IGBT Solutions for Industrial Robotics Control Systems——KKPCB Power Electronics Case Study

I. Project Background

Industry Challenges in Robotics

1. Power Density Demands: Modern 6-axis robots require 2-15kW servo drives with <100ns switching response
2. Thermal Management: 85% of robotic failures originate from power module overheating (IFR 2023 Report)
3. EMI Constraints: Industrial environments demand CISPR 11 Class A compliance

Client Profile
A leading industrial robot manufacturer sought to:

• Upgrade legacy MOSFET-based drives with IGBT solutions
• Achieve 98% uptime in 24/7 automotive welding applications
• Reduce power losses by ≥30%

II. KKPCB Technical Implementation

1. Custom IGBT Driver Board

• Key Specifications:
  • 1200V/200A IGBT modules (Infineon FF200R12KT4)
  • 3.5ns propagation delay gate drivers
  • <5μs short-circuit protection response
• PCB Innovations:

• DC BusKKPCB-IGBT-DriverDesat ProtectionTemperature MonitoringPWM Controller

2. Performance Benchmarking

Parameter	Client Previous	KKPCB Solution
Switching Frequency	8kHz	20kHz
Power Loss @ 100A	1.8W	1.1W
Thermal Resistance (J-C)	0.45K/W	0.28K/W
MTBF (Hours)	35,000	82,000

3. Application Scenarios

A. Spot Welding Robot (Automotive)

• Implemented 24x IGBT modules in parallel configuration
• Achieved 2ms weld cycle time (industry avg: 3.5ms)

B. SCARA Assembly Robot

• Reduced motor torque ripple from 12% to 4.5%
• Enabled 0.02mm repeat positioning accuracy

III. KKPCB Value Engineering

1. Thermal Optimization
   • Ceramic substrate with direct-bonded copper (DBC) technology
   • 45% smaller footprint than industry reference designs
2. Reliability Enhancements
   • 6-layer PCB with embedded temperature sensors
   • Conformal coating for harsh environments (IP67)
3. Cost Reduction
   • Achieved 22% lower assembly cost through:
     • Integrated current shunts
     • Elimination of external snubber circuits

IV. Client Outcomes

Operational Improvements

• 37% energy savings in continuous operation
• 0 unscheduled downtimes in 18 months

Market Impact

• Enabled client to secure $12M EV battery line contract
• 5 new robotics patents filed using KKPCB architecture

Case ID: KKPCB-ROB-2024-IGBT05
Contact: sales@kkpcb.com

“KKPCB’s IGBT driver design became the foundation for our next-gen robotics platform. Their expertise in high-power density layouts is exceptional.”
— Client Chief Engineer

Industry Outlook:
With the industrial robotics market projected to reach $75B by 2027 (MarketsandMarkets), KKPCB’s power electronics solutions address critical needs in:

• Collaborative robot joint control
• Mobile robot battery management
• Precision motion systems