Which Is Better for Industrial Motor Drive Applications?
Introduction
In industrial power electronics, motor drive and inverter systems are the backbone of applications such as HVAC, automation equipment, servo drives and variable frequency drives (VFD).
One of the most common design decisions engineers face is whether to use Discrete IGBT modules or an Intelligent Power Module (IPM).
Both solutions are widely adopted in the industry, but they differ significantly in terms of integration level, design complexity, reliability and time-to-market.
This article compares IPM and discrete IGBT solutions from an industrial motor drive perspective, helping engineers select the right approach for their applications.
What Is a Discrete IGBT Module?
A discrete IGBT solution typically consists of:
- IGBT modules or discrete IGBT devices
- External gate driver circuits
- Separate protection circuits (short-circuit, over-temperature, under-voltage, etc.)
- Additional PCB design for signal isolation and layout optimization
This approach provides maximum flexibility, allowing engineers to fine-tune each part of the system according to specific performance requirements.
Advantages of Discrete IGBT Modules:
- High design flexibility
- Suitable for high-power or highly customized systems
- Independent selection of IGBT, driver and protection components
Limitations
- Longer development cycle
- Higher risk of design errors
- Larger PCB area and more complex layout
- Increased validation and debugging effort
What Is an Intelligent Power Module (IPM)?
An Intelligent Power Module (IPM) is a highly integrated power semiconductor module that combines:
- IGBT devices
- Gate driver ICs
- Protection functions such as short-circuit protection, over-temperature protection and under-voltage lockout
All these functions are integrated into a compact module optimized for industrial power electronics applications.
IPMs are widely used in industrial motor drives, inverter systems, HVAC equipment and automation platforms, where reliability and development efficiency are critical.
IPM vs Discrete IGBT: Key Comparison
1. Integration and Design Complexity
Discrete IGBT solutions require engineers to design and validate multiple subsystems separately.
In contrast, IPMs integrate these functions into a single module, significantly reducing design complexity.
For motor drive applications with tight development schedules, IPMs help shorten design cycles and reduce engineering workload.
2. Reliability and Protection
Industrial motor drives often operate under harsh conditions, including voltage fluctuations, thermal stress and load variations.
Discrete solutions rely heavily on correct gate driver and protection circuit design. Any mismatch can impact system reliability.
IPMs are designed based on mature industrial power module architectures, with protection functions already optimized and validated at the module level, improving system robustness.
3. PCB Layout and System Size
Discrete IGBT designs usually require:
- Larger PCB area
- Careful isolation and signal routing
- Additional components for protection and sensing
IPMs offer a compact footprint, simplifying PCB layout and enabling smaller inverter designs, which is especially beneficial for space-constrained applications such as HVAC inverters and servo drives.
For many industrial customers, time-to-market is a key competitive factor.
Discrete IGBT solutions require longer verification and debugging phases.
IPMs, by contrast, allow engineers to focus on system-level optimization rather than low-level power stage design.
As a result, IPMs are often preferred for standardized industrial platforms and high-volume motor drive applications.
5. Cost Considerations
At first glance, discrete IGBT components may appear more flexible in cost optimization. However, when considering:
- Engineering time
- PCB complexity
- Testing and validation costs
IPMs often provide a more cost-effective solution at the system level, particularly for low-to-medium power industrial drives.
Typical Application Scenarios
Why IPMs Are Widely Adopted in Industrial Motor Drives
Mainstream industrial motor drive platforms increasingly adopt Intelligent Power Modules because they:
- Follow proven industrial power electronics design practices
- Reduce system complexity and development risk
- Improve overall reliability
- Enable faster product deployment
These advantages make IPMs a practical choice for applications traditionally served by established global power semiconductor suppliers.
SHYSEMI IPM Solutions for Industrial Applications
SHYSEMI develops Intelligent Power Modules based on widely accepted industrial IPM architectures, targeting motor drive and inverter applications.
By combining integrated IGBT devices, gate drivers and comprehensive protection functions, SHYSEMI IPM products help customers:
- Simplify inverter design
- Improve system stability
- Optimize cost-performance balance
- Enhance supply chain flexibility
Conclusion
Both discrete IGBT modules and Intelligent Power Modules play important roles in industrial power electronics.
For applications requiring maximum flexibility and very high power levels, discrete IGBT solutions remain a strong choice.
However, for industrial motor drives, HVAC inverters and standardized inverter platforms, IPMs offer clear advantages in terms of integration, reliability and development efficiency.
Selecting the right solution depends on application requirements, system complexity and project timelines—but for many industrial designs, IPMs represent the most balanced and efficient approach.