Power supplies have evolved to offer far more than just volts and amps, incorporating advanced functionality and features to meet the growing demands of industries like semiconductor manufacturing. This transformation is especially pertinent for semiconductor manufacturing equipment designers, as digital control and programmability are revolutionizing safety, performance, and reliability.
Overview
- Rapid semiconductor industry growth means the global market is expected to surpass $1 trillion by 2030.
- Challenges in semiconductor manufacturing include energy-intensive processes, load variability, space constraints, and power infrastructure limitations.
- Advanced power supplies can address these issues through enhanced flexibility and control for processes like dry etching and wafer testing.
- Modern power supplies for semifab equipment incorporate digital controls and programmability to vastly improve safety, performance, and reliability.
The semiconductor industry is experiencing a transformative period, driven by artificial intelligence (AI) and data. And this rapid growth shows no signs of slowing! According to TechInsights, the global semiconductor market is projected to surpass $1 trillion by 2030, fueled by the soaring demand for integrated circuits (ICs) in AI, digital economies, and electric vehicles. DRAM (Dynamic Random Access Memory) is set to more than double its revenue over the next decade, driven by the increasing need for AI applications.
Meeting the needs of wafer fab equipment manufacturers
Given that semiconductor production is highly energy-intensive—especially in stages like silicon wafer fabrication and testing—shifting toward more sustainable energy solutions is crucial for the environment. Power supply manufacturers must respond swiftly to the demands of wafer fab equipment producers, especially during process evaluations, as rapid delivery can directly influence a company’s ability to secure new business. However, providing speed alone is not enough; integrating enhanced controls and monitoring capabilities into power supply units is also critical.
By adding these features, manufacturers can facilitate comprehensive data logging that provides insights into a machine tool’s operational status. This data allows for quick identification and resolution of system issues, which is particularly important given the severe financial consequences of power supply failures. In the semiconductor manufacturing world, downtime can result in losses of millions of dollars.
Common power supply challenges in new machine builds
When designing new machines, selecting the right power supply presents several challenges. You should consider your power infrastructure, power supply control, integration into compact spaces and load variability for your application.
Limitations posed by three-phase power infrastructure
A lack of three-phase power infrastructure can affect where new machines can be deployed. A power supply with a universal single-phase input, ranging from 90-264 VAC, offers greater location flexibility, making it possible to operate machines in environments lacking three-phase power.
Lack of power supply control in alignment with system and application requirements
By opting for a power supply with programmable firmware, designers gain the flexibility to configure their systems through a graphical user interface (GUI), tailoring them to specific needs.
Space constraints
Traditional high-power units tend to have a large footprint, making them difficult to integrate into compact spaces. Inadequate monitoring capabilities can also lead to problems with system integration and health visibility. A power supply unit with built-in digital controls, user-defined signals, and alarms can optimize system design, reduce maintenance costs, and provide real-time insights into system health.
Load variability
System instability or damage can be caused by load variability. A power supply unit that automatically switches between constant current and constant voltage modes can protect both the PSU and the end-user system, ensuring reliable operation despite load fluctuations.
XP Power’s scalable, digital, and configurable approach
Our HP range of power supplies provides a scalable, digital, and configurable approach to semiconductor manufacturing. This range, available in compact formats, supports both three-phase and single-phase inputs, making it highly adaptable to various operational environments. With power scaling from 1.5kW to 25kW, the HP range integrates advanced digital features like signal processing, multiple communication protocols, and user-configurable functionality. The range includes:
The HPT series
The HPT series features a three-phase input that simplifies installation by eliminating the need for a neutral connection which is often unavailable in semiconductor manufacturing facilities.
The HPA series
The HPA series is a single-phase 1.5kW unit capable of operating in constant voltage (CV) and constant current (CC) modes. This flexibility, combined with programmability and user configurability, addresses the growing need for power supplies that can support the increasing sophistication of semiconductor manufacturing equipment.
The HPF series
Launched in 2023, the HPF series delivers 3kW of power from a universal single-phase input. This series also includes user-configurable output voltages, making it suitable for a wide range of semiconductor applications, including dry etching and wafer testing.
Ensuring precision in semiconductor manufacturing
In semiconductor manufacturing, ensuring consistency, quality, and reliability requires the ability to replicate precise power supply performance characteristics. For instance, dry etching, which offers superior precision in microfabrication, relies on robust power supply units like the HPF series to meet its demanding voltage requirements. Similarly, wafer testing systems, which typically require 6kW of power, benefit from the scalability and parallel operation capabilities of XP Power’s power supply units.
Summary
The integration of digital control and programmability into power supplies is not just a trend in semiconductor manufacturing; it’s a necessity. Manufacturers now need power supply solutions that enhance equipment safety, performance, and reliability and XP Power’s scalable, digital, and configurable approach offers a forward-thinking solution.
By incorporating advanced digital features, these power supplies enable proactive maintenance, maximize uptime, and support a more sustainable manufacturing process, positioning the semiconductor industry for continued success.
Discover more about our intelligent, programmable high power solutions.
Shravan Govindaraj
Shravan Govindaraj is XP Power’s Product Marketing Manager. He has over 5 years of experience in technical sales and product marketing across multiple industries including HVAC, electric motors and power supplies. Shravan joined XP Power in 2022 to develop and implement go-to-market strategies for all XP Power products.
