Motor Control Solutions Motor Control Solutions Overview………………….………..….……………...…...2 Integration………………………...……………....……...3 Markets/Applications…………………………..….....3 Digital Speed Controllers.…………………......…...4 Analog Controllers………..…………………....…...…5 Integrated Assemblies/Modules....................6 Intelligent Power Modules…….………………......7 Power Bridges..…………….…….……………......…...8 Boxes/Enclosures………..………………………....…..9 Custom Assemblies……...…..…………………….....9 Evaluation Boards..……...…..……………………....10 Advanced Thermal Capabilities…………….......10 Lightweight Packaging Technology…………….11 Development Tools………………….….…………....12 ©2015 Sensitron Semiconductor · 221 West Industry Court · Deer Park, NY 11729-4681 Phone (631) 586 7600 · Fax (631) 242 9798 · www.sensitron.com · [email protected] 146-0315 Total Motion Control Solutions Sensitron offers an extensive line of integrated COTS Motor Control products designed to meet your motor control needs, or to be tailored for your specific requirements while meeting your time-to-market and cost objectives. Sensitron’s brushless motor control expertise extends the usefulness of electronic technologies, bridging the gap between semiconductor devices and their system usage. OPEN FRAME CONTROLLER High level functions designed to fit your box Rugged enclosure connections Integrated solutions MIL-STD-461 filter INTERCONNECT ACCESSORIES Cables and harnesses Mounting brackets Daughter and IO boards MOTOR CONTROLLER INPUT POWER MIL-STD-461 filter Bridge Rectifier 28V/270V/3Phase Inrush current limiting Power factor correction Isolated power converter Active bus clamp 3-Phase Brushless DC Motor Controllers Includes output power stage Internal precision current sense resistor Closed-loop control of motor Part Number: SMC6, SMCS, SMCT, SMCV Series Intelligent Power Modules MOSFET Drivers: Up to 250V & 150A IGBT Drivers: Up to 1200V and 120A DC bus optical isolation and control input optical isolation Part Number: SPM6 Series Power Bridges BOX / ENCLOSURE Input and EMI filter Under voltage & over voltage protection Reverse battery protection Rugged enclosures MIL-STD-810, IP67 ACTIVE/PASSIVE COOLING Heat sinks and mounting Cooling and thermal management Integrated passive & active cooling 100V to 1200V Max voltage Current ratings from 20A to 150A Part Number: SPM10xx Series EVALUATION / INTERFACE BOARD Tuning & operation of motor control system compatible with SMCx Series Isolated CAN, RS232, Digital I/O Rapid prototype © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 2 Motor Controller Product Integration Sensitron has heritage in over two decades of motion, from packaged devices to hybrids and modules - Non-hermetic Cryo Cooler Packaged Fets & IGBT Discretes Open Frame Module Controllers 3-Phase IPM High Current Drives Dual Axis Motor Control System COTS Controller 3-Phase Torque & Sensorless 1990’s H-Bridge 3-Phase Field Oriented Controller 800A IGBT Module Dual MOSFET Modules 2010’s Ultrafast IGBT 3-Phase Bridge Fully Integrated Hermetic Motor Controller Pin-Fin IGBT Module Hermetic Cryo Coolers 2000’s IGBT and MOSFET Drives 3-Ph BLDC Motor Control w/ EMI Filter © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 3 3-Phase Half Bridge High Current Hermetic IGBT Module Integrated heat sink H-Bridge Digital Speed/Torque Controllers Features/Benefits Sinusoidal Drive – lower distortion, smoother torque Field Oriented Control with Space Vector PWM Program for Speed, Torque, or Sensorless applications Top speed over 70,000 RPM (4 pole) Re-configurable firmware GUI Interface configures controller and motor parameters Isolated RS-232 Interface. Larger modules also have CAN, RS485/422 Telemetry – reports current, speed, motor & bus voltages, baseplate temperature -55oC to +85oC baseplate, operating temp range 1500Vdc pin to case isolation Evaluation boards available for quick testing • Part Number The Sensitron Advantage Flexibility of this design allows for use of a single device/part number for multiple motor applications with few hardware changes. Size 1 Pkg Package Size: 3.10” x 2.10” x 0.385” Weight: 3.0 oz Size 2 Pkg Package Size: 3.59” x 1.55” x 0.80” Weight: 5.0 oz Size 3 Pkg Package Size: 3.70” x 2.90” x 0.80” Weight: 13.0 oz Open Frame Pkg Package Size: 2.50” x 2.10” x 0.65“ Weight: 1.0 oz Best used in high reliability military and industrial motor control applications. Operating DC Bus Supply Voltage Absolute Peak DC Bus Voltage RMS Output Motor Current Peak Over Current Shutdown Protection Package SMCV6G080-120-1 600 1200 40 83 SMCV6G040-120-1 600 1200 20 39 Size 3 Size 2 SMCV6M020-060FC 350 600 19 27 Open Frame SMCV6G120-060-1 350 600 100 128 Size 3 SMCV6G050-060-1 350 600 25 39 Size 2 SMCV6M050-025FC 150 250 39 55 Open Frame SMCV6M120-025-1 150 250 100 128 Size 3 SMCV6M060-025-1 150 250 25 39 Size 2 SMCV6M080-010FC 60 100 68 96 Open Frame SMCV6M150-010-1 50 100 100 158 Size 3 SMCV6M080-010-1 50 100 25 39 Size 2 600 50 74 Size 2 Configuration Utility300 SMCV6G050-060-1A SMCV6M060-025-1A 120 250 50 74 Size 2 SMCV6M080-010-1A 50 100 50 74 Size 2 Configuration Utility Utilizing the application information, this motor controller can be configured for specific motor control systems with little to no impact on hardware. Features/Benefits Decreases design time by over 50% Excel-based software with motor drive GUI GUI controls motor and modifies parameters Built-in data logger Popup explanations for most fields © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 4 3-Phase / BLDC Motor Controllers The Sensitron Advantage Complete controller, wide standard product range to fit most motors. Features/Benefits Tach output voltage with average output proportional to speed Direction input to control motor direction Programmable cycle by cycle current limiting Enable/ Disable input and cycle-by-cycle current limit Analog, no software certification needed The SMC6 Series is best used as two quadrant speed controller for fans, pumps, & motors Speed/Velocity Controllers, SMC6 Series Part Number Operating DC Bus Supply Voltage 60 Absolute Peak DC Bus Voltage 100 RMS Output Motor Current 30 Absolute Peak Output Current 60 SMC6M070-010-1 60 100 50 70 Size 2 SMC6M080-010FC SMC6M40-25-1 SMC6M050-025FC SMC6G20-60 SMC6G25-60-1 SMC6M020-060FC SMC6G070-060-1 SMC6G060-120-1 60 150 150 350 350 350 400 700 100 250 250 600 600 600 600 1200 68 30 39 15 15 19 50 30 96 60 55 20 25 27 70 60 Open Frame Size 1 Open Frame Size 1 Size 1 Open Frame Size 2 Size 2 SMC6M40-10-1 SMCT6M40-10-1 SMCT6G150-010-1 SMCT6M070-010-1 SMCT6M40-25-1 SMCT6G20-60-1 SMCT6G120-060-1 SMCT6G070-060-1 SMCT6G060-120-1 Operating DC Bus Supply Voltage 60 60 60 150 350 350 350 700 Absolute Peak DC Bus Voltage 100 100 100 250 600 600 600 1200 RMS Output Motor Current 40 150 60 30 10 80 50 25 Absolute Peak Output Current 50 180 20 40 20 120 70 60 Package Size 1 Size 3 Size 2 Size 1 Size 1 Size 3 Size 2 Size 2 The SMCS6 Series is best used for simple speed control applications requiring medium accuracy Sensorless Controllers, SMCS6 Series Part Number Size 1 The SMCT6 Series is best used for high performance/ fast dynamic servo systems requiring holding torque Torque Controllers, SMCT6 Series Part Number Package Operating DC Bus Supply Voltage Absolute Peak DC Bus Voltage RMS Output Motor Current Absolute Peak Output Current SMCS6M40-10-1 60 100 40 60 Size 1 SMCS6M080-010FC SMCS6M40-25-1 SMCS6M050-025FC SMCS6G25-60-1 SMCS6M020-060FC SMCS6G070-060-1 SMCS6G060-120-1 60 150 150 350 350 350 700 100 250 250 600 600 600 1200 68 30 39 15 19 50 30 96 40 55 25 27 70 60 Open Frame Size 1 Open Frame Size 1 Open Frame Size 1 Size 1 © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 5 Package Integrated Motor Control Assemblies 3-Phase Brushless DC Motor Controller with EMI Filter/Power Supply Features/Benefits Includes all features of the SMC or SMCV Series, plus: Fully integrated 3-phase BLDC motor controller EMI filter and auxiliary power supply Nominal 40A with maximum bus voltage of 50Vdc Small package: 3.84” x 4.19” max x 1.24” max Light weight: 20 oz. Intended for UAV, aircraft and military applications Rugged design intended to drive fans, pumps, compressors Part Number Operating DC Bus Supply Voltage Absolute Peak DC Bus Voltage RMS Output Motor Current Adjustable Peak Over Current Limit 50 50 80 80 up to 65 up to 65 up to 54 up to 54 SEC6M040-010-O SECV6M040-010-O Open Frame Module Features/Benefits Substantial weight and cost savings, easy connections SMC, SMCS, and SMCV types are available in this form factor P suffix option has 4x 0.050” pins for each power connection Small Package: 2.50” x 2.10” x 0.65“ Very Lightweight: 1 oz Part Number Operating DC Bus Supply Voltage Absolute Peak DC Bus Voltage RMS Output Motor Current Peak Over Current Shutdown Protection SMCV6M080-010FC 60 100 68 96 SMCV6M050-025FC 150 250 39 55 SMCV6M020-060FC 350 600 19 27 SMC6M080-010FC 60 100 68 96 SMC6M050-025FC 150 250 39 55 SMC6M020-060FC 350 600 19 27 SMCS6M080-010FC 60 100 68 96 SMCS6M050-025FC 150 250 39 55 SMCS6M020-060FC 350 600 19 27 Digital Speed/Torque Speed/Velocity Sensorless © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 6 Intelligent Power Modules Sensitron’s SPM Series of Intelligent Power Modules feature MOSFET Drivers up to 600V/150A and IGBT Drivers up to 1200V/120A. These standard off-the-shelf modules have DC bus and control optical isolation, with sensing and shutdown features that surpass industry standard drivers. The Sensitron Advantage Standard off-the shelf product with a wide voltage and current range containing sensing & shutdown features not widely available in industry standard drivers Features/Benefits Module includes FETs/IGBTs and drivers, protection and monitoring 100V to 1200V Max voltage Current ratings from 20A to 150A -40oC to 150oC operating temp Most have isolated signal I/O Most report baseplate and dc link current with analog signals The high current modules (>100A): o Provide a differential signal for each phase current o Include a brake switch and pin for an external brake resistor Recommend Max Op DC Bus (V) Absolute Max Io pk, 25C (A) Io @ hi temp (A/Tcase) SPM6M060-010D 60 50 50 /120C 100 SPM6M080-010D 60 80 60 /90C SPM6M150-010D 60 150 SPM6M040-025D 150 SPM6M060-025D Max BV (V) Package Footprint (LxW”) Isolated I/O OCP Desat Enable /SD Idc mon Tcase mon 2.30 x 1.70 - - - - Y - Y 100 3.59 x 1.55 OPTO ADJ Y Y Y Y Y 100 /120C 100 3.70 x 2.90 MAG ADJ - Y Y Y Y 50 39 /100 250 2.30 x 1.70 - - - - Y - Y 150 70 40 /90C 250 3.59 x 1.55 OPTO ADJ Y Y Y Y Y SPM6M020-060D 350 20 10 /90C 600 3.59 x 1.55 OPTO ADJ Y Y Y Y Y SPM6G070-060D 350 75 60 /80C 600 3.59 x 1.55 OPTO ADJ Y Y Y Y Y SPM6G140-060D 350 140 100 /80C 600 3.70 x 2.90 MAG ADJ - Y Y Y Y SPM6G060-120D 700 60 25 /90C 1200 3.59 x 1.55 OPTO ADJ Y Y Y Y Y SPM6G120-120D 700 120 80 /80C 1200 3.70 x 2.90 MAG ADJ - Y Y Y Y Part Number OTP © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 7 Power Bridges with Advanced Lightweight Packaging Sensitron’s modules with advanced packaging have superior temperature cycling resistance and lower overall weight compared to traditional copper base plate modules. These composite materials are specifically engineered to have a coefficient of thermal expansion (CTE) that is similar to ceramic and silicon materials, which is commonly used in power modules, while maintaining a high thermal conductivity. These two desirable properties allow these modules to efficiently dissipate power losses over the entire lifetime of the module. Three Phase IGBT or MOSFET Bridges with SiC diodes Features/Benefits SPM1001/1002 Lightweight, fully isolated package 600V & 1200V, 15A to 150A -65oC to 150oC or 175oC Options for integrated gate resistors, brake switches, brake resistors, thermistors Superior fatigue resistance & superior temperature cycling Integrated G-E & G-S resistors for higher ESD immunity Integrated brake resistor with direct heat transfer to base RTD to monitor module temperature P/N o o PIV, 25 C Io, 25 C (V) (A) RθJC Features Packaging Base L in W in H in AlSiC 3.2 1.6 0.46 AlSiC 3.2 1.6 0.46 AlSiC 4.6 3.365 0.8 3-Ph IGBT Bridge Brake IGBT + High Side Brake IGBT Low Loss Ultrafast IGBT 3-Ph Bridge Module with SiC Freewheeling Diodes Low Loss Ultrafast IGBT 3-Ph Bridge Module AlSiC 4.6 3.365 0.8 AIN 1.90max 1.05 0.22 max AIN 1.90max 1.05 0.22 max o (C/W C) 3-PH IGBT Bridge with SiC Diodes, Brake MOSFET and Integrated Brake Resistor 3-PH IGBT Bridge with SiC Diodes, Brake MOSFET and Integrated Brake Resistor 3-Ph IGBT Bridge Brake IGBT + Inrush SCR SPM1001 600 50 1.0 SPM1002 600 30 1.0 SPM1003 1200 150 0.42 SPM1004 1200 150 0.42 SPM1005 600 30 3 SPM1006 600 60 2 SPM1007 1200 29 1.7 3-Ph SiC MOSFET Bridge with SiC Diodes, Hi Temp AIN 1.90max 1.05 0.22 max SPM1008 1200 30 1.0 AIN 1.90max 1.05 0.22 max SPM1009 600 30 3 3-Ph SiC MOSFET Bridge Low Loss Ultrafast IGBT 3-Ph Bridge Module, Ultrafast Freewheeling Diodes AIN 1.90max 1.05 0.22 max Three Phase IGBT Bridge with Brake IGBT plus Three Phase Bridge Rectifier with Inrush SCR Features/Benefits 1200V, 150A, three-phase IGBT bridge 1200V, 133A SCR input bridge w/63A diodes (P/N:SCM1001) 1200V, 32A SCR for half-controlled bridge w/80A diodes (P/N:SHM1001) Upper and lower regenerative brake IGBT switches Use of latest 4th generation IGBTs & diodes to minimize total losses AlSiC baseplate for high temperature cycling capability Low profile, light weight package with near-hermetic construction Leapfrog device in the Bridge Market © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 8 Boxes and Enclosures Features/Benefits Sensorless field oriented sinewave BLDC motor speed controller EMI to MIL-STD461 IP 67 and Nema rated enclosures available Open frame available MIL-STD circular connectors Power conditioning and DC bus filtering Re-configurable firmware Isolated CAN, RS232, RS485 interface, CAN 2.0 compliant SAE J1939 available Operating baseplate temperature: -40oC to 80oC Part Number: SEC Series SECV6G040-120-67 SECV6G060-060-67 SECV6M070-025-67 SECV6M090-010-67 Rec Operating DC Bus Supply Voltage 600 300 120 28 Absolute Peak DC Bus Voltage 700 400 200 60 Rec RMS Output Motor Current 40 60 70 90 Custom Assemblies 3-Phase Open Frame BLDC Motor Control w/ EMI Filter • 400HZ 3 phase input driver , output to 10A peak • Hall sensor commutation, with 6 pulse 3 phase output drive • Locked rotor operation and protection, 25 RPM to 5000 RPM closed loop operation • 12 Pole motor operation with internal tach • MIL-STD-704 and MIL-STD-461 compliant Power Conditioning Module & Motor Control, PCM Series • 400HZ, 3 phase AC rectifier, available from 100V/80A to 1200V/42A • 500V, 100 joules active bus voltage clamping • Isolated 28V, 28W auxiliary converter with storage capacitors • In rush current limiting • MIL-STD-704 Compliant, EMI filter meets MIL-STD-461 3-Phase Bridge IGBT Hybrid • 600V, 150Amps in a space qualified hermetic package • Low CTE • Moly/copper base plate • Very large, 4.3” x 2.9” package • MIL-PRF-38534 and MIL-STD-883 Compliant High Current Half Bridge IGBT Module • 600V, 1000A in a hermetic core construction • Increased creepage and clearance distances for high altitude operation • High frequency switching • Operation at temperature extremes • Internal layout with minimized stray inductances High Performance Cryogenic Cooler Temperature Controller / Driver • Designed to be compatible with a 1/3W cryogenic cooler • Converts standard 28VDC aircraft power to AC out • Operating input voltage 17VDC to 33VDC • Operating temperature range -54oC to +100oC continuous operation case temperature • © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 9 Peak Over Current Shutdown Protection 83 158 158 158 Evaluation Boards Features/Benefits Fast product evaluation Rapid prototyping and system integration testing Offer Evaluation Boards and FAE support Offer higher level assemblies by leveraging on evaluation cards Stackable daughter boards for other communication options Evaluation board design information available to aid customers’ assembly design Advanced Thermal Capabilities Heat Sink Features/Benefits Passive and active heatsinks/exchangers Highly integrated baseplate for rugged environments Conduction and convection cooling schemes Numerical simulation methods and analysis-based design Electrical operations up to 175 degrees Celsius COTS and purpose-built options Integrated Cross-Hatched Heatsink High transient power capability Very compact package Low thermal resistivity Multilayer structure capable Integrated, cross-hatched heat sink for greater efficiency and installation versatality H-Bridge Motor Module Integrated Module and Heatsink Assemblies Module operation temperature above 130°C o Pin fin heatsink base for silicone cooling o No-flow / start-up operation capability Integrated heat sink with membrane and gasket inserts o Uniformly distributed coolant flow o Light, multi-piece design Complete design analysis: o Computational Fluid Dynamics Analysis o Pressure Drop Computations o Conjugate Heat Transfer Analysis o Steady-State / Transient Thermal Computations o Stress Analysis (Thermal Stress and Burst Pressure) IGBT Pin-Fin Module with Heatsink Lightweight Packaging Technology Lower profile and light weight Lowest possible thermal resistance Higher temperature applications Lower cost Automation friendly © 2015 Sensitron Semiconductor 221 West Industry Court Deer Park, NY 11729-4681 Phone (631) 586 7600 Fax (631) 242 9798 www.sensitron.com [email protected] Page 10 Ultrafast 3-Phase Bridge Lightweight Packaging Technology Sensitron's Advanced Baseless Packaging Technology is a cost effective packaging solution that generates maximum weight savings with high thermal conductivity and fatigue resistance. Sensitron is positioned as a world leader in the advanced technology industry, with products that are designed, manufactured, tested, and qualified for high reliability applications where size, weight, and reliability are critical to mission success. From engineering design to finished product, our advanced simulation and modeling tools enable us to provide you with innovative product to meet your power solution requirements. Product Features Typical Applications Lower profile and light weight Aircraft Power Electronics Lowest possible thermal resistance Severe Environment Higher temperature applications Weight Sensitive Applications Removes CTE mismatch between substrate & Long Cycle Life baseplate Higher reliability Lower cost Automation friendly Performance Options Low cost (Alumina) High thermal conductivity (Aluminum Nitride) High Strength (Silicon Nitride) Attribute Comparison by Compositon Advanced Traditional Baseless Packaging Technology Copper Baseplate AlSiC Baseplate Aluminum Baseplate IMS Technology (Al) 0.4 1.0 1.1 1.2 1.4 Thermal Performance Thermal resistance index Max usable temperature 200°C 150°C 150°C 150°C 150 °C Fatigue resistance superior fair good poor excellent Flatness (per inch) <=0.003 >=0.005 N/A** >= 0.005 >= 0.005 $ $$$$ $$$$$ $$$ $$ Cost factor Weight index Typical package height (for a comparable module) 0.2 1.0 0.5 0.5 0.5 0.2 inch 0.325 inch 0.37 inch 0.325 inch 0.325 inch ** Bottom surface of AlSiC baseplates is normally designed to have curvature. © 2015 Sensitron Semiconductor • 221 West Industry Court • Deer Park, NY 11729-4681 Phone (631) 586 7600 • Fax (631) 242 9798 • www.sensitron.com • [email protected] Page 11 To o ls a nd Ca pa bilit ies ( Engin e er ing & Pr o duc t io n) Product Development Equipment • • • • • • • • • • • • • • Software Tools AutoCAD 2005 4 Dual quadcore simulation workstations Inventor 9 Dukane ultrasonic welder Solidworks 2010 SST DAP sealer Design Modeler SSEC seam welder ANSYS Mechanical v.13 Sonix ultrasonic scanner CFX v.13 BTU belt reflow furnaces MTBF Computational Tool Relex Architect 2008 Orthodyne 360 fully automatic Mathematical Tools wirebonder MathCAD 14 K&S 4526 semi-automatic wirebonder Visual Basic Dage bond pull tester APDL Polaris percussion welder C++ Trebor eutectic die bonder Origin 8.1 Trebor epoxy pick & place Rapid Prototyping Tool ZCorp 3D Plus K&S semi-automatic pick & place ESPEC thermal cycling machine Visit us online at: www.sensitron.com Powered By Sensitron Sensitron Semiconductor Corporate Headquarters Microelectronics Division 100 Engineers Road Hauppauge, NY 11788 Discrete Semiconductor Division 221 West Industry Court Deer Park, NY 11729 About Sensitron: Sensitron is a leading manufacturer of high reliability power electronic solutions including motor controllers, diodes, smart power management and conversion, voltage protection components and embedded boards, with over 40 years heritage serving space, aerospace, and defense markets.