INDUSTRIAL WELDING POWER SUPPLY SOLUTIONS

High Speed, High Efciency, High Reliability, High Performance

Fairchilds broad power portfolio offers energy and cost-saving solutions to meet the diverse range of low-, mid- and high-power welding inverter design requirementshigh efciency, high switching frequency while decreasing size and weight. Our high-end IGBT technology offers optimum performance where low conduction and switching losses are essentialeven at high current levels. Rectier provides low voltage drop as well as fast reverse recovery time and softness factor. Integrated FPS series enables the auxiliary (aux) power design to achieve lower standby power losses with compact size and reliability. Optically isolated gate drivers offer wide operating voltage range and high common-mode transient immunity. In addition, high-voltage gate drivers have excellent noise immunity and low power consumption.

Full-Bridge/Half-Bridge Topology for Single-(>20 kHz) and Three (<40 kHz)-Phase Inverters
Excellent transformer utilization Reduced inductor current ripple (by doubling the switching frequency)
Welding Machine Block Diagram (Full Bridge Inverter Type)

Stage PFC

Solutions
600/650 V Field Stop IGBTs without Anti-Parallel Diode 1-Phase: 600/650 V Field Stop IGBTs with Anti-Parallel Diode 3-Phase: 1000/1200 V Field Stop IGBTs with Anti-Parallel Diode Fast Reverse Recovery Diodes with Low VF and Softness factor 800 V FPS Series, Integrated Power Switches PWM Controllers, 800 V Power MOSFETs

Bridge Rectifier

PFC (Option)

Primary Inverter Rectifier

Driver

Driver

Welding Torch

AC Output

Ctrl

DC-Link

Inverter

Driver

Driver

AUX Power Secondary Inverter

DC Output for Steel Welding

Rectier

Driver

Driver

Welding Torch

Ctrl

AUX Power Output

Aux

Optocoupler
Driver Driver

AC Output for Aluminum Welding

Two-Switch Forward Topology for Single-Phase Inverters (>20 kHz)

Suited for sudden load-changes Excellent noise immunity No need for reset-circuit compared to forward topology
Stage PFC Inverter Rectier Solutions
600/650 V Field Stop IGBTs without Anti-Parallel Diode 1-Phase: 600/650 V Field Stop IGBTs without Anti-Parallel Diode Fast Reverse Recovery Diodes with Low VF and Softness factor 800 V FPS Series, Integrated Power Switches PWM Controllers, 800 V Power MOSFETs
Ctrl

Bridge Rectifier

PFC (Option)

Inverter Rectifier
Driver

Welding Torch

AC Output

Ctrl

DC-Link

Driver

DC Output for Steel Welding AUX Power Optocoupler

Aux

AUX Power Output

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High-Speed Field Stop IGBT Technology Optimized for High-End Welding Applications
Energy saving, high reliability, and compact design can be achieved by using Fairchilds latest Field Stop IGBT technology. Our solution is especially optimized for welding applications that require high-speed switching characteristics balancing between switching and conduction losses. Fairchilds high-speed IGBTs offer superior switching performance characteristics that ensure improved system efciency as well as minimizing total losses.
Gate Emitter N+ P-base

Features and Benets

Low switching and conduction loss suitable for industrial applications Positive temperature coefcient for easy parallel operation Maximum junction temperature: TJ = 175C High current capability up to 75 A Wide SOA (Safe Operating Area) Higher breakdown voltage with excellent ruggedness characteristics

N-

N P+ Collector

Additional Applications
Solar inverters, UPS, SMPS, PFC and hard switching topologies

IGBT EOFF vs. VCE(SAT) Trade-off Characteristics

15

Power Loss Simulations on Welding Machine

FGH40N60UFD Switching Loss, E OFF / A (uJ)

10

FGH40N60SFD FGH40N60SMD FGA40N65SMD V CE(SAT) 20%

Total Power Loss, P D (W)

E OFF 45%

FGH40N60UFD FGH40N60SFD FGH40N60SMD FGA40N65SMD

Measurement Conditions
- Full-Bridge Inverter Topology - Input: Single-phase 220 VAC - Output: 160 A, 26.4 VDC - PO = 4.3 kW, TC = 80C

5 1.6

1.8

2.0

2.2

2.4

Collector-Emitter Voltage, V CE(SAT) (V)

Switching Frequency, f SW (Hz)

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