New IGBT power module concept for wind power application in NPC topology with extended reliability

In this paper an IGBT power module that can help reduce the cost of a wind turbine, solar inverter or motor drive by reducing copper as well as silicon is proposed. Reduction in copper is achieved by using 3-level topology and reduction in silicon is achieved by using copper bond wires instead of aluminum in the module. By using a high power 3-level neutral point clamped (NPC) IGBT power module a 1 MW converter with 1500Vpc and 950 VAC can be designed. This can reduce the copper required in the transformer and cables. DFIG wind turbines or motor drives with low frequencies lead to high thermos-mechanical stress on bond wires of the power modules. Thus, designing IGBT module for 20 years of lifetime is a challenge. This leads to high de-rating of power modules and changing the power modules several times during the lifetime.