Reliability of Power Electronic Converter Systems
2: Department of Energy Technology, Aalborg University, Aalborg, Denmark
3: Department of Energy Technology, Aalborg University, Aalborg, Denmark
4: Center for Advanced Life Cycle Engineering, University of Maryland, Maryland, United States
The main aims of power electronic converter systems (PECS) are to control, convert, and condition electrical power flow from one form to another through the use of solid-state electronics. This book outlines current research into the scientific modeling, experimentation, and remedial measures for advancing the reliability, availability, system robustness, and maintainability of PECS at different levels of complexity. Drawing on the experience of an international team of experts, this book explores the reliability of PECS covering topics including an introduction to reliability engineering in power electronic converter systems; anomaly detection and remaining-life prediction for power electronics; reliability of DC-link capacitors in power electronic converters; reliability of power electronics packaging; modelling for life-time prediction of power semiconductor modules; minimization of DC-link capacitance in power electronic converter systems; wind turbine systems; smart control strategies for improved reliability of power electronics system; lifetime modelling; power module lifetime test and state monitoring; tools for performance and reliability analysis of power electronics systems; fault-tolerant adjustable speed drive systems; mission profile-oriented reliability design in wind turbine and photovoltaic systems; reliability of power conversion systems in photovoltaic applications; power supplies for computers; and high-power converters. Reliability of Power Electronic Converter Systems is essential reading for researchers, professionals and students working with power electronics and their applications, particularly those specialising in the development and application of power electronic converters and systems.
Inspec keywords: variable speed drives; wind turbines; electronics packaging; photovoltaic power systems; reliability; power convertors
Other keywords: power module; wind turbine systems; reliability engineering; photovoltaic systems; power electronic converter systems; adjustable speed drive; power electronic packaging
Subjects: Reliability; Solar power stations and photovoltaic power systems; Power convertors and power supplies to apparatus; General electrical engineering topics; Product packaging; Drives; Wind power plants; Power electronics, supply and supervisory circuits
- Book DOI: 10.1049/PBPO080E
- Chapter DOI: 10.1049/PBPO080E
- ISBN: 9781849199018
- e-ISBN: 9781849199025
- Format: PDF
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Front Matter
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1 Reliability engineering in power electronic converter systems
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Electrical energy conversion by power electronic systems can be classified into the following four categories: 1. Voltage conversion and power conversion for both direct current (DC) and alternate current (AC) 2. Frequency conversion 3. Wave-shape conversion 4. Poly-phase conversion.
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2 Anomaly detection and remaining life prediction for power electronics
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Power electronics is the application of solid-state electronics (pulse-width modulation (PWM) converters, insulated-gate bipolar transistor (IGBT)-module, capacitors, magnetics, etc.) for the control and conversion of electric power. Power electronics devices are widely applied in electrical systems and play a critical role in almost all aspects of daily life, such as aerospace, nuclear power, high-speed rail, transportation systems, industrial processes, and national security. Ensuring the reliability of power electronics is important, as their failure can cause enormous losses or casualties.
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3 Reliability of DC-link capacitors in power electronic converters
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DC-link capacitors are widely used in power electronic converters to balance the instantaneous power difference between the input source and output load and to minimize voltage variation in the DC-link. In some applications, they are also used to provide energy storage. Figure 3.1 shows some typical configurations of power electronic conversion systems with capacitive DC-links. Such configurations cover a wide range of power electronics applications, for example, power factor corrections, wind turbines, photovoltaic systems, motor drives, electric vehicles, and lighting systems. It should be noted that a capacitive DC-link discussed here does not necessarily consist of capacitors only. There could also be some inductive components (e.g., DC choke) in the DC bus in some of the above applications.
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4 Reliability of power electronic packaging
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In this chapter, basic reliability concepts for power electronic packaging and modules are presented. Standard reliability testing, such as temperature cycling, power cycling, and high-temperature gate bias, is described. Due to the typical large operation temperature excursions for power packages and modules, thermomechanical stresses become important for many failure mechanisms. Manson-Coffin and Arrhenius relationships are useful in describing these failure mechanisms. At the time of writing of this chapter, new standards are critically needed to standardize the testing and reliability of these power packages and power electronic modules operating at high temperatures, defined as temperatures higher than 175 °C.
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5 Modelling for the lifetime prediction of power semiconductor modules
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Reliability engineering has emerged as a relatively new branch of power electronics (PE) supporting the fast progress towards advanced power electronic converter systems (PECS) with significantly improved reliability ratings. PECS operate under increasingly severe temperature profiles, i.e., fast temperature cycling (TC) between extreme temperature levels. Accordingly, the reliability requirements for power semiconductor modules as fundamental components of PECS are significantly increased. Power module manufacturers have been working on new power module designs and packaging technologies in order to increase endurance and prolong the lifetime of power modules in the future, and subsequently enable high performance of the PECS also concerning reliability [1]. In the future, the reliability aspects have to be included into novel multi-domain optimization tools that will further improve the design of PECS. The first step towards this goal is to allow the integration of lifetime models of the system components into the design process.
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6 Minimization of DC-link capacitance in power electronic converter systems
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Recently, many research investigations have been devoted to improving the reliability of power electronic converter systems by minimizing DC-link capacitance, so that small capacitors of long lifetime can be used to replace electrolytic capacitors. This chapter gives a review of various techniques, including performance tradeoff, passive approach, and active approach. All of them have their merits and limitations. In particular, the increased circuit complexity might cause efficiency and performance degradation and extra reliability concern. One of the key objectives of this chapter has been to give avenues for further research on a method that can help minimize the use of DC-link capacitance without introducing additional drawbacks.
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7 Wind turbine systems
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This chapter will outline the major power electronic architectures that have been used in WTs and then discuss the reliability of those innovations. This is particularly important for the growing number of offshore WTs, where early information is suggesting that the significant power electronic failure rates are causing increased downtimes because of lengthy mobilisations to clear relatively minor faults.
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8 Active thermal control for improved reliability of power electronics systems
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The thermal stress, especially the thermal cycling in the power semiconductor devices, can be significantly reduced by proper controls, modulations strategies, and the activation of ESSs. The corresponding studies on this topic are still underway with promising opportunities.
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9 Lifetime modeling and prediction of power devices
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Accurate and robust procedures for lifetime modeling are an important prerequisite for the design of reliable power systems. The basic failure mechanisms of siliconbased power semiconductors have been exposed in conjunction with the major stress factors influencing the failure rate. Failure rate metrology procedures have been discussed for the case of a constant failure rate (exponential) and for a failure rate increasing in time (Weibull). The principles behind the most popular handbook-based prediction models have been shortly presented, and the main standards have been benchmarked in the case of a simple device.
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10 Power module lifetime test and state monitoring
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This chapter presents PC method capable to emulate closest field stresses in PMs using full-scale converter. This method could enable to optimize end-of-life investigation of PMs for laboratory test as well as for field applications. A rise in Vce,on and VFD can be used as a precursor parameter to understand aging in PMs in a real time. The presented online voltage monitoring technique is suitable for state of health monitoring as well as to generate alarming signal to make smart decision on power de-rating, operation and maintenance, removal of faulty part to prevent from catastrophic failures, etc.
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11 Stochastic hybrid systems models for performance and reliability analysis of power electronic systems
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Stochastic hybrid systems (SHS) are a class of stochastic processes with a state space composed of a discrete state and a continuous state. The transitions of the discrete state are random, and the rates at which these transitions occur are, in general, a function of the value of the continuous state. For each value that the discrete state takes - referred to subsequently as modes of the system - the evolution of the continuous state is described by a stochastic differential equation. The vector fields that govern the evolution of the continuous state in each mode depend on the operational characteristics of the system in that mode. Reset maps associated with mode transitions define how the discrete and continuous states map into posttransition discrete and continuous states.
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12 Fault-tolerant adjustable speed drive systems
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In this chapter, fault tolerance in adjustable speed drive (ASD) systems is examined in detail. The chapter begins with a study of important factors affecting the reliability of ASDs. Then this chapter examines various power converter configurations employed in ASD systems and their modifications to enhance fault tolerance.
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13 Mission profile-oriented reliability design in wind turbine and photovoltaic systems
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This chapter has discussed the developments and requirements for the power electronics technology in renewable energy systems, where the reliability performance is especially focused. The state-of-the-art converter solutions for wind turbine and PV systems have been presented. Principles, concepts, paradigm shifts, and practical issues about how to achieve more reliable power electronics have been discussed with consideration of mission profile. Case studies on wind turbine and PV systems, which demonstrate how to translate mission profiles into the lifetime of power semiconductor devices, have also been presented. It is concluded that, with the thriving development of renewable energy technology, the reliability of the associated power electronics is getting more and more critical. Consequently, there are many emerging challenges as well as technology opportunities to achieve more reliable power electronics in various applications. It is also worth mentioning that at present reliability calculation and analysis for power electronics are ongoing. Thus, many other issues beyond advancing power semiconductor technology should also be taken into account in the final product.
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14 Reliability of power conversion systems in photovoltaic applications
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A photovoltaic (PV) inverter is a balance-of-systems (i.e., every component except for the module component whose purpose is to control and convert power flow through the PV system). Namely, the inverter transforms the nominal DC power produced by the PV module to AC power, which can be transported through the electrical power grid or used on-site by various power-consuming units (Figure 14.1). As the interface between the DC and AC sides of the system, the inverter must meet rather stringent requirements for both.
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15 Reliability of power supplies for computers
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Many factors can affect the reliability of a computer power supply. It is necessary to establish a consistent methodology to verify the performance of a power supply under different situations during the design stage and manufacturing process to ensure the product's reliability. This chapter will describe the commonly used methods for assuring the reliability of power supplies for computer.
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16 High-power converters
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This chapter presents an introduction to the main applications and some general guidelines for high-power converters. Afterward, new thyristor-based devices are introduced that may be used in future medium-voltage power converters. Following that, a short introduction to high-power inverters and dc-dc converters is given.
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Back Matter
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