Project overview

Power electronics facilitate the conversion and control of electrical energy and are used in various application fields, such as energy infrastructure, electromobility, and industrial control systems. Due to the increasing product diversity, the current production environment for power electronics is reaching its limits. The research project FlaMe addresses this challenge: The project aims to make the production of power electronics modules more efficient and flexible through a highly adaptable, robot-assisted manufacturing concept, intending to replace traditional, energy-intensive manufacturing processes. One of the project´s goals is to enable manufacturing in lot size 1 to meet the varying product requirements arising from different application areas and functions for customers.

As part of FlaMe, the application of high-brilliance laser radiation in the visible wavelength range (515 nm) for joining current-carrying copper components is being investigated. In this context, laser beam welding shall substitute traditional wire bonding processes. This innovation allows a higher manufacturing precision, increases system reliability, and improves the thermal performance of the modules. In combination with industrial robots for handling and positioning, the components, and a multi-sensor approach for data-driven quality assurance, a highly flexible and robust value chain is created. Another focus of FlaMe is the use of innovative wide-bandgap semiconductor materials, such as silicon carbide and gallium nitride. These materials can handle higher electrical voltages, temperatures, and switching frequencies than silicon, contributing to the reduction of switching and conversion losses, and thereby increasing operational efficiency. Overall, FlaMe pursues a manufacturing concept that aims to reduce process complexity and resource needs by substituting traditional manufacturing processes while simultaneously increasing flexibility.

Acknowledgement

The presented project is funded by the Federal Ministry for Economic Affairs and Climate Protection (BMWK) under the funding code 03EN4008A as part of the 7th Energy Research Program of the Federal Republic of Germany and is supervised by the Project Management Agency Jülich (PtJ). We thank the BMWK and the PtJ for their support and the good and trusting cooperation.