Power Factor Correction (PFC) is used in motor control power management. PFC requirements vary from country to country; typically in appliances with power requirements greater than 75Watts. Its purpose is to minimize inefficient and costly reactive loads on the power grid. Alternatively, implementing a PFC front-end in a product can maximize the available power that can be drawn from a standard outlet. PFC does this by making the appliance look purely resistive; e.g. no phase difference between the voltage (Vac) and current (Iac) from the grid. PFC also minimizes any transients/harmonics that can feed back into the home/building electrical grid and disrupt the power source to other appliances. The result: PFC saves money by saving electrical energy.
Fairchild Semiconductor offers both integrated and discrete PFC solutions:
Integrated PFC-SPMs (Power Factor Correction-Smart Power Module): Interleaved, Boost and Bridgeless topologies.
Features:
Optimized IGBTs, diodes, and driving IC
Good thermal resistance due to Direct-Bond Copper (DBC) substrate of package
SPM package meets the basic creepage and clearance spacing
Isolation voltage of 2500Vrms [@ 1min]
UL certified No. E209204
Fairchild Advantages:
PFC-SPMs use the same advantageous SPM Direct-Copper Bond (DCB) substrate packaging used by the Motion-SPMs. SPM packaging enables high voltage motor drivers; and now enables PFC for high voltage motor control.
Integrated into the PFC-SPM is a front-end rectifier circuit, partial switching converter circuit, and power factor correction circuit which can be controlled by an external controller; e.g. Fairchild's BLDC/PMSM Controller, third-party micro-controller (MCU), DSP controller, or FPGA (Field Programmable Gate Array).
Because the PFC-SPM devices have the same mechanical dimension as the motor driver SPMs;
both can be installed on the same heat sink. Enabling easy assembly and increased productivity.
Comparisons of Integrated PFC-SPM
Topology
Passive PFC
Interleaved
Boost
Bridgeless
Application
EMI
★★★
★★
★
☆
Inductor Cost
★
★★★
★★
★★
Capacitor Cost
★
★★★
★★
★★
Fairchild Solution
Yes
Yes
Yes
Yes
Switching Frequency
-
Over 20KHz
20KHz
20KHz
PF
☆
★★
★★
★★
IGBT/Sensing Quantity
0
2
1
2
Free Wheeling Diode Quantity
0
2
1
2
Bridge Diode Quantity
4
4
4
2
★★★ Best ★★ Better ★ Good ☆ Fair
Interleaved PFC-SPM: is an advanced 2-phase interleaved PFC Smart Power Module. Featuring: Single phase rectifier for AC input; 2-phase interleaved PFC; Control IC for gate driving and protection; UL Certified No. E209024.
Boost PFC-SPM: is an advanced PFC Smart Power Module mainly targeting high-power applications (3kW – 6kW).
Bridgeless PFC-SPM: is an advanced PFC Smart Power Module mainly targeting high-power applications (3kW – 6kW).
Ordering Codes: Click on thumbnail picture to enlarge. PFC-SPM3 Module Ordering Codes
PFC controller IC's for Discrete PFC implementations
Fairchild Semiconductor has a wide breadth of discrete PFC controllers; e.g. Continuous Conduction Mode (CCM), Critical / Boundary Conduction Mode (CrCM / BCM), and Interleaved. Please find here a feature listing of our Interleaved Dual BCM PFC Controllers.
Interleaved Dual BCM PFC controllers:
Efficiency
Interleaved Lower > Turn-off Losses
Valley Switching > Minimize COSS losses
Strong gate drivers > reduce switching losses
Boost-follower ("tracking boost") possible
Protection
Closed-loop soft-start w/ Prog. Ramp Time
Power and Current Limit per Channel
Input Voltage Feed-forward
Secondary Latched OVP
Input Brown-out Protection
Line OVP
Internal maximum fSW clamp limit
Ease of Design & Solution Size
Easy Valley Detection Implementation
Easy Loop Compensation (constant BW and PWM Gain)
Integrated +2.0A/-1.0A Gate Drivers
Works with DC, 50Hz to 400Hz AC Inputs
Documentation
Application Notes
ID
Product / Topic
Description - click on description below to view app note
This design tool provides motion control design engineers with efficient means of calculating the power losses and temperature rise in Fairchild motor drive SPM modules. The tool addresses three-phase inverter sinusoidal modulation for variable speed drive applications powering permanent magnet synchronous motor (PMSM) and AC induction motors.
Online Seminars
Fundamentals of Motor Evoluion (2009)
This presentation provides a brief history of motor evolution and reviews the most common modern motor types in detail.
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