On June 26, the charging head network held the 2024 power tool new technology online seminar, aiming to gain an in-depth understanding of the latest technologies and solutions in the field of power tools from major chip companies.
In this seminar, Zhang Long, Director of AOS Product Application Center (hereinafter referred to as AOS), shared with us some new solutions about AOS power tools.
AOS is mainly divided into three categories of products in the field of power tools, namely smart motor modules, independent driver ICs and half-bridge power MOSFETs. Product applications mainly include power tools, drones, fans, and electric bicycles and other vehicles.
The smart motor module integrates the driver IC, half-bridge MOSFET, and protection functions into a unified module. This integration can effectively reduce volume, especially in volume-critical applications, such as small fans and drones.
However, for high-power applications, such as power tools or e-bikes, the driver IC needs to be designed separately from the power MOSFET to achieve higher drive efficiency and heat dissipation.
In the field of smart motor modules, AOS's SMM modules have a variety of product options, covering QFN4x4, QFN4x5, DFN3x3 and other package types, with a suitable voltage range of 30V to 100V, mainly serving small and medium-power battery applications, with voltages between 12V and 24V.
For example, the AOZ9530QV is a smaller module integrated in a QFN 3x3 package, while the AQZ9551QV is larger and has a 12A current output capability.
AOS's smart motor module can effectively save PCB area. AOS compares three different solutions: discrete N+N solution, discrete P+N solution, and driver IC solution. The results show that the smart motor module has obvious advantages in the number of components and PCB area when using the driver IC solution, which can save 9 to 14 components, which is a great advantage for application scenarios where space is limited, such as small fans and small motors.
AOS's intelligent motor module has the following characteristics: highly integrated, using QFN package suitable for heat dissipation, and integrated LDO, which can achieve 100% duty cycle control, and has good application effect in low speed and stalled rotor conditions. AOS has also made some innovations in the driver, which can adjust the sink and source currents separately, so as to achieve EMI and efficiency optimization. In addition, there are comprehensive protection features that can be customized by monitoring the temperature of the internal diode voltage for temperature monitoring.
AOS has three main module layout packages, the QFN package places the V1 and V2 parts of the power in the bottom where the heat dissipation area is the largest, the power modules are concentrated together, and the control circuit is placed on the other side, which helps engineers to design.
AOC's AOZ9530 and AOZ9510 series integrate protection and auto-adjustment functions to regulate DVDT and drive current. The drive current is controlled by setting resistors on the DVS1 and DVS2 pins, and the speed is adjusted according to EMI and efficiency requirements. The VTP pin can collect diode voltage, 1.9V at 25 degrees Celsius and 1.3V at 125 degrees, which is used to monitor the operating temperature of the module and indirectly obtain the working condition of the module. The operating currents of these two modules are 7A and 20A, respectively.
These are some examples. The picture in the upper left corner is an actual demo board, which shows a four-layer 12V input, 7.84A electric fan driver board. Its speed can reach 4000 rpm, and the working power can reach about 100W.
The picture on the right is a practical example showing the smallest DFN3x3mm module, which can be placed on a coin-sized motor PCB, achieves a high speed of 42,000 rpm, and passes the double 85 test. In these practical cases, AOS's smart motor modules are ideal for small power tools and integrated fan applications, with the advantages of high integration and ease of use.
AOS's motor driver ICs include four products: AOZ32103MQV, AOZ32103MQV-06, AOZ32063MQV, and AOZ32101MDV, covering the range of 60V to 100V. All ICs integrate a Bootstrap Switch with adaptive drive roll-up, and the three-phase driver IC also integrates current sensing, dead-time control, and automatic power-down mode, as well as comprehensive protection features.
Here are some layout diagrams of the AOS driver IC. The smallest package is DFN 3x3mm, which is a half-bridge driver IC. The other three QFN packages (4x4mm to 5x4mm) are three-phase driver ICs with more pins. All of these ICs have been mass-produced, and some customers have already started using them.
AOZ32063MQV is a 60V three-phase driver IC, which is a classic motor three-phase driver IC of AOS, and its application diagram is in the lower right corner. This chip comes with its own power supply, does not need to be connected to an external VCC, shares the power input with the main power part, supports a boost voltage of up to 70V, can achieve 100% duty cycle drive, and has comprehensive protection functions, suitable for low and medium power motor drive power tools, such as electric drills, bench drills and high-speed fans and other applications.
The AOZ32103MQV-06 is a 60V driver IC with VCC external, which is suitable for scenarios where the control part is shared with a 100V IC and supports 100% duty cycle control.
AOZ32103MQV is a 100V motor driver IC, which is suitable for higher power motor drives and power tools, and can also be used in the field of electric bicycles.
The image on the left shows the actual 100V driver IC plus the motor driver demo board of the TOLL MOSFET. On the left is the AOZ32103MQV driver IC, in the middle is the battery control board using AOS's AOTL66912 MOSFET, and on the right is the motor driver board, each with a AOTL66912 on the three-phase bridge, a total of six AOTL66912 MOSFETs, with the AOZ32103MQV driver IC, can drive 500W to 1000W high-power motors, suitable for medium and large power tool applications.
The above is a AONS6696 solution for AOZ32103MQV driver IC with AOS. AONS6696 is a 100V DFN 5x6mm MOSFET with upper and lower tubes arranged on the front and back of the PCB board to effectively save area. This layout is suitable for power tools, because the motor rotor needs to protrude from the middle hole, so the shape of the PCB board is conducive to integration with the motor in practical applications.
AOS's AOZ32103MQV driver ICs have also passed various rigorous tests and certifications on lawn mowers. AOS also compared AOZ32103MQV to some of its competitors' driver ICs. On the experimental platform, we put 12 AOTL66912 MOSFETs on the three-phase bridge. The measured results show that the current of the AOZ32103MQV driver IC exceeds the competitor in many ways, and it is suitable for parallel use with two AOTL66912 MOSFETs. In the range of 350W to 800W, a AOZ32103MQV driver IC and AOS MOSFET can be used to achieve a perfect motor drive.
In addition, AOS also compares efficiency and temperature rise, which is similar to that of competitors at the same load and speed.
AOS also has a half-bridge driver IC solution. AOZ32101MDV is a DFN 3x3mm package half-bridge driver IC designed for half-bridge driver applications that require a small footprint. It has a source current of 1.5A and a sink current of up to 2.5A, and integrates a 120V Bootstrap Diode that is capable of operating at higher voltages. It can also be tested in outdoor conditions for a variety of lawn mowers.
An interesting application of AOZ32101MDV is on server cooling fans. Nowadays, AI servers are a big problem with heat dissipation, and large cooling fans are installed on such servers, and 16 high-speed fans are installed to quickly extract heat from the cabinet. Such a fan power can reach 400W or even 600W, so a small and highly integrated solution is required. By using the AOZ32101MDV plus AOTL6692 scheme, a single fan power of 850W can be achieved. In addition to fan applications, this solution is also very valuable on power tools.
Finally, AOS has a new product under development that is expected to enter mass production soon. It is characterized by a wide temperature rise range and can be adapted to environments from -40°C to 100°C, so this driver IC will be very useful in the case of harsh outdoor working conditions.
On the half-bridge MOSFET, AOS has introduced a new 40V product by integrating the upper and lower tubes of the half-bridge in a DFN 5x6mm package. What is unique is that this product has a very low RDS(on).
For example, AON6590A, the DFN 5x6mm package 40V product has a nominal RDS(on) value of only 0.78mΩ. The new AOS product has a top-tube RDS(on) of 0.8 mΩ and a down-tube of 1 mΩ. By stacking two wafers on top of each other (stacked die), it is possible to achieve smaller RDS(on) in the same package, which greatly saves volume and ensures heat dissipation.
This is a demo version of AOS using Stacked die MOSFETs with a power of 500V. Compared to traditional discrete solutions, the area of this stacked die MOSFET is reduced by 17%. This is a valuable solution for those who have high requirements for area but also have a high demand for power.
At the same time, AOS also adopts a special packaging method, which puts the HS drain in the middle and the HS source at one end, so as to increase the heat dissipation area and reduce the inductance between the top and bottom tubes to about 100pF. This is very helpful in reducing the oscillation of power tools in high-speed switching and improving the reliability of the system.
At the same time, AOS also carried out a temperature rise comparison. Under the conditions of 360V and 450V, the temperature rise of this drive half-bridge was compared. It can be seen that compared with the traditional discrete scheme, although the traditional discrete scheme has a larger heat dissipation area and a smaller RDS(on), their temperature rise is similar under the same output power conditions. This shows that this integrated solution is not only small in size, but also has great advantages in terms of heat dissipation function and temperature rise.
To sum up, this new stacked die half-bridge MOSFET saves PCB area in power tools for more compact, portable, and high-power applications. Compared to traditional discrete solutions, it does not increase in temperature rise, so more motor power can be achieved in smaller power tools.
Summary of the charging head network
AOS's layout in the field of power tools mainly includes three categories of products: intelligent motor modules, independent drive ICs and half-bridge power MOSFETs. The intelligent motor module integrates the driver IC, half-bridge MOSFET and protection functions to meet the needs of small fans, drones and other applications with high volume requirements. In high-power scenarios such as power tools and e-bikes, the separation of the independent driver IC from the power MOSFET provides higher drive efficiency and heat dissipation.
With a variety of package types and a wide range of voltage coverage, AOS's smart motor modules and driver IC products are suitable for small to medium to high power battery applications. In specific products, modules such as AOZ9530QV and AQZ9551QV successfully solve the challenges of PCB area and heat dissipation due to their small package size and strong output capability, especially for small power tools and integrated fan applications.
AOS's driver IC lineup covers a wide range of ICs from 60V to 100V, with integrated bootstrap switches, adaptive drivers and other functions, and is optimized in terms of EMI, efficiency, and protection functions. Its highly integrated half-bridge driver ICs demonstrate excellent performance and reliability in applications such as server cooling fans and power tools. In addition, AOS's new stacked die half-bridge MOSFET provides an energy-efficient solution for power tool applications by reducing the size while ensuring excellent heat dissipation and temperature rise performance through a unique packaging method and low RDS(on) design.