Electrically Triggered Thyristor Board

Thyristor Trigger Board (IPDM Solution) | Power Industry

Customer Needs and Core Challenges

• Core Industry Needs: Focusing on UHV DC transmission scenarios, customers require a thyristor trigger board adapted to UHV DC systems. Key requirements include stable signal transmission (distortion-free optical pulse signals), ultra-long service life (≥100,000 hours), high-voltage isolation protection (withstanding ±800kV voltage), and compliance with Power electronics PCB design's high reliability standards and EMI/EMC PCB design's anti-interference requirements.

• Key Technical Challenges:

  • Signal Transmission: Optical pulse signals are susceptible to electromagnetic interference, resulting in transmission delays and distortion, affecting triggering accuracy.
  • Durability: Under UHV environments, high temperature, high humidity, and strong electric fields combine, making it difficult for conventional PCB materials and processes to meet long-term stable operation requirements.
  • System Compatibility: Seamless integration with existing control modules in the power transmission system is required, along with high synchronization of multi-channel signal outputs.

One-Stop IPDM Solution

Based on the Integrated Product Design & Manufacturing (IPDM) system, we integrate three core businesses: IPD, IPM, and PCB, to create customized solutions:

• IPD (Integrated Product Design) Technology Empowerment:

  • Core Platform Selection: Utilizing an FPGA platform (Xilinx XC7K325T), we construct a dual-system parallel design architecture to ensure seamless system switching in the event of a single point of failure;
  • Signal Integrity Optimization: Employing SI/PI simulation technology, we reduce signal interference and reflection through differential pair routing and impedance matching design (impedance control tolerance ±5%);
  • Multi-Channel Synchronous Control: Supports 28 independent signal output channels with a channel synchronization error ≤1μs, adapting to the requirements of polythyristor collaborative triggering in UHV transmission.

• IPM (Integrated Product Manufacturing) Process Assurance:

  • Precise KBOM Material Selection: Leveraging a database of 3.27 million certified materials, we select high-voltage and high-temperature resistant components, providing domestic alternatives and reducing supply chain risks.
  • PCBA Process Enhancement: Utilizing high-density SMT technology with conformal coating (a mixture of red epoxy and solder paste), coupled with highly reliable nitrogen reflow soldering, meeting the IPC-A-610G Ⅲ standard.
  • EES Full-Process Verification: Conducting DFM manufacturability analysis to proactively avoid production defects and resolving mass production issues within a 24-hour closed-loop process.

• PCB (Printed Circuit Board) Specific Optimization:

  • Substrate Selection: Selecting high-TG FR-4 material (Tg≥170℃) to enhance mechanical strength and electrical stability under high-temperature environments.
  • Surface Treatment Process: Employing immersion gold plating to improve soldering reliability and corrosion resistance, adapting to harsh outdoor environments with ultra-high voltage.
  • Heat Dissipation and Protection Design: Increasing heat dissipation holes and copper-filled layout, optimizing the arrangement of heat-generating components; ensuring an EMC pass rate of 98.5% through EMC protection design.

Core Technical Parameter Table

Implementation results and project application

• Core achievements:

  • Significantly improved signal transmission stability: Optical pulse signal distortion rate reduced from 3% to 0.5%, synchronization accuracy meets UHV transmission control requirements;
  • Significantly enhanced durability: Product service life extended to 120,000 hours, failure rate reduced by 60%, adaptable to long-term operation in complex UHV environments;
  • Optimized system compatibility: Seamless integration with existing transmission control modules, shortening the integration and debugging cycle by 30%.

• Key Project Applications:
  This solution has been successfully implemented in several key national UHV DC projects, with a total investment exceeding RMB 150 million, including:

  • Luxi Back-to-Back Asynchronous DC Interconnection Project;
  • Jiuquan-Hunan ±800kV UHVDC Transmission Project;
  • Inner Mongolia Xilingol-Jiangsu Taizhou ±800kV UHVDC Transmission Project;
  • Wudongde Hybrid DC Transmission Project.