and a supply board are designed to relevant rules and standards, and prototypes are implemented to enable fast testing. The experimental program includes thermal resistance validation, switching behavior characterization of GaN on IMS, and load and inverter tests with sinusoidal output, focusing on thermal behavior, switching performance, and prototyping speed. The report consolidates practical challenges, design choices, and lessons learned, and evaluates IMS as a platform for WBG-based PFC motor drives; detailed results and conclusions are presented in later chapters.
Denne afhandling undersøger, om isolerede metalsubstrater (IMS) kan opfylde de termiske krav i en kompakt, lavomkostnings PFC-motordrevsløsning baseret på wide-bandgap (WBG) halvledere som GaN og SiC. Baggrunden er behovet for højere virkningsgrad, højere effekttæthed og bedre varmehåndtering i moderne effektelektronik. Arbejdet omfatter en analyse af PFC-topologier (herunder bro-løse løsninger), valg af halvlederteknologi, og afvejninger i PCB-layout mellem elektrisk og termisk ydeevne. Der identificeres komponent- og designparametre, og der gennemføres systemmodeller og simuleringer af både PFC-konverteren og en efterfølgende trefase-inverter til motordrift. Der udvikles IMS-baserede print og forsyningskort efter relevante designregler, og prototyper implementeres for at muliggøre hurtig afprøvning. Den eksperimentelle del omfatter validering af termisk modstand, karakterisering af skifteegenskaber for GaN på IMS samt belastnings- og invertertests med sinusformet udgang, med fokus på termisk adfærd, skifteperformance og prototypningshastighed. Rapporten samler erfaringer, designvalg og udfordringer fra udviklingsforløbet og vurderer dermed IMS som platform for PFC-motordrev med WBG-enheder; detaljerede resultater og konklusioner præsenteres i de senere kapitler.
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