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Power | Volume 23
Use coupled inductors in multiphase buck converters to improve efficiency Maximize power-device control efficiency with the right gate-driver power converter Use transient voltage suppression diodes to ruggedize circuits and maintain electrical integrity Exploring how silicon carbide is transforming energy systems
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Leveraging configurable power solutions for mission-critical applications Sponsored by Advanced Energy
Maintaining continuous power in modern industrial environments Sponsored by TDK-Lambda
A bridge to 48 V power architecture Sponsored by Vicor
Gain advantages with GaN power devices Sponsored by Infineon
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Special feature: retroelectro Forgotten genius: William Stanley Jr.’s legacy in electrical engineering
Use coupled inductors in multiphase buck converters to improve efficiency
Maximize power-device control efficiency with the right gate-driver power converter
Use transient voltage suppression diodes to ruggedize circuits and maintain electrical integrity
Exploring how silicon carbide is transforming energy systems
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Editor’s note Welcome to the DigiKey eMagazine Volume 23 – Power.
This issue delves into the evolving world of power electronics and innovative system design. As technology continues to push the boundaries of performance, efficiency, and reliability, engineers are met with both unprecedented challenges and opportunities. In this issue, we spotlight groundbreaking advancements shaping the future of power systems. From the high-speed efficiency of GaN technologies to the versatility of configurable power solutions tailored for precision, our articles reflect the pulse of progress. We also examine cutting-edge components like the DUSH960-1248 DC UPS DIN Rail and DCM3717 high-density converter modules, each offering compact and robust answers to today’s power demands. For design engineers striving to optimize performance, our deep dives into multiphase buck converters, gate-driver power converters, and TVS diodes provide critical insights for achieving greater efficiency and protection. Finally, we look toward the horizon with “Exploring How Silicon Carbide is Transforming Energy Systems”, highlighting the materials revolution redefining what’s possible in energy infrastructure. Whether you're designing for industrial, automotive, or advanced computing systems, we hope this issue equips and inspires you with practical knowledge and forward-thinking solutions.
Leveraging configurable power solutions for mission- critical applications By Abhishek Jadhav for DigiKey
For many engineers, powering complex industrial systems means stacking multiple single- output power supplies, from 24 V for displays, 12 V for logic, to 48 V for motors. Whether the design team chooses a standard part or a full custom unit, this one rail, one supply approach is common across industries. But this approach comes at a price. Fragmented power architectures increase component count, complicate cabling, and drive up design time and cost. Furthermore, any late-stage changes in power requirements can trigger an
expensive redesign or integration of an additional PSU (power supply unit). In the high-reliability applications of medical devices and industrial automation, adding a new PSU introduces more points of failure, which is a significant drawback. To address these challenges, Advanced Energy offers a more flexible, multi-output power solution, moving away from the one-output-per-supply strategy. Customers can choose between: ■ Configurable power supplies, which are modular hardware platforms that can integrate various DC output modules
■ Fully programmable power supplies, which enable real-time software-based adjustments to the output using digital control protocols like PMBus or CAN bus By leveraging these configurable power supplies, design teams can power all their loads from one integrated system that is customizable to the specific voltage needs. This results in a clearer design with fewer components and easy integration. Advanced Energy power supplies will suit the needs from a 600 W fanless unit for a surgical device to a 30 W rack system for a semiconductor fab.
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modules to yield multiple isolated outputs, each set to a different voltage and current limit, all powered from one AC input. This offers design flexibility because, as needs change, engineers can reconfigure by simply swapping a module rather than redesigning the entire power architecture. But to further add more flexibility in the power supply designs, fully programmable power supplies incorporate digital control for real-time adjustments. This means they are not only hardware modular but also allow output settings to be fine-tuned through software commands on the fly. The internal
architecture uses microprocessor control for both the front-end and each module, exposing interfaces like PMBus, CANBus, and Ethernet for external monitoring and control. Engineering teams can not only change the output voltage, but can also adjust current limit, ramp rate, sequences, and even certain protection thresholds. This means that a single power system can adapt to different operating modes by software programming rather than physical changes. In summary, the key distinction is that configurable units are flexible at build-time and
Flexibility in power supply designs Configurable power supply
units consist of a standard AC/ DC digitally controlled power conversion front end with power factor correction and several swappable DC output modules installed in slots. Design teams can choose appropriate modules that can be configured to provide the required set of output voltages. This optimization is achieved without custom engineering, simply by slotting in the right module. For example, a single configurable unit can host several
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Leveraging configurable power solutions for mission-critical applications
upgrade time, whereas fully programmable units emphasize on-the-fly control. Both of these power supply architectures eliminate the one-supply, one- output approach that limits traditional PSU designs. Configurable power supplies with CoolX and uMP Advanced Energy offers a series of configurable power supply units for scenarios where multiple outputs and specialized performance are required. Still, design cycles and budgets won’t allow full custom power units. In addition to a modular hardware platform, these configurable power supplies enable design teams to mix and match standard modules to create a composite supply that meets the voltage rail requirements. The Advanced Energy CoolX modular power supplies, which target medical and precision lab systems, have a wide range of configurable AC/DC solutions that range from 600 W to 3000 W. The power units in this product line include both natural convection cooled, and variable speed fan cooled systems that are capable of delivering up to 24 outputs with series and parallel options.
Figure 1: Advanced Energy CoolX600 series is a convection-cooled, modular power supply platform, delivering 600 W from a compact 215.9 x 114.3 x 39.1 mm package. (Image source: Advanced Energy)
For example, the CoolX600 (Figure 1) can host up to four modules to provide as many as eight isolated DC outputs (1 - 58 V). For higher power, the CoolX1000 supports up to six modules and twelve outputs for a total of 1000 W. These units are designed with stringent medical safety standards, such as IEC 60601-1 certifications, ensuring the product meets low leakage current requirements. For a medical diagnostic OEM, designing a biomedical analyzer requires a configurable multi- output PSU with medical safety certification and integration support. Advanced Energy CoolX1800 units enable customers to combine all power needs into one compact power supply, improving system integration.
Advanced Energy also offers a low-power range of configurable power supply units under the uMP series (Figure 2). . A single uMP power supply unit can pack up to 1200 W of output across multiple channels in a slim 1U-tall chassis, which is far smaller and lighter than using several individual PSUs of equivalent combined power. For instance, a 6-slot uMP chassis can provide six different voltages, each isolated, or some outputs can be paralleled for higher current on a particular rail. This flexibility makes uMP an ideal solution for industrial automation, test and measurement, and laboratory systems where a variety of voltages are needed to power motors, sensors, controls, and test circuits.
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its core, NeoPower provides up to 4,000 W of output power in a modular design with eight output slots. These slots can be fitted with various modules to achieve the required mix of output voltages and currents. The key technology that makes programmable power supplies more adaptable is a digital platform that supports multiple communication protocols for control and monitoring. For example, out of the box, the NP08 can be controlled via Modbus RTU to configure output setpoints, read back telemetry, and manage faults.
Despite the small size of uMP supplies, they are built for robust performance and carry industrial EN 60950/62368-1 safety approval and even meet military- standard shock and vibration specifications with options for conformal coating. These features make sure the units are ideal for deployment in harsh industrial environments. However, when industries demand a power supply that can adjust to changing power requirements on the fly, they also want more control over optimizing output power in real-time. Advanced Energy offers fully programmable PSUs for teams where output requirements may change during operation.
Software-driven programmable power supplies These power supplies offer software-defined intelligence where the output parameters can be adjusted in real-time through firmware commands and remote interfaces. Advanced Energy’s NeoPower (Figure 3) is a configurable AC/ DC power supply that provides high power density as either a programmable voltage or current source. The NeoPower NP08 is the latest programmable AC/DC power system in the 4 kW class, targeting medical and industrial markets. At
Figure 2: Advanced Energy uMP Gen I digitally configurable power supply is housed in a 1U case with 4 or 6 slot card options and power ratings from 400 W to 1200 W. (Image source: Advanced Energy)
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Leveraging configurable power solutions for mission-critical applications
Figure 3: Advanced Energy NeoPower NP08 AC-DC configurable power supply with power density of 18 W/in 3 . (Image source: Advanced Energy)
For example, in an automation system, the NeoPower can change an output from 24 V to 28 V on the fly to speed up a motor, or a test system can sweep the voltage to a device under test via software commands. Use cases for NeoPower include advanced manufacturing and automation scenarios where one power system might drive PLC I/O racks, sensors, and machine vision cameras (each with different voltage). Another solution with high power programmability from Advanced Energy is the iHP (Intelligent High Power) Series, which is designed for mission- critical applications, demanding
Figure 4: Advanced Energy iHP Air-Cooled Series accepts 3000 W single slot modules for up to eight different outputs for a total output power of 24 kW. (Image source: Advanced Energy)
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kilowatts of power, multiple outputs, and robust performance under harsh conditions. An iHP power system (Figure 4) is a scalable rack-mounted platform that can be configured from a few kW up to 30 kW output. The system is digitally controlled with a high-speed internal communication bus that enables capabilities like user-programmable slew rates and voltage or current mode programming. The iHP series also supports redundancy and fault- tolerant configuration, with multiple modules that can be paralleled with OR-ing diodes for N+1 redundancy. This ensures that if one module
From mid-range configurable modular power supplies to high- power programmable systems, Advanced Energy delivers flexibility without complexity. Engineers can meet their specific power requirements with a solution that adapts to their changing needs, whether for a fanless 4-output medical supply or a smart 8-output industrial unit. Conclusion Building a power supply system is not easy. However, the move from a one-output-per-supply strategy to a multi-output power solution is key to adapting to the evolving needs of medical and industrial systems. Advanced Energy
changes the mindset from “I need this PSU and that PSU to get all my voltages” to “I can get this- and-that in one package.” In conclusion, Advanced Energy’s configurable and programmable power solutions allow engineers
to remove the pain points of traditional complex power
systems. The power supply is no longer a limitation or afterthought; it has become an enabling, adaptable part of innovation. (CTA) To learn more, visit Configurable Power Supplies.
fails, others can take over to maintain power continuity.
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Maintaining continuous power in modern industrial environments By Abhishek Jadhav for DigiKey
In modern industrial automation systems, maintaining continuous DC power to controllers, sensors, and actuators is crucial, as devices like Programmable logic controllers (PLCs), SCADA nodes, and drive electronics are sensitive to even short power interruptions. These interruptions can result in significant production downtime or require time-consuming system reboots. Traditionally, engineers relied on backup batteries or supercapacitors with switchover circuits to bridge power losses, and often an AC UPS upstream for a critical environment. However, DC-side backup introduces key challenges, like the backup source voltage must match the load voltage, or additional converters are needed to charge batteries and supply loads at different levels. For instance, a building automation panel might require a 24 V DC bus, but prefer a higher voltage battery bank for more energy storage. Implementing this using conventional components would require separate DC/DC converters for charging and discharging, along with control circuitry to manage the switchover. To address these issues, TDK- Lambda offers its DUSH960-1248 DIN rail mount DC uninterruptible power supply (DC-UPS) that integrates backup power management with DC conversion in a single intelligent unit.
depending on the mode. The module also imposes no minimum load requirement and maintains a low ripple (<690 mV) on the output, which prevents the introduction of noise that could interfere with sensitive control electronics. The DUSH960-1248 operates in a wide voltage range on input from 10 V to 60 V DC and provides a programmable, regulated output between 10 V and 58 V DC. In practical terms, this single module can accommodate 12 V, 24 V, 48 V nominal systems and anything in between, whether the main supply or the battery. For example, an integrator could use a 24 V AC/DC supply with a 48 V battery bank and 24 V loads, configurations that generally would be difficult without multiple converters. The module's maximum output power is 960 W at 48 V and 20 A, which is sufficient for large PLC racks, motors, and safety systems in industrial environments. The DUSH960-1248 is available in two models, -0M and -1M, to suit different user needs and budgets. Both variants share the same core electrical specifications and performance, but the primary difference lies in the user interface and a minor power output feature. The -0M model provides a 5 A auxiliary output that is tied to the battery, which can be used to power small auxiliary loads that need
Technical details of the DUSH960-1248
The DUSH960-1248 is designed to perform two critical functions in one device. First, under normal conditions, it acts as a DC-UPS, routing power from an external AC/ DC source to the DC load while simultaneously charging an attached battery. In the event of an input power loss, it seamlessly switches to the battery to maintain a regulated DC output, ensuring continuous power to downstream electronics during outages or voltage dips. Second, the module serves as a bidirectional DC/DC buck-boost converter, decoupling the battery voltage from the load voltage. This means that the battery’s nominal voltage can be higher or lower than the load’s voltage; the DUSH960 dynamically steps the voltage up or down as required. Under normal power, it will buck or boost the input to the appropriate level to charge the battery, and under backup, it will buck or boost the battery output to sustain the load. This dual-purpose approach eliminates the need for separate charger and regulator units. The internal design of the DUSH960-1248 uses a bi-directional DC-DC converter topology to manage power flow in both directions with high efficiency. Efficiency is another important aspect of the module that operates at up to 96-98 percent efficiency
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Maintaining continuous power in modern industrial environments
Figure 1: Block diagram of DUSH960-1248 showing power stage, control, and monitoring. (Image Source: TDK-Lambda)
battery voltage, for example, a lighting circuit or fan that should run off the battery during an outage. The other module does not include the auxiliary output. In addition to the power hardware, the DUSH960-1248 includes robust monitoring and communication
display with control buttons, allowing on-site human operators to view status information and adjust settings. The DUSH960 series supports remote monitoring through Modbus/RTU over RS- 485 and a mini-USB port for direct connection to a PC. These interfaces allow engineers to read data such as input voltage,
output load level, battery charge percentage, temperature, and other parameters. The power design engineers can configure the output set-points, charge current limits, and threshold alarms. TDK-Lambda provides a PowerCMC control and monitoring software to help engineers with maintenance, which can log alarms and display real- time status values.
capabilities. The front panel features a 1.5-inch color LCD
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reliability can decrease despite having redundancy on paper.
Solution: The TDK-Lambda DUSH960-1248 module is designed with full integration into automated control networks. It provides both discrete signals and digital communication to interface with PLCs and SCADA. For simple integration, the two configuration alarm relay contacts can be wired to the PLC inputs to signify events like AC Power Loss or Battery low. The Modbus/RTU interface via RS-485 allows a SCADA system or PLC with Modbus support to query dozens of parameters from the DUSH960, like input voltage, output voltage, current, battery charge percentage, battery temperature, etc. Conclusion The DUSH960-1248 DC UPS module combines power backup and conversion in a single unit. From an engineering perspective, it addresses multiple pain points, including voltage incompatibility, space constraints, complex wiring, and limited monitoring, with a single drop-in solution. By deploying the DUSH9601248, system integrators can ensure the uninterrupted operation of critical DC loads without changing the entire power architecture.
Solution: The DUSH960-1248 can simplify system architecture by acting as a single coordination point for power flow. It connects the power supply, load, and battery in one unit, which allows it to inherently handle the redundancy function, which would otherwise require OR-ring circuits. The module ensures that whichever source is available will power the load and prevent back feeding into the supply when on battery. For better system redundancy, the DUSH960 can be paired with a redundant primary supply as well, such as using a dual AC/DC supply configuration with a redundancy module on the input. In such a case, the DUSH will draw from whichever supply is active and still manage the battery, which adds a second layer of redundancy by covering the case where both AC supplies fail by using the battery. Problem : In an industrial environment, backup power systems need to be integrated with PLCs and SCADA systems and are not helpful if they operate in isolation. Plant operators need to know the status of the UPS, such as whether the system is on battery power, how much backup time is left, whether a battery fault has occurred, etc. With traditional DC UPS setups, monitoring relies on basic signals that indicate a mains failure but may not indicate a low battery.
Figure 2: TDK-Lambda’s DUSH960-1248 DIN rail mount DC uninterruptible power supply is available in two variants -0M and –1M. (Image source: TDK-Lambda)
All of these communication features show that DUSH960-1248 is not a black box power supply, but rather an intelligent device that communicates with the larger control system. In a SCADA environment, for instance, the DUSH960 module can report its status over Modbus to the SCADA host, which can display backup system health. A problem-solution analysis for integrators Problem: In traditional DC power backup setups, achieving redundancy and high reliability often means adding more hardware. Each additional component, such as diodes and external relays, introduces points of failure and voltage drops. As the system becomes more complex, it becomes more challenging to ensure consistent operation, and the overall
(CTA) To learn more, visit DUSH960-1248
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A bridge to 48 V power architecture By Abhishek Jadhav for DigiKey
One of the most critical problems in the modern industrial infrastructure is the increasing power consumption. Although many high-power systems still run on 12 V distribution architectures, delivering large amounts of power at this voltage requires very high current. For example, 1 kW at 12 V necessitates about 83 A. This approach leads to bulky copper bus bars, thick cable harnesses, and high resistive losses. To overcome these inefficiencies, the industry is shifting towards 48 V power delivery networks (PDNs). These higher-voltage systems reduce I 2 R transmission losses and enable the use of lighter, more efficient cabling compared to 12 V distribution. However, a significant compatibility gap remains, as many existing subsystems still operate at 12 V and cannot be easily replaced. For example, delivering a given amount of power at 48 V requires only one-quarter of the current needed at 12 V, which in turn can cut distribution loss by up to ~75%. In the same example as above, 1 kW at 48 V would only require 20.82 A, which is four times less current, directly reducing cable thickness, weight, and resistive losses. This creates a complex engineering challenge: how to adopt 48 V architecture without
discarding legacy 12 V loads. This is where Vicor Corporation offers its DCM3717 (Figure 1), a high- density DC/DC converter module that is specifically designed to bridge the 48 V to 12 V divide. Vicor offers the module as an off- the-shelf converter that is ready to be integrated into high-power systems that will convert a 48 V bus to 12 V at the point of load. Introducing the Vicor DCM3717 DC/DC converter module The Vicor DCM3717 accepts a wide range of input voltage of 40 to 60 VDC and provides a regulated, adjusted output from 10 to 12.5 VDC. This single module replaces the traditional step-down converter or intermediate bus converter in a much smaller form factor. The DCM3717 comes in two power ratings: one model that delivers up to 750 W and another that delivers up to 1000 W. Both models are packaged in a compact ChiP (Converter housed in Package) format, measuring only 36.7 x 17.3 x 5.2 mm. Despite its small footprint, the module achieves a high-power density of approximately 5 kW/ in 3 by using smaller conductors and components for the same power transfer.
Figure 1. Vicor Corporation's DCM3717 48V DC/DC Converter Module. (Image Source: Vicor Corporation)
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A bridge to 48 V power architecture
fault, such as a short or excessive temperature, thereby protecting both the module and the load. Additionally, the DC/DC converter supports PMBus digital telemetry and control, which allows the system controller to monitor parameters like output voltage, current, and temperature in real- time. This ensures power design engineers can adjust the output setpoints and perform remote on/off via PMBus. The digital interface makes it easy to integrate the converter into smart power management schemes. Functional working of the DCM3717 The converter uses a patented zero- voltage switching (ZVS) buck-boost regulator front-end, followed by the ZVS/ZCS Sine Amplitude Converter (SAC) current multiplier stage. This two-stage architecture allows efficient operation over a wide range of input voltages. ZVS reduces switching losses by ensuring the transistors switch when the voltage is near zero, while the resonant SAC stage transforms and filters the energy into a 12 V output. Stage 2 has a fixed ratio of 4:1 that quadruples both the voltage and the current. For example, if Stage 1 produces 48 V, Stage 2’s output will be 12 V. Because the feedback is taken at the final V out pins,
Typical application of DCM3717 to point-of-load. (Image Source: Vicor Corporation)
In practical terms, the dramatically smaller size is equivalent to a traditional DC/DC converter that allows engineers to add more features to the free space on the PCB or reduce the size of the overall system. This translates to weight saving, as large heatsinks or bulky magnetics are no longer needed to achieve the same power delivery. Beyond size, the efficiency of the DCM3717 is high, peaking around 96 to 97 percent. This shows that little input power is lost as heat. The reduction in waste heat yield benefits, such as easing cooling requirements, allowing smaller heatsinks and less airflow to keep its temperature in check. The module is also scalable. In the case of power systems that
require more than 1 kW, up to four DCM3717 modules can be used in parallel for roughly 3 to 4 kW on a single 12 V rail. This allows power design engineers to adopt 48 V distribution incrementally and with low risk. The DCM3717 module requires minimal external components, allowing the module to be integrated into an existing board, with minor layout adjustments. The DCM3717 integrates numerous protective and control features, including built-in safeguards for over- current, short-circuit, and over-temperature conditions. For example, the module will automatically limit output current or shut down upon detecting a
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the control loop automatically corrects for any variation introduced by the multiplier, such as those caused by temperature, load, and aging. This is how the DCM3717 module achieves tight regulation at the load terminals. As the DCM3717 is designed to handle dynamic loads, the module can deliver peak current and power levels up to 20 percent higher than its continuous rating for up to 1 ms. This full peak capability is available for output voltages up to 12.2 V. Above this, the peak current limit is linearly reduced to prevent output-over-voltage events during fast load changes. When the input voltage is applied, the module captures the PMBus address by sensing the resistor connected to the ADDR pin. This
address remains fixed until the input power is removed. The start- up sequence begins once the input voltage is within its undervoltage and overvoltage thresholds. The FLT signal then goes high to indicate readiness, after which Stage 2 begins switching, and Stage 1 ramps its output reference to generate a smooth soft-start rise in the output stage. However, if a fault is detected by the module, which can be input overvoltage, undervoltage, over- temperature, or load-related issues, the FLT pin is driven low, and power conversion stops within the specified fault-response time. The module does not restart while the fault condition persists. The DCM3717 module combines an intelligent digital interface
through PMBus with advanced power-train design, soft-switching efficiency, and robust fault handling, delivering a tightly regulated, high-density conversion stage that is straightforward to integrate into high-performance 48 V power delivery networks.
Conclusion The shift to a 48 V power
architecture is driving the need to achieve high efficiency in smaller and lighter weight converters for industrial and automotive systems. The Vicor Corporation DCM3717 high-density DC/ DC module serves as a bridge between 48 V and 12 V loads, allowing power design engineers to modernize power delivery networks without compromising existing 12 V infrastructure. To learn more, visit DCM3717 Converter Modules.
A functional block diagram of the Vicor Corporation DCM3717 high-density DC/DC converter module. (Image source: Vicor Corporation)
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Gain advantages with GaN power devices By Abhishek Jadhav for DigiKey
Silicon power devices such as MOSFETs and IGBTs have long been used in power electronics. However, they are increasingly constrained by fundamental performance limits in high- frequency and high-density designs. Design engineers often face trade-offs between conduction and switching losses, which restrict both efficiency and switching speed in silicon power converters. Gallium Nitride (GaN), a wide bandgap semiconductor, offers a compelling alternative by overcoming many of silicon’s inherent limitations. GaN
transistors feature significantly lower output charge and gate charge, along with an almost negligible reverse-recovery charge for a given on-resistance. These characteristics enable much faster switching and substantially reduced switching losses. Additionally, GaN’s material advantages include high electron mobility, a high breakdown field, and low intrinsic capacitance, which allow performance levels well beyond those of traditional silicon MOSFETs. Take, for example, 48 V PMSM motor drives, where switching losses at higher PWM frequencies
often limit efficiency and torque control accuracy. GaN offers lower R DS(on) , which reduces I 2 R conduction losses, improving drive efficiency and extending motor runtime. Its near-zero reverse recovery charge Q rr also enables tighter deadtime optimization, minimizing signal distortion. In a conference, Infineon Technologies evaluated such a drive using GaN HEMTs and increased the switching frequency from 20 kHz to 100 kHz under field-oriented control. The higher frequency reduced motor phase current ripple and, together with FOC, improved overall system
Infineon IGB070S10S1 CoolGaN ™ transistor 100 V G3 with industrial grade 3 x 3 mm package. (Image source: Infineon Technologies)
leverages decades of expertise in power semiconductors and robust infrastructure to deliver key advantages. These include silicon compatibility, drop-in packaging, high thermal performance and reliability, broad voltage coverage,
efficiency by more than 5 percent, without impacting device temperature or loss. Infineon offers a wide range of GaN power transistors that are available in voltage classes from 60 to 700 V and in a broad variety of packages. In particular, their medium voltage CoolGaN™ G3 discrete HEMT devices are high-performance transistors that are used for power conversion in a voltage range up to 200 V. The CoolGaN™ G3 devices are enhancement-mode GaN HEMTs that are usually off for safe
operations. They integrate a gate structure that turns on with a positive gate bias, similar to driving a MOSFET. This means standard driver ICs can often drive them and will fail-safe if gate drive power is lost. Why Infineon GaN? As GaN power devices transition from emerging technology to mainstream adoption, choosing the right supplier becomes critical for design engineers. Infineon
and strong field application engineering (FAE) support.
1. Drop-in compatibility Infineon GaN discretes are
designed in industry-standard packages, making it easier for integrators to replace the silicon
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Gain advantages with GaN power devices
MOSFETs with GaN devices. The medium-voltage CoolGaN™ G3 series is available in compact PQFN packages with dual-side cooling metal pads, aligned with standard MOSFET layouts for true pin-to-pin compatibility. This allows engineers to reuse the existing PCB footprint and socket, enabling multi-sourcing strategies and accelerating time to market. In addition to standard QFN packages, the G3 series includes options such as 3 x 3 mm 4-pin VSON for lower current devices and a larger 3 x 5 mm 6-pin package with exposed top cooling for higher power levels. 2. Thermal performance Infineon’s GaN devices are built with quality for reliable operation over a long period and in harsh conditions. GaN transistors inherently offer higher thermal conductivity than silicon devices, and when combined with Infineon package engineering, result in better heat dissipation and lower junction temperatures during operations. For high-power designs, the CoolGaN™ G3 is also offered in packages with exposed die attach for enhanced cooling. For example, the 3 x 5 mm PG-TSON-6 package exposes the GaN die on the top side, enabling direct heat sinking
Infineon IGC019S06S CoolGaN™ transistor 60 V G3 in PQFN 3 x 5 mm package. (Image source: Infineon Technologies)
4. Broad voltage portfolio The CoolGaN™ G3 covers a
and extremely low junction-to-case thermal resistance. This top-side cooling heat spreads over a larger area into the heatsink, minimizing temperature rise and allowing the device to handle high power levels. 3. Manufacturing scale Infineon has made significant investments in GaN manufacturing capacity. The CoolGaN™ G3 family is manufactured on high-volume 8-inch silicon wafer process lines. Moving GaN to 200 mm wafers drives down cost and ensures the scalability of supply. Infineon has also demonstrated GaN growth on 12-inch wafers, further strengthening its long-term production capacity.
wide range of medium voltages, including 60 V, 80 V, 100 V, 120 V, and 200 V classes. This allows designers to choose the most suitable device rating for their system, minimizing R DS(on) and Q G by not using over-rated devices. For example, a 48 V application can use an 80 V device instead of a 150 V device with better performance. 5. Application support Beyond hardware, Infineon backs its GaN portfolio with extensive application resources. Its global network of field application engineers, trained
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in GaN applications, provides hands-on guidance for design- in, PCB layout, gate driving, and troubleshooting. In addition, the company complements this with detailed application notes, reference designs, and a wide range of evaluation boards that help engineers reduce development cycles and optimize performance. How to implement GaN? After choosing the right GaN supplier, it is important to be able to successfully design power converters. Infineon offers evaluation kits such as the EVALMTR48V20AGAN for low-voltage motor drives, the REFIBC1600WGAN board for scalable 48 to 12 V regulated intermediate bus converters, and the EVAL7126G100VGANC half-bridge evaluation board, among others. These boards provide proven layouts and schematics using CoolGaN™ G3 devices. By testing on these devices, designers can familiarize themselves with GaN behavior, such as fast switching waveforms and thermal performance, and adapt the design patterns to their specific projects. Infineon also sometimes provides user guides and design files for reference designs.
Infineon EVALMTR48V20AGAN for low-voltage motor drives with CoolGaN™ Transistor 100 V G3 and TDI EiceDRIVER™ 1EDN7126U. (Image source: Infineon Technologies)
Conclusion GaN transistors have changed the power electronics landscape by addressing the limitations of silicon-based power devices. It allows engineers to design power converters and inverters with better efficiency, speed, and power density. Infineon’s CoolGaN™ discrete portfolio amplifies these advantages by providing high- quality, application-specific
GaN devices backed by strong engineering support. Design engineers can push the performance limits while reducing risks, benefitting from silicon- compatible packaging, broad device selection, and reliability.
To learn more, visit CoolGaN™.
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retroelectro
Painting of Williston Academy from the late 1870s.
Forgotten genius: William Stanley Jr.’s legacy in electrical engineering By David Ray Cyber City Circuits
William Stanley Jr. In the history of invention, many names have been lost to time or overshadowed by the ‘giants of industry.’ Stanley is one of the names that haven’t been lost from the public’s mind, but not for the reasons many might think. In his lifetime, he was granted one hundred twenty-nine patents covering a wide range of devices, many related to the electrical field, some not. While the reader may recognize his name from the side of their all- metal, vacuum-sealed coffee cup, his most notable contribution is the AC power transformer that brought AC power transmission to civilization. Stanley's patent #349,611 changed everything and became the prototype for all future power transformers.
Childhood William Stanley Jr. was born in Brooklyn, New York, in 1858, but soon moved to his ancestral home, being raised in Great Barrington, Massachusetts. Stanley’s father, William Stanley Sr, was a successful Yale-educated New York lawyer, and his mother was the daughter of a wealthy New York importer. At a very young age, Stanley showed a talent for mechanical things. It is said that at age ten, he took a pocket watch apart and reassembled it, and it kept perfect time afterward. Stanley attended Williston Academy (also known as Williston Seminary) in Easthampton, MA, and graduated in 1877. Afterwards, his father sent him to Yale to study law, but by
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retroelectro
Christmas break, he had become disenchanted with school in general and dropped out. He would comment many years later, “I am afraid there is a good deal of stuff taught in school that clogs instead of clears the brain.” Retro Electro Fun Fact: During this era, Massachusetts was a hotbed for innovation. Along with many important inventions, one of the most essential tools of the period originated in Boston: the Stillson Wrench. Learn more in the Retro Electro article, Steel and Steam. (Link: https://emedia. digikey.com/eMagazine- Vol-20-Test-Tools-and- Measurement/28-29/) Early career After leaving school, he took no time getting to work and fell into the electrical industry. With his strong mechanical mind, he began working for a telegraph equipment manufacturer in 1877 named Charles T Chester.
Images from a period Chester catalog of equipment that Stanley would have been working on during his time there.
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thin, but what he lacked in bulk he made up in activity. He was boiling over with enthusiasm. Nothing went fast enough for him. I believe he preferred that each week should contain about 10 days and that the days should be about 48 hours long. Whatever was given to him to do he laid himself out to do in the most thorough manner. He would spare no trouble or expense to accomplish the task which was given him to do, after laying out his own money in order to obtain material which he thought might be better than what was available in the works.” Eventually, Stanley was made the first assistant in charge of research and development for Maxim, where he worked on developing new incandescent light bulbs. While Thomas Edison was working on the light bulb, many others in the New England area were also working on similar projects. The following year, 1881, Maxim would leave and return to England, selling his interest in the United States Electric Light Company to the American Electric Company, which would then rebrand as the Thomson-Houston Electric Company. This company would later be merged with Edison’s company to create the General Electric company.
Retro Electro Fun Fact: In 1877, the US Patent Office’s model archive caught fire and destroyed many of the original patent models submitted by their inventors, including the Elisha Gray and Alexander Graham Bell models. This event brought fire suppression systems to the front of mind for many inventors and engineers.
Chester developed many fire alarm and suppression systems that integrated with the telegraph systems of the day. While working for Chester, he saved up money and, with a loan from his father, bought into a nickel-plating shop. While working there, he developed new methods for electroplating, speeding up the process, which became very successful within his first year of involvement.
Soon he found that the day-to- day routine at the shop no longer could keep his interest, and in 1880 he went to work for a British inventor named Hiram Maxim at the United States Electric Lighting Company. Stanley’s salary was cut significantly, but he was satisfied being able to work on new problems every day. The best description the writer can find of young Stanley comes from Maxim as a “very tall and
Drawing of Maxim’s United States Electric Lighting Co.
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Retro Electro Fun Fact: Sir Hiram Maxim was one of the members present at the 1881 International Electrical Congress when the units of measure, like Ohm and Volt, were standardized for the first time. Read more about that event in the Retro Electro article ‘Ohm’s Day.’ (Link: https://emedia.digikey.com/view/639112496/21/)
George Westinghouse and the air brake George Westinghouse Jr. was born in 1846 in New York. His father owned a successful machine shop and Westinghouse was quick to learn the trade. Following his naval service in the Civil War at age nineteen, he received his first patent for a rotary steam engine. His first groundbreaking invention was the air brake for trains, which he patented in 1869 at the age of twenty-two.
Hiram Maxim with his magnum opus, the Maxim Machine Gun.
One of the major innovations from Stanley during this period was a ‘lamp regulator.’ Prior to this, a lamp’s brightness would fluctuate constantly depending on the generator’s load. This invention would help keep a steady current through the bulb’s filament, allowing for a consistent brightness. This caught the attention of railway industrialist George Westinghouse. Soon after, Swan Electric Lamp Company was sold to Brush Electric Light in 1884.
After Maxim left the country, Stanley went to work for the Swan Electric Lamp Company in Boston. While working at the Swan Electric Lamp Company, Stanley was responsible for numerous patents related to improvements in incandescent lamps. For the next few years, he worked for Swan in a private lab in New Jersey. It was here that he met his wife, Lila Courtney Wetmore, with whom he would have six sons and three daughters.
George Westinghouse
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During the mid-19th century, with the start of the Second Industrial Revolution, trains were the primary way to carry goods and people long distances. The number of trains on the railway increased in size, quantity, and speed more than ever before. Horrific train crashes were regularly reported in newspapers across the country. At that time, the best way to slow down or stop a train was by having a ‘brakeman’ riding on top of the train cars. When the engineer sounded the whistle, the brakeman would jump up and turn the wheel to engage the brakes, then move to the next car to do the same for each following car. A speeding train could take up to two miles to come to a complete stop, and that was only if the brakeman survived the trip. It was not uncommon for a brakeman to fall to his death while trying to perform his job, and if that happened, there was no better way to stop the train and prevent a catastrophic crash. It was said that during this period, up to five thousand brakemen would die in a year. Westinghouse, reportedly personally affected by a disastrous crash, turned his attention to the new field of industrial pneumatics, creating the air brake. The new invention enabled trains to stop in a
Brakemen would run up and down a train to operate the brakes on the train cars as the train moved.
Deadly train crashes were not uncommon during this time.
fraction of the distance, allowing them to become longer and heavier, thereby carrying more goods and more people. In 1869, he formed the Westinghouse Air Brake Company and started demonstrations of his new system across the country,
selling thousands of units a year. By 1877, most passenger trains were equipped with Westinghouse Air Brakes, making Westinghouse very wealthy. He used this wealth to invest in many inventions and innovations.
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Edison was heavily invested in DC power transmission. He would negotiate deals with cities and municipalities to install numerous power stations throughout their areas, in exchange for the profits from those stations. With little to no upfront cost, towns were eager to grant him anything he wanted in exchange for streetlights and lit storefronts. The problem was that if anything emerged to threaten all the investment he had already made into DC systems, he would suffer significant losses. Alternating current (AC) was the solution to this distance problem, but unfortunately for Edison, he was already waist- deep in DC power by the time he realized he could not pivot to AC easily. AC was superior to DC for power transmission because it could travel much farther with less loss. This was because AC voltage could be increased (stepped up) using a transformer, which reduced the current in the wires and thus minimized
energy lost through heat from resistance. Once it reached its destination, the voltage could be safely stepped down again for use in homes and businesses. AC required fewer power stations and smaller transmission lines, making it overall much more cost-effective than anything Edison was doing.
Solving the problem with Edison’s DC power Up to this point in electrical history, direct current (DC) was the dominant system of power transmission, but it presented significant limitations. DC power could only be transmitted effectively over very short distances (up to one and half miles) due to the voltage drops of the power lines. To resolve this, the number of power stations increased, generating more pollution, while the power lines became thicker and more expensive. It was obvious that widespread urban electrification would never be practical and would be difficult and expensive to maintain. As Stanley himself said, “It was the common saying of the day that, if one should attempt to light Fifth Avenue from Fourteenth Street to Fifty- Ninth Street, the (DC) conductors required would be as large as a man’s leg.”
Thomas Edison as he looked during this time.
Retro Electro Fun Fact: Around this time, Edison enlisted the help of a former Navy Officer named Frank J Sprague to try to solve his power transmission issues. Sprague found Edison to be insufferable and left to start his own company, developing the first practical electric motor for trolleys and railways. Read more about his story in the Retro Electro article ‘Frank J Sprague and the Richmond Union Passenger Railway.’ (Link: https://emedia.digikey.com/view/251481832/16-17/)
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determined that the harsh Pittsburgh industrial environment worsened his condition, and his doctor recommended that he move out of the city. He moved back to his childhood home in Great Barrington, MA, and rented a defunct rubber mill in November of the same year. The mill was in operation for many years until the Housatonic River’s water level dropped eleven inches, making it impossible to run the necessary machinery.
his lighting projects, Stanley was committed to demonstrating that alternating current could be a safe, scalable, and efficient solution. When illness compelled him to leave Pittsburgh, Great Barrington offered a convenient testing ground. Its layout and small size made it perfect for trialing a new, ambitious system. The first primitive transformer was designed by European inventors, Lucien Gaulard and John Dixon Gibbs. At the time, the term transformer had not been coined yet, instead calling it the ‘secondary generator.’ Soon after, in 1885, Stanley would have Westinghouse
Newspaper clipping from 1886.
The electrification of Great Barrington In 1884, when George Westinghouse discovered Stanley’s lamp regulator, he sought out Stanley to work for him. Stanley was glad to work for Westinghouse in Pittsburgh, developing new inventions, but he became deathly ill with tuberculosis in 1885. It was
During his ‘recovery retreat,’ Stanley's drive for invention
remained strong. He aimed to tackle one of the most pressing electrical engineering challenges of his time. Having firsthand experience with the limitations of direct current in
purchase the patent rights to Gaulard and Gibbs’ invention.
The Gaulard and Gibbs Secondary Generator
The Horace Day Rubber Mill that Stanley worked out of in Great Barrington.
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was that using a closed magnetic path (a looped iron core instead of an open air core) and improved insulation would resolve these issues. His improvements made the transformer more reliable, easier to manufacture, and scalable, turning it from an experimental novelty into the backbone of his new AC system. In early 1886, Stanley had a twenty- five horsepower Westinghouse automatic steam engine installed
in his laboratory, which energized a five-hundred-volt Siemens alternator. He hand-built several of his new transformers (called ‘exhorters’ at the time) to study. Starting in February through the first half of March, he hung over 4,000 feet of No. 6 wire along elm trees to Main Street. He used a large transformer in the rubber mill to step up the voltage to three thousand volts and he placed six of his transformers (dropping
An 1886 Stanley Transformer
Stanley had a critical but constructive view of the secondary generator—the early transformer concept developed by Gaulard and Gibbs. He saw its promise, but also its shortcomings. He appreciated the underlying principle: magnetic induction could transfer electrical energy between circuits, but he criticized its efficiency and instability. The open-core design leaked magnetic flux, struggled to handle varying loads, and resulted in unpredictable voltage drops. After studying its construction, Stanley experienced a ‘Eureka’ moment. Stanley’s key insight
Plaque placed near the location of the original rubber mill in 2004.
“On 20 March 1886 William Stanley provided alternating current electrification to offices and stores on Main Street in Great Barrington, Massachusetts. He thus demonstrated the first practical system for providing electrical illumination using alternating current with transformers to adjust voltage levels of the distribution system.” – A dedication plaque located on the corner of Cottage and Mill streets in Great Barrington, MA, close to where the original rubber mill power station was located.
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