Current Sensing Integration with Lead Frames in 6-in-1 IGBT Modules

To improve the power density and reliability of the energy conversion systems, lead frames have been used in power modules as replacement for bond wires. Giant magnetoresistive (GMR) detectors have already been integrated in the external screw terminals of 2-in-1 IGBT modules for current sensing. To achieve a higher level of sensing integration, this work introduces methodologies for GMR integration inside 6-in-1 IGBTs with customized lead frames. A methodology for lead frame design suitable for GMR integration is presented. This design can be scaled for module terminals and external bus bars. Inter-phase and intra-module decoupling are implemented to decouple the cross-coupled fields from adjacent phase currents and die region currents. The closed-loop control of a three-phase inverter for an AC machine is realized based on the integrated GMR sensing in the lead frame module.