eNewsletter

May 2008

In This Issue:

COMPANY NEWS

  • Call for Presentations – 2009 Motor, Drive & Automation Systems Conference
  • Lenze-AC Tech Introduces Higher Power, Enhanced Variable Frequency Drives Utility
  • KB Electronics Now Offering Custom Control Solutions
  • Are Brushless Motors Sweeping Up The Competition?
  • Frost & Sullivan Recognizes Yaskawa for Providing High Value in the Micro Electric Drives Market

PRODUCT NEWS

  • WEG Provides a Packaged Solution for Medium Voltage Applications
  • First Intelligent Power Module for Solder-Free Assembly
  • IR Introduces High Performance MOSFETs for Power Supplies and Electric Motors
  • ElectroCraft Unveils CompletePower Line of Servo Drives and Speed Controls for Brushless, PMDC and   Stepper Technologies
  • Dynapar Introduces Economical Encoder for Brushless Motors
  • Fairchild Launches Industry's First SPM Products for Driving Two-Phase Switched Reluctance Motors
  • Infineon Intelligent Power Modules Designed to Increase Energy Efficiency and Reliability of Home Appliance Motors
  • Autotrol Corp. Introduces New High Torque AC Synchronous Motor
  • Integrated Gearmotor from Dynetic Systems Improves Efficiency While Reducing Size and Noise Levels
FEATURE

  • Digital Power: A Panoramic View of Applications and Challenges - By Steve Mappus, Systems Engineer, Fairchild Semiconductor, High Power Solutions

FEATURED COMPANY

  • Baldor Electric Company

EVENT LISTING

  • 2009 Motor, Drive & Automation Systems Conference
  • Software Ecosystems Summit

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Registration Begins May 27th, 2008


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Yokogawa WT3000 Precision Power Analyzer

Look to Yokogawa for your total solution for precision power measurements. Yokogawa offers acomplete line of Precision Power Analyzers to meet your measurement applications in areas such as Energy Star®, Stand-by-Power, Inverter, Motor and Efficiency testing.   Products are available from single phase up to six phases, with accuracies as high as 0.02%.  For more information, contact Yokogawa Corporation of America.

Contact us for more information.


Infolytica MotorSolve BLDC,
IM and SRM design software



MotorSolve has your solution for all types of electric machines. The modern and intuitive template-based interface makes it effortless to design any number of brushless dc, induction and switched reluctance machines for extensive analysis.

Request your free evaluation copy today!

 

2008 Motor, Drive & Automation Systems Conference – Call for Presentations

This sixth annual, two-day technical conference will  take place March 3-4 in Orlando, Fla. and serve an   audience of decision makers from around the world   who are interested in learning the latest advancements and capabilities in electric motor, drive, power & automation systems technology. Don’t miss the once- a-year opportunity to share your technology solutions with hundreds of potential business partners.

We are looking for various types of presentations as  they relate to the following categories:
 
• MOTOR & DRIVE SYSTEMS
• POWER ELECTRONICS & EFFICIENCY - NEW!
• MECHATRONICS - NEW!
• PRECISION MOTION CONTROL
• AUTOMATION TECHNOLOGY & APPS

The deadline for submitting abstracts is July 31, 2008.
Speaking slots are limited and early submissions are strongly encouraged.
 
 For more information about Motors 2009 visit www.e-driveonline.com or contact jeremym@infowebcom.com.   


Lenze-AC Tech Introduces Higher Power, Enhanced Variable Frequency Drives

Lenze-AC Tech recently introduced its higher power, enhanced SMVector NEMA1 drives. 
   
According to company officials, with its price, flexibility and power range now extended to reach 30 Hp, the SMVector drive is well suited for traditional VFD applications as well as in environments where inverter technology was once considered too costly. Lenze-AC Tech describes the drive’s increased capabilities as including an additional programmable digital input, terminals for RS-485 communications and an enhanced keypad.
   
“In the past, we needed an external module for RS-485 communications,” said Steve Dextraze, VFD product manager at Lenze-AC Tech. “Now the 15 to 30 HP SMVector has the capability to wire RS485 right into the drive. To give users immediate access to drive operation if external control is removed, we have added a simple CTRL button for real time control of Local/Remote and Manual/Auto functions.”     

For more information visit www.actech.com  


KB Electronics Now Offering Custom Control Solutions

KB Electronics, a provider of high quality off-the-shelf controls, is now offering custom control solutions for almost any application. The company, devoted exclusively to the development of quality controls, combined with a hand picked team of professionals, provides a wealth of knowledge and expertise for control hardware and software solutions. KB has designed custom control solutions for some of the world’s leading manufacturers. The benefits derived from the implementation of these custom applications include: performance enhancements, lower maintenance costs, lower production costs, lower installation costs, improved reliability and a strong competitive edge.

For more information visit www.kbelectronics.com 


Are Brushless Motors Sweeping Up The Competition?

For years, manufacturers of brushless DC motors have promoted the advantages of their products, with growth in the market strongly influenced by the replacement of other motor technologies. Although clearly viewed as a premium product, levels of replacement have been, whilst steady, less than many anticipated.

The benefits of brushless DC motors are well publicized, and include high levels of performance, reduced maintenance, quieter operation and longer lifetime. The main driver of growth in the market for these products, which globally was estimated at approximately $490 million in 2007, is through replacement of products in the massive ($6.7billion) brushed DC motor market. With growth rates for brushless DC motors forecast at approximately double that of brushed products, an increasing number of suppliers have begun introducing brushless products as part of their portfolio.

Certain industries, such as medical and industrial automation, have readily accepted the higher cost in exchange for the performance benefits, however, in many other applications the higher prices remain prohibitive. This is most evident in cost competitive markets such as domestic appliances and power tools, and also for the largest sector for small motors; automotive. Although some applications currently use brushless products, the majority of these sectors remain untapped.

In spite of this, there is the potential for a cascade effect that could result in more applications switching to brushless products. Specifically, if a particular application consuming large volumes of brushed DC motors switched to brushless DC motors, this would result in the potential to reduce production costs through economies of scale. As companies were able to produce these products at lower costs this would in turn create opportunities in a broader range of markets.

For more information visit www.imsresearch.com


Frost & Sullivan Recognizes Yaskawa for Providing High Value in the Micro Electric Drives Market

Based on its recent analysis of the micro electric drives domain (0 to 10 kW) market, Frost & Sullivan has presented Yaskawa Electric America, Inc. with the 2008 Global Frost & Sullivan Award for Customer Value Leadership. The award recognizes Yaskawa’s efforts to meet customer needs and its ability to reduce total cost of ownership for its global customers in micro electric drives.

Ever-changing customer needs drive manufacturers to bring out cost-effective solutions with enhanced product features. Increasingly, micro drives are used to aid in improving process control along with energy conservation. This in turn has augmented the business potential for micro electric drives coupled with an ardent challenge for drive manufacturers to invest significantly in their R&D.

“Yaskawa’s customer-centric technological innovations have resulted in superior product features such as programmable functions, ability to withstand rugged operational conditions, and high reliability,” said Frost & Sullivan Industry Analyst Deepthi Pamadiparthi. “The company’s relentless efforts on R&D have resulted in drives with smaller foot prints that offer superior performance capabilities for its customers.”

Bringing out a single product that can address functionalities of a wide spectrum of customers is a major challenge for drives manufacturers. Yaskawa has remained a pioneer in bringing out the right product for the right application. Yaskawa’s drives encompass a mean time between failures of 28 years, which is far higher when compared to the industry average, thereby making it the preferred choice for industrial applications.

Strategic mergers and acquisitions have further strengthened Yaskawa’s position in the drives market. It acquired the drives group of MagneTek and purchased the rights of Omron IDM Controls’ HVAC and Industrial channels. The former provided a strong distribution network to offer customers a better accessibility for sales and after sales support while the latter gave Yaskawa an exceptional exposure to technological advancements, thereby enabling it to offer drives with better features for its customers.

For more information visit www.yaskawa.com

WEG Provides a Packaged Solution for Medium Voltage Applications

WEG Electric Motors Corp., a global supplier of motors, drives, controls, transformers and generators, now offers a comprehensive line of variable frequency drives for powering medium voltage (MV) motors from 500 to 4500 HP. Designated the MVW-01 family, the new drives provide a comprehensive variable speed control solution for medium voltage motors powered from 2300, 3300 and 4160 VAC mains, in critical high volume pumping, mixing and milling applications across a wide range of industries.

MVW-01 drives are designed with a multiprocessing control architecture powered by a high-performance 32-bit processor with 64-bit bus and floating point capability. Using WEG standard Superdrive programming software, this Windows compatible processor delivers a simple straightforward speed variation solution for a medium voltage motor that can be controlled using an external PC or an integral digital keypad to upload or download operating parameters and monitor motor performance.

Each MVW-01 drive is delivered in a self-cooled IP41/NEMA 1 enclosure. Power sections are secured with mechanical interlocks, and the main circuit breaker includes an electromechanical interlock, preventing possible entry when the power is on to protect factory workers. Optical isolation between all power and control circuits provides an additional level of safety and security, and the simplified control connections and withdrawable power arms within the inverter section speed maintenance and rapid repair.

“With the introduction of our new MVW-01 drives, WEG becomes the first single source vendor in the medium voltage world,” Bridgeforth noted, “delivering the MV motor, switchgear, dry or wet phase shifting transformer and variable frequency drive in a fully integrated package. Such a fully integrated solution should pay big dividends in terms of maintainability and performance for these critical prime movers of industry.”

For more information visit www.weg.net.


First Intelligent Power Module for Solder-Free Assembly

Semikron has introduced an intelligent power module for quick and easy solder-free assembly. The Miniskiip IPM is developed for motor power up to 15 kW and has a latch-up free SOI driver IC for reliable driving already integrated. Compared to other intelligent power modules this new IPM demonstrates the lowest thermal resistance of 0,95K/W and the highest junction temperature of 175°C.

Power, control and auxiliary contacts are connected directly to the printed circuit board via springs, not solder joints. The elimination of any solder connections results in a higher quality of the assembly. With the simple snap-on mounting with one standard screw a cost-efficient assembly of module, printed circuit board and heat sink is achieved. The user has the advantage of using a module where handling is reduced and the parts count is less compared to discrete designs.

A high voltage driver IC with an advanced level shifter technology is integrated into the 600 V Converter-Inverter-Brake IPM and the 1200V inverter (6-pack) Miniskiip IPM providing IGBT driving without an optocoupler. The SOI technology provides complete latch-up immunity since all switches are dielectrically insulated. A down-level shifter for each channel allows the presence of negative secondary offset voltages. The integrated gate driver remains fully operational for any applied offset voltage down to -50 V, providing flexibility in the design of a power system. The gate driver IC features an over-current shut-down circuit protection by using an external shunt resistor in the ground plane shutting down the IPM in case of over-current as well as an under-voltage lockout for all channels and fault signaling. A shut-down can be also forced by the system controller using the shut-down input. Cross-conductions are prevented by the interlock logic.

The MiniSKiiP IPM achieves the best thermal resistance and an optimized current density, leading to high power cycling capability and a longer lifetime compared to existing IPM technologies. These advantages are the result of the pressure contact technology which evenly distributes the vertical pressure, the spring contacts and the base plate free package.

MiniSKiiP® IPM is suitable for industrial and consumer drives up to 15kW as well as process control and solar applications. Using state-of-the-art Trench-Field-Stop IGBTs, the IPMs are available in 600V and 1200V and designed for nominal current ratings up to 72A. The module is RoHS compliant.

 
For more information visit www.semikron.com 


IR Introduces High Performance MOSFETs for Power Supplies and Electric Motors

International Rectifier, IR, a global provider of power management technology, has introduced a new family of 60 V and 75 V MOSFETs optimized for industrial battery applications such as E-bikes, scooters and utility carts.
The new N-channel devices utilize IR’s trench MOSFET technology with on-state resistance (RDS(on)) for improved system efficiency and high reliability, also making them well suited for battery back-up systems such as uninterruptible power supplies (UPS) as well as hard switched or high frequency circuits common in switch mode power supplies (SMPS).
“As industrial battery applications continue to proliferate, these new MOSFETs provide engineers with the expanded voltage ranges and current levels to meet their design requirements,” said Brian LaValle, marketing manager for IR’s Power Management Devices Business Unit.
The new devices are offered lead free, in TO-220, D-PAK and D2 PAK packages and are RoHS compliant and available immediately. Pricing begins at US$0.46 each for the IRFB3806PbF and US$0.60 each for the IRFB3607PbF and IRF1018EPbF, all in 1,000-unit quantities. Pricing is subject to change.

For more information visit www.irf.com    


ElectroCraft Unveils CompletePower Line of Servo   Drives and Speed Controls for Brushless, PMDC and Stepper Technologies

ElectroCraft has released its new line of CompletePower motion control products. The CompletePower product line will power the entire range of PMDC, BLDC and stepper motors available from ElectroCraft, allowing the company to provide complete motion solutions to their customers worldwide.

Based on technology obtained through the acquisition of e-Motion in November 2007, the complete line of rugged, compact drives are all built with the same form factor and use identical accessories to make them easy for OEM engineers to apply to a variety of applications. The drive family unveiled today includes:

•  Three 4-Quadrant Brush-type (PMDC) Servo Drives, 11-70 VDC, from 18-60 A peak and 9-30 A continuous;
•  Three 4-Quadrant Brushless (BLDC) Servo Drives, 11-70 VDC, from 18-60 A peak and 9-30 A continuous;
•  Two 2-Quadrant Brushless (BLDC) Speed Control Drives, 11-70 VDC, from 18-36 A peak and 9-18 A continuous;    and
•  Two Micro-Stepping Stepper Motor Drives, 11-50 VDC, with phase currents of 5 amps and 10 amps.

"These new CompletePower drives are ideal for OEM design engineers looking for a compact, easy to integrate motion control solution," said Rob Kerber, vice president of sales and marketing at ElectroCraft. "ElectroCraft has a long history of being a recognized name in motion control. This product line, along with our expanding global presence, re-positions us to service those customers requiring high performance motion systems around the world."

For more information visit www.electrocraft.com


Dynapar Introduces Economical Encoder for Brushless Motors

Dynapar has introduced the HC20, a commutation encoder priced over forty percent lower than previous models, and designed for use in brushless servo and step motor applications. Unlike some other encoders in this price range, the HC20 features direct-read non-interpolated technology that stems from a custom phased array ASIC, and is available with a wide 5 to 26 VDC operating range. In addition, the 120°C temperature rating won't limit motor performance, allowing manufacturers to keep from de-rating torque specs. The encoder is capable of up to 2,500 PPR (pulses per revolution) and is available with commutation tracks for four, six or eight pole variants of brushless motors.
 
The space-saving design of the phased array ASIC allows for compact dimensions on the HC20. With an industry-standard 50 mm diameter and 36 mm mounting depth, the encoder is well suited for use on NEMA 23 and 34 size brushless servo and stepper motors. The compact dimensions allow its use inside standard motor endbells, saving the motor manufacturer from costly redesign.
  
With multiple shaft sizes and tether options, the HC20 can be used with a variety of motors. The choice of 6 mm or 8 mm hollow or hub shaft options is standard, as is a 9 mm shaft with 10:1 taper. Two tether options are also offered, in 40 mm and 55 mm bolt circles. The mounting holes are crescent-shaped, allowing rotation of the encoder body to help with alignment of the commutation channels with rotor position.
 
The HC20 commutation encoder is built to order and immediately available for the general market. Dynapar will market the encoder under the Dynapar brand name, and list pricing starts at $95.
 
For more information visit www.dynapar.com


Fairchild Launches Industry's First SPM Products for Driving Two-Phase Switched Reluctance Motors

Fairchild Semiconductor recently introduced a breakthrough in SPM technology with the industry's first SRM-SPM power modules for driving two-phase switched reluctance motors (SRM) in small motor applications such as vacuum cleaners. Switched reluctance motors are an attractive alternative to AC drives due to their high efficiency. The small motor industry is migrating from single-phase to two-phase SRM motors due to their ability to startup under difficult load conditions and the lower components that these motors require.
 
Each SRM-SPM module, FCAS20DN60BB and FCAS30DN60BB, integrates two HVICs, one LVIC, four NPT IGBTs, four fast recovery diodes (FRDs), two bootstrap diodes, a thermistor and various protection functions in a single package. By integrating 14 fully tested power components in a compact 45 mm by 28 mm SIP package, these products offer 40 percent space savings. This space conservation allows vacuum cleaner designers to incorporate the controller into the SRM assembly, and also improves design productivity and manufacturability. System reliability is further enhanced by incorporating protection features such as under-voltage lock-out and short circuit protection into this thermally efficient package. 

For more information visit www.fairchildsemi.com


 Infineon Intelligent Power Modules Designed to Increase Energy Efficiency and Reliability of Home Appliance Motors

Infineon Technologies Industrial Power offers highly integrated, intelligent power modules that contain nearly all of the semiconductor components required to realize electronically controlled variable-speed electric motors. Infineon’s commitment to improving energy efficiency of electrical drives is reflected in the CiPoS (Control Integrated Power System) modules, which are designed to enable energy-efficient operation of consumer appliances such as washing machines and air conditioners, offering efficiencies up to 94 percent.

In response to regulatory requirements and growing consumer demand, variable-speed motors are used to reduce the energy consumed by household appliances such as clothes washers, dish washers, air conditioners and vacuum cleaners, in addition to fans and blower motors.  Smart design of drive control electronics to make best use of these motors presents manufacturers with further opportunities for efficiency and savings.  Peter Stipan, of Infineon Technologies Consumer Power’s Marketing & Business Development group adds, "There is a high level of quality and reliability provided by CiPoS. In some applications, customer feedback indicates that CiPoS runs 10 degrees cooler than the competition, having a significant impact on design performance."

CiPoS modules incorporate a three-phase inverter power stage with a SOI (Silicon-On-Insulator) gate driver, boot strap diodes, capacitors, thermal sensor and auxiliary circuitry in a compact, high-performance, fully isolated package. Based on a combination of Infineon’s leading-edge TrenchStop IGBT (Insulated Gate Bipolar Transistor) and EmCon (Emitter Controlled) diode technology, they eliminate as many as 23 discrete components compared to a design based solely on discrete components. The result - manufacturers’ costs can be reduced, including decreased inventory and logistics costs, reduced circuit board space, simplified layout and assembly, improved overall reliability, reduced EMI and shorter time-to-market. With a basic drive system requiring only nine external components and one microcontroller, CiPoS modules represent ready-to-use solutions for all motor drive systems with a power rating of up to 3 kW.

In addition, the CiPoS modules offer the industry’s lowest junction-to-case resistance, increasing output current by up to 20 percent. For example, the junction-to-case thermal resistance of the IGBTs of the CiPoS module IKCS12F60AA is 3.6 K/W, and that of the EmCon diodes is 4.9 K/W. At a nominal operating supply (VDD) voltage of 15 V, this low resistance results in an output current of 6.0 A, compared to the 5.0 A typically produced by some competitors. This makes higher output power possible in designs with equivalent-sized heatsinks, or the use of a smaller heatsink for the same power.

Interfacing to the microcontroller is through direct connection of the control terminals supported by pull-up resistors. A feedback control loop can be easily implemented by adding an external operational amplifier. Infineon offers a demo three-phase motor drive kit which is built around the 8-bit XC886 MCU which is capable of running field oriented control (FOC) and CiPoS.

For more information visit www.infineon.com


Autotrol Corp. Introduces New High Torque AC Synchronous Motor

Building upon their AC synchronous motor knowledge of the timing and appliance industries, Autotrol Corp. has developed a compact, high torque, economically priced AC synchronous motor, the model 525. It has proven to be a durable motor for many high load and long life applications. Current applications include appliance, water filtration and security. It is available with both plastic and metal gears in ratios from 1 to 100 RPM. In addition, Autotrol Corp. offers additional value by assembling the motor into the customer’s sub-assembly.

For more information visit www.autotrol.com

Integrated Gearmotor from Dynetic Systems Improves Efficiency While Reducing Size and Noise Levels

Offered in NEMA17, 23 & 34 sizes, this segmented lamination motor delivers an extremely higher power density through an integrated gearing system, all packaged in a one-piece housing. Standard features include sealing to IP65, high strength neodymium magnets, dampened ABEC ball bearings and commutating encoder. Options available include resolvers, brakes, temperature switch, EMI/RFI filtering, special connectors, cables and much more. This package offers Power ranging up to 1.2 Kw, torque as high as 130 ft/lb, and gear ratios exceeding 10,000:1.

For more information visit www.dynetic.com/brushless integrated gearing.htm

FEATURE

Digital Power: A Panoramic View of Applications and Challenges - By Steve Mappus, Systems Engineer,Fairchild Semiconductor, High Power Solutions

Figure 1. Global Digital Power Semiconductor Revenue Forecast

When digital power first emerged as a topic of debate in the early 2000s, most hard core power supply designers cast their doubts at the thought of replacing analog PWM controllers with a DSP based digital power supply controller. Power engineers associated digital power with fears of z-transforms, software coding or blowing up power supplies due to “blue screen of death”, as sometimes seen in a particular computer operating system. Furthermore, prior to the introduction of semiconductors that included all the functionality necessary to digitally communicate and control a complex power system, the fundamental concepts were proven using high cost DSPs or performance limited FPGAs. Even though digital power techniques had demonstrated the ability to raise power system performance, the industry could not accept mimicking digitally what was already being done in analog at more than 10 times the silicon cost. Much progress has been made during the past several years and market analysts as well as financial investors appear very optimistic regarding the future growth of digital power.
 
Today’s digital power market is made up of numerous semiconductor suppliers and original equipment manufacturers (OEMs) each contributing unique solutions. It’s important to first distinguish what is meant by digital power. Power system supervision, monitoring, fault detection and data logging is one aspect of “digital power management” (DPM) that can be implemented using an inexpensive microcontroller, FPGA or PLD, where the time base requirements are relatively slow. However, the more challenging example of digital power refers to “digital control of power” (DCP) where one or more power supply control loops are closed around a high speed analog to digital converter (ADC) and a micro-controller, state machine or DSP-based control algorithm.

Semiconductor market research firm, iSuppli estimates that the total world wide digital power market will grow from its current 2008 revenue of just more than $200 million to about $900 million in 2011. The digital power rate of revenue growth is summarized graphically in figure 1 indicating a progressive growth pattern with DPM far outpacing DCP for the next several years.

The majority of dedicated digital controllers available to date are targeted for high volume, non-isolated, DC-DC power conversion, including voltage regulator modules (VRM) and point of load (POL) converters. These types of DC-DC converters typically deliver power to low voltage, high current digital loads such as microprocessors, DSPs and other high speed digital circuits that are very dynamic in nature. It is becoming increasingly difficult to maintain accurate voltage regulation around 1V, while meeting load transient requirements approaching 200 A/ns using pure analog control techniques. Some digital controllers can offer certain features, such as non-linear control which may be more difficult or impossible to realize in an equivalent analog IC. In fact, just about all digital POL controllers include some distinguishing control technique aimed at improving transient response.  Since most of these proprietary control algorithms were developed by start-up venture companies, the OEM’s demand for preferred suppliers and dual sourcing became a barrier to gaining market acceptance. This in turn has led to licensing agreements between a number of digital power start-ups and the more established analog semiconductor suppliers. Non-isolated, DC-DC POL applications are viewed as a digital power entry point into the power conversion market. However, it is eventually expected that isolated DC-DC and AC-DC power factor correction (PFC), which currently implement digital control using non-dedicated DSPs, will gain even higher acceptance in coming years.

Figure 2. Digital Power Semiconductor Market Penetration Rates

The functional requirements for a digital PFC controller are much different compared to a POL controller. PFC regulators require less load regulation accuracy and operate at a lower switching frequency and lower overall control loop bandwidth making quantization errors, limit cycling and ADC resolution less of a design challenge. Still, there are unique design issues with PFC controllers demanding significant system knowledge and experience. Although load transient requirements and dead-time optimization are not concerns for PFC, non-linear control could be useful for handling line transient conditions which are characteristic of virtually all off-line converters.

AC-DC power supplies generally require an electro-magnetic interference (EMI) filter capable of attenuating noise generated by harmonic distortion and switching regulators. Since EMI filters are designed using networks of inductors and capacitors that appear in series with the AC mains, they have a negative effect on overall efficiency but are necessary for meeting certain equipment specifications. Some digital PFC regulators can incorporate features aimed at reducing EMI filter requirements, resulting in smaller more efficient EMI filters. Analog PFC controllers are distinguishable by various control algorithms and operating modes such as discontinuous conduction mode (DCM), continuous conduction mode (CCM) or boundary conduction mode (BCM). Each PFC operating mode has advantages and disadvantages that become more evident at various power levels. Similar to the multi-mode operation of a digital POL, a digital PFC controller could be assigned to operate in either PFC control mode. Whether for PFC or POL applications, a controller that is configurable across many OEM product platforms provides value through faster development time and less component inventory to maintain.

Higher power AC-DC applications are better candidates for digital power because they require one or more PFC regulators as well as multiple, isolated and non-isolated power rails and complex cooling profiles. Server power systems are one example where digital control and power management can offer performance and efficiency benefits in a distributed power architecture (DPA). As more digital power content makes its way into the server and computing power segments, other high power DPA systems such as those used in telecom and datacom are beginning to embrace digital power solutions. The depth of present and forecasted market penetration for all digital power semiconductors is clearly being led by these types of high power applications, as shown graphically in figure 2. Interestingly, recent government and regulatory requirements for PFC above certain power levels combined with the falling costs of silicon for digital controllers may enable the feasibility for digital power development in some consumer ac-dc power supplies such as game systems, set-top boxes, digital televisions, AC adaptors and battery chargers.
Regardless of analog or digital, power supplies developed for consumer market applications are especially cost sensitive. The cost pressure compared to existing analog solutions has made digital power a tough sell for consumer applications but some industry analysts predict that within 2008 the silicon cost of existing digital controllers may approach price parity compared to similar analog solutions. The value proposition of digital power will never be compelling enough if compared to a simple analog power supply solution. One power supply OEM in particular has designed a platform of digital power solutions that has been shown to beat their existing analog solutions in terms of performance and overall cost. Issues such as system complexity and proprietary intellectual property demanded that the proof come from within their own company.

The cost comparison between digital and analog power solutions has to be looked at from the entire system point of view including: the cost of design, process development, test, qualification, manufacturing, inventory control and component savings.

Although wide market adoption of digital power is still early in its infancy, there are several key factors for acceptance that cannot be ignored. Tougher global efficiency requirements beg the question: What can digital power contribute towards increasing efficiency? When implemented correctly, digital control can potentially offer some efficiency improvements through duty cycle optimization, adaptive shoot-thru control, meeting transient requirements while enabling lower switching frequency, real time adaptation of critical timing such as synchronous rectification or resonant dead time, phase shedding and varying operating modes based upon load current. Digital control can yield better overall efficiency results because the system power is managed more efficiently according to the demands of the load. Any efficiency improvement is always welcome but in order to set realistic expectations, it is important to emphasize that efficiency is primarily determined by the power stage design.

A reliable, easy to use graphical user interface (GUI) is an essential requirement for the success of any digital power controller. Many power designers are quick to nod in agreement at the thought of wanting all the flexibility a digital controller can offer. Enabling flexibility through hundreds of programmable commands requires careful consideration in terms of software layers, partitioning, protection features and command grouping. The GUI needs to have an intuitive, natural feel but most importantly it needs to work one hundred percent of the time. Power supply design is difficult enough without adding doubt as to whether the controller is behaving the way it was programmed.
Digital controllers also need to be self-configurable, meaning that no calibration should be required by the end user. Some power supplies are manufactured in an environment where the controller module and power stage might be arriving from different suppliers and are not integrated until final assembly. In this case, there is no opportunity to calibrate the controller since the power stage is unavailable at the time of delivery.

Every digitally controlled power converter inevitably requires a certain amount of analog circuitry. Whether external or integrated into the same package, gate drivers are just one example of an interface between the analog and digital domains. ADCs, voltage references, regulators and comparators are also required analog functions that must perform seamlessly in or around a digital controller. Because there are numerous ways to partition digital and analog functions, obtaining the optimal balance between silicon performance, efficiency, intelligence, cost, process capability and die area continually poses a difficult challenge for system engineers. In retrospect, the concept of digital power is really nothing new or revolutionary. DSPs and microcontrollers have been widely used in industrial motor control applications for many years. The power supply industry has been inching toward digital power adoption but the necessary standards and dedicated semiconductors were not available until recently.

Digital content such as combinational logic, clocks, counters and timers have always existed inside analog controllers. As mixed signal design processes continue to improve, expect the relationship between digital and analog components to be optimized to a much higher degree. Depending on the complexity of a targeted application, some functions would benefit best from a digital process while others should remain in the analog domain. At least in the near term, the most cost-effective, optimal solutions appear to be mixed signal approaches no matter how “digital” a digital power system becomes. The fundamental groundwork necessary for shaping the landscape of digital power is in place but there are still questions remaining as to how digital power will complement or compete with traditional analog solutions. Most accomplished power supply designers who recognize the value of digital power will update their design skills accordingly but regardless of different viewpoints on adoption rates, one thing is certain: digital power is inevitable.

About the Author
Steve Mappus is a systems engineer working in the High Power Solutions group at Fairchild Semiconductor. In his current role, he is responsible for new product development and definition of power supply control ICs. He has more than 17 years of power supply design experience including 10 years designing military and commercial power systems for avionic applications. More recently, he has spent the last 7 years working in the power management semiconductor business specializing in Systems and Applications Engineering. He has authored more than 25 power electronic design articles and application notes. His areas of interest include high-power converter topologies, soft switching converters, synchronous rectification, high-frequency power conversion and power factor correction.

FEATURED COMPANY

Baldor Electric Company

From our home office in Fort Smith, Arkansas, we support the sales offices/warehouses that stock Baldor products
worldwide, selling to distributors and original equipment manufacturers in more than 70 countries.

Baldor products are available from 50 sales offices/warehouses in North America and 26 offices serving international markets. These products are produced at 26 plants in the US, Canada, England, Mexico and China.

At Baldor Electric Company, our mission is to be the best (as determined by our customers) marketers, designers and manufacturers of industrial electric motors, power transmission products, drives and generators.

For more information visit www.baldor.com

EVENT LISTING

2009 Motor, Drive & Automation Systems Conference
March 3-4, 2009
Hilton Disney / Orlando, Florida
http://www.e-driveonline.com/Conf-09/motors_conf09_index.php

Contact Jeremy Martin regarding speaking opportunities.
jeremym@infowebcom.com



Ecosystems Summit 2008 • Denver, Colo. • June 25-26

The rules are changing in IT alliances and partnerships. Today, more than ever, software, IT and technology companies need to know how to build their ecosystems of strategic alliances and partners, and how best to profit from these relationships.

At Ecosystems Summit 2008, Charles Weaver, President, Managed Services Alliance, will discuss the business drivers behind the growth in companies outsourcing key business processes such as network security, data protection, network administration and more, and what this growing acceptance of the service provider model means for future business opportunities. He'll also offer specific advice on how MSPs and vendors should work more closely together to benefit end-users.

Join alliance & partner program managers, C-level executives, channel managers, VARs, market development and product managers at Ecosystems Summit 2008, June 25-26 in Denver, to learn from the best at developing, managing and profiting from strategic alliances.

Click here to register: http://www.softwarebusinessonline.com/ses_conf08_reg.php.


  Upcoming Industry Events - Click here to view full Calendar

June 2008
    3-5
    MD&M East,
New York, NY.
    ATX East, New York, NY.
    Atlantic Design & Manufacuring Show, New York, NY.

    9-11
    Sensors Expo
, Rosemont, Ill.  


ATX East 2008
June 3-5, 2008
Jacob K. Javits Convention Center, New York, NY

Your Total Resource for Automation Technology

Register Today for FREE Expo Hall Admission

Attend ATX East to find the innovative products and technologies you need. ATX East features:
The latest advances in automation including adhesives/dispensing equipment, assembly systems, custom automation, control software/hardware, materials handling, motion control, robotics, sensors, vision inspection systems, and much more.
Technical experts in every booth who are ready to discuss your product specifications and requirements. Match their expertise and capabilities with your needs.
Five industry-relevant co-located shows:
Your ATX East badge also provides free admission to MD&M East , EastPack, Atlantic Design & Manufacturing, PLASTEC East, and Green Manufacturing Expo.


Advanced Capacitor World Summit 2008
July 14-16, 2008
San Diego, CA

Now in its 6th year, Advanced Capacitor World Summit 2008 will focus on the latest market opportunities and engineering trends for the electrochemical capacitor (EC) industry including supply and demand, applications, design, and new materials and manufacturing development.

Conference content at Advanced Capacitors World Summit 2008 will be devoted to helping developers, producers, and users of electrochemical capacitors assess market dynamics, emerging applications, and new methods to reduce manufacturing and deployment costs. Attendees will receive a comprehensive appraisal of global demand, manufacturing and cost hurdles, market characteristics, and applications such as public transport, automobiles, office machinery, industrial power conditioning, distributed generation, and portable electronics end uses.
FMI: please contact Mike Robert at mrobert@intertechusa.com or +1 207 781 9631

Visit - www.acw-summit.com


SEMICON West 2008
July 15-17
San Francisco, Calif.

SEMICON West2008–Infinite Innovations, Infinite Ideas SEMICON West is the place to see the companies, technologies, and people driving the future of micro design and manufacturing. No other event this year has more new products, more new technologies, and more solutions than SEMICON West.
From the latest developments in cutting-edge materials, to the systems and technologies driving semiconductor designs to the limits of Moore's Law, you'll find everything and everyone in the industry at SEMICON West.

Registration is now open! Plan now to participate and get ready to discover the infinite opportunities shaping the design and manufacture of semiconductors, MEMS, photovoltaics, flexible electronics, and more!

For more information, visit www.semiconwest.org.


IMTS 2008
September 8-13, 2008
Chicago, Illinois

Improve Productivity

If you utilize electrodynamic and electromotive systems in your company’s products, then IMTS, the International Manufacturing Technology Show (September 8-13, 2008 at Chicago’s McCormick Place) has the answers you need to become more productive. IMTS 2008 features mo0re than 1200 exhibitors offering some 15,000 products. Because IMTS is organized into pavilions, you can easily find the solutions you need. You’ll see faster, more precise machines; cutting tools designed to process virtually any material; finishing technologies; automation systems; sophisticated quality instruments and manufacturing software. You’ll meet and talk to experts in advanced manufacturing technologies. You’ll see how to reduce cycle times and increase productivity. Plan now to attend. For more information, and to register, go to www.imts.com.



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