Key Considerations for Designing a Power Semiconductor Assembly

In addition to distributing standard semiconductor components from world leading manufacturers such as IXYS, Semikron, Dynex and EDI, GD Rectifiers has developed a full range of power semiconductor assemblies designed and tailored to customer specifications.

Finding the Right Designer and Power Semiconductor Assembly

At GD Rectifiers, our team of engineers have been manufacturing power semiconductor assemblies for more than 20 years and are available to offer specific power solutions by adapting existing configurations or designing custom builds using state-of-the-art diodes and thyristors.

At GD Rectifiers, we offer a wide range of power assemblies and controllers, which can be manufactured with customer specific components or power semiconductors from our partners. An extensive product portfolio includes diode/thyristor assemblies; discrete device and isolated module assemblies, single-phase, three-phase and hex-phase assemblies, rotating diode assemblies, photovoltaic triple diode assemblies, rectifiers, regulators, and power assembly controllers and accessories.

GD Rectifiers offers a large range of standard off-the-shelf assemblies, assembly components and traction refurbishment services, offering 24 designs in 3 configurations, incorporating a range of forced air, natural air, and liquid cooled methods. High-power diode and thyristor rectifier assemblies are available from 5kW up to 5MW and are designed in-house, incorporating bespoke clamping systems and thermal management solutions.

GD Rectifiers serve all traditional power assembly fields including high powered high voltage rectifier for charging, resistance welding, plating, heating, lighting, cathodic protection, magnetic supplies, pulse power, variable speed drives and renewables.

Power Semiconductor Assembly Types

Rectifiers

• Single phase controlled and uncontrolled rectifier assemblies
• Three phase rectifier assemblies
• Hex-phase rectifier assemblies
• Selenium rectifiers

Regulators

• Single phase fully and half controlled regulators
• Three phase fully and half controlled regulators

Partner with a Reliable Power Semiconductor Assembly Designer

At GD Rectifiers, our power assembly design team have been working with customers for over 20 years to create and develop customised power assemblies to meet stringent requirements. With the benefit of in-house manufacturing and build, GD Rectifiers are able to provide prototypes on a quick turnaround for most applications if utilising the semiconductor components, we have in stock.

Once an enquiry is received our design teamwork with customers to spec out the assembly, ensuring they collate all the information required to offer a suitable assembly. Our team will discuss the assembly type, whether discrete or module semiconductors are required, understand the circuit, identifying if it’s a bridge, AC control or star rectifier circuit. We’ll then explore the input and operating current voltage, DC current, ambient/water inlet temperature and cooling conditions. At this stage we’ll discuss the maximum mechanical outlines and if there’s any size constraints and any associated auxiliary components required in addition to the assembly, such as fuses or thermal trips.

The Power Assembly Design Process

GD Rectifiers works with customers closely on creating prototypes with a strong focus on maximising semiconductor performance within an assembly. Typically, we will assess; type of heatsink, transient conditions, overloads, and ambient temperature, finishing and cooling method before a large production run. With a wealth of experience in the design and manufacture of high-power semiconductor assemblies, our team will create a design in CAD software designed to meet your requirements.

After design discussions, we’ll then progress forward to prototyping. With a broad range of semiconductor devices in stock, we can deliver a fast turnaround on assemblies, ensuring that even standard power assemblies are optimised for customer applications.

10 Crucial Power Assembly Design Considerations

1. Thermal management –consider heatsink selection, mounting surface preparation, cooling method, transient conditions and overloads, surface geometry and finish.
2. Electrical performance – identify high current traces, component placement, decoupling capacitors and EMI/EMC compliance.
3. Reliability – understand the mounting hardware, surface finish, vibration and shock resistance, mounting holes, surface flatness.
4. Application capabilities – understand the full application capabilities before enquiring including maintenance scheduling.
5. Design and thermal management challenges – consider the design and thermal management challenges at all stages of the project and communicate potential issues to the designer/manufacturer.
6. Semiconductor selection – careful consideration regarding semiconductor selection on the type and packages required to meet application requirements.
7. Standardise components – use common, readily available components to simplify assembly and reduce costs.
8. Develop a prototype to test and refine design – consider assembly constraints such as how the unit will be handled, orientated and assembled. Prototypes will help identify any potential design issues early on.
9. Address design issues – liaise with your power assembly manufacturer to ensure they have the skillset and expertise required for the project and can address design issues.
10. Partner with a one stop shop – find a power assembly designer and manufacturer that can provide the heatsinks, clamps and semiconductors to build the power assembly, to help reduce costs and time to market.

Why Choose GD Rectifiers as your Power Assembly Designer and Manufacturer?

• Over 60 year’s industry experience
• Design and manufacture high-quality power assemblies following industry standards
• A wealth of power electronics experience and engineering expertise including in-house design and problem-solving
• Standard off-the-shelf power semiconductor assemblies available with fast delivery
• Custom assemblies designed and tailored to suit your application with expert technical consultancy and support
• Aftercare support from all business areas, including direct access to our engineering teams
• Our in-house CNC shop and heatsink manufacturing capabilities helps reduce time to market, offering a wider specialist, contract manufacturing service
• Our extensive product portfolio of semiconductors, circuit protection, passives and power supplies complement our in-house manufacturing abilities
• Refurbishment service to repair or replace faulty and ageing rectifiers
• An ISO 9001:2015 certified manufacturer, our assemblies are built to the latest BSI standards

Power assembly design can often be a critical factor in developing the next generation of products and applications, ensure your assembly designer provides specialist technical support from enquiry right the way through to delivery.

Customers can rely on GD Rectifiers to help design a completely new build or to supply a replacement rectifier quickly to get your application back up and running. Our repair and replacement service for faulty or ageing semiconductor rectifiers, converters, inverters and regulators helps red tape industries get back to being fully operational with a quick and cost-effective solution.

For further information or technical support on our power assembly range, or to discuss your requirements, please contact us on 01444 243 452 / [email protected].