Power Integrations Launches BridgeSwitch-2 BLDC IC to Enhance Performance in Motor Drive Applications

Using a combination of hardware and software to reduce the BLDC motor inverter sleep mode power consumption to less than 10mW, and expand the output power to 1 horsepower applications

PCIM Europe, Nuremberg, Germany, June 11, 2024 – Power Integrations, the leader in high-voltage integrated circuits for energy-efficient power conversion, today announced the introduction of BridgeSwitch™-2, a new family of high-voltage integrated half-bridge (IHB) motor-driver ICs that further enhances its combined hardware and software solutions for brushless DC motors (BLDCs) up to 1 hp (746 W). The new ICs integrate high- and low-side drivers and two enhanced FREDFETs with lossless current sensing to deliver up to 99% inverter efficiency. The IHB architecture eliminates hotspots in the system, improving design flexibility and reliability, while significantly reducing component count and PCB area. BridgeSwitch-2 is supported by Power Integrations’ MotorXpert™ software suite, which includes single-phase trapezoidal control and three-phase sensorless field-oriented control (FOC) modules to accelerate inverter development.

BridgeSwitch-2 can handle abnormalities in operation in hardware, so that Class A safety software in IEC 60730 standard can be used, which can shorten product certification time by several months. The brushless DC inverter can be set to enter sleep mode when not working, thus reducing the power consumption of the driver to less than 10mW; this means that within the specified standby power consumption limit, more power can be provided for circuit loads that realize network access and monitoring functions.

Comments Cristian Ionescu-Catrina, product marketing manager at Power Integrations : “BridgeSwitch-2-based motor drives feature very low standby power consumption, enabling designers to meet the new EU ERP regulations. BridgeSwitch-2 ICs are also much more efficient than IGBT-based IPM modules across the entire load range.” He continues: “From start-up to performance optimization, the MotorXpert GUI-based tool ‘Terminal Emulator’ and MISRA C-compliant code library greatly simplifies the design process, optimizing the motor operating architecture in real time without the need for repeated firmware updates. BridgeSwitch-2 works with any microprocessor, making it easy to adopt in existing systems – an important consideration for engineers updating designs to meet stricter standby regulations.”

The BridgeSwitch-2 ICs are available in a power range of 30W to 746W (1HP) for a wide range of applications, including heat exchanger fans, refrigerator compressors, fluid circulation pumps, gas boiler combustion fans, washing machine drums, and kitchen mixers and blenders. Compared to discrete designs, the IHB architecture eliminates the need for current sense resistors and associated signal conditioning circuitry, reducing component count by 50% and PCB space by 30%. In addition, sense resistor losses are eliminated, further improving efficiency. Accurate motor control is achieved through built-in real-time reporting of phase current (IPH) information. Through precise control of the gate switch drive signal and the use of a body diode with soft recovery characteristics, its typical EMI characteristics are 10dB lower than existing drivers, so a smaller EMI filter can be selected.

BridgeSwitch-2 ICs feature built-in DC overvoltage protection and current limiting to protect the inverter and system without relying on system software. Error flags or comprehensive fault bus reporting can be selected to meet a variety of system requirements. Now, with high-precision built-in IPH information and comprehensive reporting provided through the fault bus, the use requirements of emerging applications such as fault prediction can be realized. The BridgeSwitch-2 motor drive uses built-in hardware-based low- and high-current protection for the lower and upper tubes, which meets IEC 60335-1 Class A requirements. In addition, BridgeSwitch-2 can operate without an auxiliary power supply, further reducing PCB area and reducing component count.

Supply and related resources

The BridgeSwitch-2 IC is priced at $0.48 each in 10,000-piece quantities. A 150W reference design and design report RDK-974 are also available for free download. For more information, please contact a Power Integrations sales representative or the company's authorized global distributors: DigiKey, Newark, Mouser and RS Components, or visit the official website.