A 2MW Power Stack Design with LV100 Package for Renewable Energy Application

Inhalt:
In this paper, a single-phase power stack with LV100-package Insulated Gate Bipolar Transistor (IGBT) modules connected in 3-parallel was designed with electrical and thermal co-simulation using Simplorer, Q3D and Workbench, ANSYS, for achieving two targets: lower temperature rise and current balancing. The design process involves minimizing thermal cross coupling among paralleled IGBTs, reducing the temperature rise of DC laminated busbar and AC busbar, optimizing the difference in impedance among parallel paths. The temperature distribution and current sharing were verified by thermal test using a DC current test (1800A) and a double-pulse test (DPT) with DC-link = 1000 V and output current IO = 3600 A. The final design achieved 7.7% of maximum temperature deviation and 2.1% of imbalance current ratio which indicates significant design optimization. The DC laminated busbar is also designed at the connection area with the IGBT to improve the heat dissipation path, the IGBT temperature of high- and low-side chips can be reduced by 5.5 K and 8.9 K, respectively. Additionally, the temperature rise of DC laminated busbar and IGBTs was also compared under different cooling methodology. Finally, a singlephase inverter test was conducted to confirm the system performance.