IGBT Modules Research Articles

EVALUATING THE POSSIBILITY OF APPLYING CONTROLLED COMPENSATION SYSTEMS TO IMPROVE EFFICIENCY IN ELECTRIC GRIDS

The paper considers issues of increasing efficiency of multilevel power converter based on IGCT and IGBT modules to improve energy performance by compensating reactive power in electric networks. By the example of a local power grid using SEMIS SimulationTool design tool the results of calculations of variants of multilevel converters with IGCT and IGBT are presented. The study of possibilities to increase the efficiency of multilevel power converters (MPE) for reactive power compensation (RPC) in local electrical networks (LES) on the basis of plenipotentiary controlled semiconductor cells is of particular interest, because the efficiency of network operation is insufficient, especially in changing load modes with large electric power losses (PEM). And from these positions, one of the most effective tools are fast controlled (PFC) systems. For this purpose, research has been carried out to obtain the best results. Used in calculations tool and methodology are certified software products and algorithms of ABB-SEMIS Simulation Tool computer design.

Arm cortex M4 microprocessors based ± 100 kVAR energy quality regulator for reactive power/neutral current compensation, load balancing and harmonic mitigation

In this work, the design and implementation of a three-phase ± 100 kVAR energy quality regulator (EQR) which is capable of providing reactive power/neutral current compensation, load balancing as well as low order current harmonic mitigation is presented. The proposed EQR is based on three-leg four-wire voltage source converter topology with split capacitors in the DC link. At first, the power stage and the control system of the EQR are modelled and verified in PSCAD/EMTDC by extracting the compensation reference currents in synchronous reference frame. After that, the hardware of the EQR based on naturel air forced IGBT modules switching at 5 kHz is developed and practically implemented. The developed EQR control card is based on two Arm Cortex-M4 microprocessors © which handles all control and protection functions. Closed loop operation of the EQR is ensured with P, PI and PR type controllers due to their simplicity and reliability in practical applications. The field tests in a 50 Hz live distribution circuit are carried out by connecting the EQR to the low voltage side of a three-phase 34.5/0.4 kV 400 kVA distribution transformer. It is verified by real-time measurements that the EQR is able to perform the aforementioned compensation functions simultaneously.

Numerical analysis of heat dissipation performance of heat sink for IGBT module depending on serpentine channel shape

Numerical analysis of heat dissipation performance of heat sink for IGBT module depending on serpentine channel shape

The three-level inverter topologies analysis for application by electric centrifugal pump units

In the article, the schemes for providing AC power with frequency conversion for the induction submersible electric drive of oil production units are analyzed. The electric submersible drive is widely used and has stringent efficiency requirements, so this research is relevant. The centrifugal pump units are composed of a low-voltage power source, a frequency converter, a step-up transformer, a cable line, an electric drive and a centrifugal pump. This article discusses options for replacing the step-up transformer and two-level voltage / frequency converter with a three-level flying capacitor converter (FCC) or a three-level clamping diode converter (NPC). The expected states of the power high voltage IGBT modules are described. The waveforms of the inverter output voltage and the submersible induction motor stator voltage in different circuits are shown. A voltage levels analysis for each module is done, the electric drive starting time change is estimated, the total harmonic distortions (THD) are calculated, and a 1.1% THD reduction by applying the NPC circuit is shown. The harmonic current spectrum for each circuit is presented.

Non-destructive peak junction temperature measurement of double-chip IGBT modules with temperature inhomogeneity

Considering the problem of measuring the peak junction temperature of a double-chip module with temperature inhomogeneity, we use a double-chip parallel model to analyze peak junction temperature measurement error for the traditional electrical method. An improved test method is proposed that is based on the small current–voltage drop method—specifically the dual current test method employing an extended-dimension calibration curve library. This method realizes a match of the calibration current with the test current by expanding the dimension database, eliminates errors of temperature measurements, and finally obtains the peak junction temperature of the module. The measurement result is close to the set temperature of the model, thereby verifying its accuracy.

A lifetime extension strategy to increase the reliability of PFC in Co-phase TPSS

Co-phase traction power supply system (TPSS) is proposed to solve the problems of neutral section and power quality in electrical railways. As the key component of co-phase TPSS, the lifetime of the power flow controller (PFC) largely relies on the power module (PM)’s reliability. The PMs’ lifetime is affected by junction temperature, including average temperature and temperature fluctuation. In this paper, a lifetime extension strategy is presented for junction temperature management, which combines switching frequency conversion with modulation changes. Firstly, in the low-load area, switching frequency conversion is utilized to minimize temperature fluctuation; in the high-load area, an optimized single-phase space vector pulse width modulation (SVPWM) is introduced to reduce the average temperature. Secondly, the particle swarm optimization with constriction factor is applied to solve the load partition point, as well as optimize switching frequency for PFC. Finally, the validity of the proposed lifetime extension strategy is verified by case studies, the result is shown that the failure rate of IGBT module can be reduced by 39.01% and the mean time to failure (MTTF) of the PFC is prolonged by 16.28%. The optimization algorithm can effectively improve the reliability of PFC.

Evaluation of IGBT Module Remaining Lifetime in Wind Power Converters Considering Impacts of Failure Location

Operational and health management for the reliability of power electronic converters requires sensitive condition monitoring and accurate estimation of the remaining lifetime. This study adds to the second aspect by examining the effects of failure locations on junction temperature profiles under different conditions. It is found that die-attach solder fatigue and direct bonding copper (DBC) solder fatigue, which occur frequently during the serving time, have different effects on thermal loads. This article investigates the dependence of thermal stress effects on failure locations and output electrical frequencies using finite-element models and proposes an updated strategy for the Cauer-type thermal model according to the failure location. Experimental results validate the proposed model. The remaining lifetime of the doubly fed induction generator converter is calculated under different health conditions and failure locations using a modified lifetime model. This article is intended for the health management of converter systems and is supposed to be in service reliably.

Rectangular current pulse generator to test varistors with pulsed electrical load

A brand-new circuit of a rectangular pulse current generator is presented. As a rule, generators consisting of 6-10 LC cells connected in series are used to obtain rectangular current pulses. Such units are very cumbersome and complicated in the selection of element parameters and adjustment, so a new scheme of pulse current generator was proposed. The main difference from the classical circuit is the method of generating a rectangular current pulse, i.e. by adding the currents from two parallel circuits connected to the load. The first circuit at discharge generates an aperiodic current pulse, the second generates an oscillatory current pulse. The total current pulse flowing through varistor has constant amplitude for some time. In a specified period of time, while the current pulse has a constant amplitude, there is an interruption of current with the help of a switching device. The given circuit solution is possible to implement when using fundamentally new switching devices of the IGBT module. A connection diagram of a pulse current generator for testing varistors with a classification voltage to 1200 V with adjustable pulse duration of 50, 1000, 2000 µs is proposed. The parameters of the generator circuit elements are determined. The measures aimed at suppression of overvoltages arising at break of current in circuits with high inductance as well as the tests confirming the operability of the designed circuit are carried out.

Design and Control of a Three-Phase T-Type Inverter using Reverse-Blocking IGBTs

This paper proposes the design and implementation of a 15kW three-phase T-type inverter. Fuji Electric's new generation IGBT module (V series) using RB-IGBT technology is applied for the converter, due to its higher efficiency from conventional IGBTs to reduce switching losses on the semiconductors. Under full load conditions, the overall efficiency of the converter can reach over 98%. The control design and sine PWM modulation are implemented on a DSP kit named TMS320F3F28379D. In addition, the PWM is generated with the fundamental and third harmonics of a sin wave, allowing a modulation factor up to 1,154 compared to traditional PWM. The output voltage of 220V/50Hz with less than 2% of THD can be achieved at the minimum input DC voltage of 550V.

A Finite Element Analysis on the Reliability of Heavy Bonding Wire for High-Power IGBT Module

Several methods that could effectively increase the strength of heavy aluminum bonding wire and broaden the scope for high-power IGBT module applications with a high degree of integration have been proposed. In this work, a series of finite element analysis has been carried out to study the thermomechanical reliability of bonding wire/ribbon under different conditions. The effects of structural loop parameters, bonding wire materials, bonding ribbon, and polymer coating are discussed based on simulation results, and the primary cause for the effect of geometric parameters has been developed. It is worth noticing that the reliability of the heavy bonding wires increases with the increase in Young's modulus and Poisson's rate in a polymer coating. This present study provides new insights into the thermomechanical behaviors of heavy bonding wire/ribbon, as well as a practical guide for designing an optimal structural loop shape and selecting an appropriate material of bonding wires or polymer, which will accelerate functional applications in industries.

리튬이온전지를 사용하는 ESS에서 CMV 및 누설전류의 발생원인과 저감방법에 관한 연구

ESS(Energy Storage Systems) using lithium ion battery are rapidly increasing their capacity because they can efficiently store electrical energy in a small area with high energy density. However, 29 fire accidents have been reported in Korea for last 4 years. Up to now, the root cause of ESS fire has not been clearly defined, but some lithium ion battery manufacturer assert that the reason of fire may be caused by CMV(Common Mode Voltage) and leakage current. This study investigated the mechanism, measuring, acceptable level, and mitigation of CMV and leakage current through experimental field analysis with its corresponding simulation. The stray capacitance of IGBT module and lithium-ion battery are investigated as the cause of CMV and leakage current, and the magnitude variation of CMV and leakage current by the type of system earthing of the AC side is investigated too, then this paper suggested the use of an isolation transformer as a mitigation method. In addition, it was analyzed how the use of an isolation transformer can reduce CMV and this study proved that the installation of an isolation transformer is a complete and fundamental solution to reduce both CMV and leakage current by simulation and field measurement results. On the other hand, this study found the shape and period of the waveform of CMV and leakage current are completely identical, and prove that these two are produced by the same cause and the leakage current was also demonstrated to be lowered when the CMV was lowered. On the other hand, based on the analyzing the path of the leakage current flow in the grounded system and the non-ground systems, this study found that it was reasonable to measure CMV and leakage current on the DC side of PCS, and this was proved by P-Sim simulation and field experiments.

Modelling the conduction mechanisms in low density polyethylene material using finite element method

Polymers used as insulating materials are increasingly popular in many different fields. In electrical engineering - electronics, polymers are used in high-voltage transmission cables, capacitors, transformers, or as part of an embedded system in the IGBT module thanks to its superior thermal and electrical insulation properties. One of the disadvantages of polymers is the possible accumulation of space charge in the material volume for a long time, leading to an increase in the electric field compared to the original design value. Charge transport models in polymer materials have been increasingly developed to predict the conduction mechanisms under thermal-electrical stress. In this study, from a finite volume method (FVM), the authors developed a charge transport model in low density polyethylene (LDPE) based on the finite element method (FEM). The simulation results of this model are also compared to experimental results and to the FVM model under different electric fields for LDPE.

A Review on IGBT Module Failure Modes and Lifetime Testing

This article focuses on failure modes and lifetime testing of IGBT modules being one of the most vulnerable components in power electronic converters. IGBT modules have already located themselves in the heart of many critical applications, such as automotive, aerospace, transportation, and energy. They are required to work under harsh operational and environmental conditions for extended target lifetime that may reach 30 to 40 years in some applications. Therefore, addressing the reliability of IGBT modules is of paramount importance. The paper provides a comprehensive review on IGBT modules dominant failure modes, and long-term reliability. A detailed discussion on accelerated testing, and lifetime and degradation characterization considering thermo-mechanical stress is also presented in details.

Comparison between the influence of mechanical vibration and junction temperature rise originated bond wires detachment on the characteristics of IGBT module

As the main device in a power system, the IGBT module works in the frequent power cycle for a long time, resulting to the fluctuation of junction temperature and heavy mechanical stress loading. These two factors threaten the reliability of bond wires and the IGBT module significantly. This study aimed at improving the reliability of the semiconductor device. IGBT dual bridge module was used as the primary research object, establishing the relationship between the bond wires detachment and resistance. MATLAB was used for mathematical analysis to determine the quantitative influence of the two conditions on several static characteristics of the IGBT module. Our study provides more samples and references to monitoring the IGBT bond wires and demonstrates the difference and similarity of these two factors.

Lifetime Estimation of Grid-Connected Battery Storage and Power Electronics Inverter Providing Primary Frequency Regulation

Battery Energy Storage Systems (BESSs) are a new asset for Primary Frequency Regulation (PFR), an ancillary service for improving the grid stability. The system operators determine the implementation and remuneration of PFR. However, assessing the revenue stream is not enough to define the business case, as also the components' lifetime has to be estimated. Previous studies of lifetime estimation for BESSs performing PFR considered only the electrochemical storage, disregarding the power electronics (PE). Nonetheless, researchers have shown the importance of estimating PE wear due to the operation when applied in renewable energy generation and microgrids. This paper presents a lifetime analysis of BESSs providing PFR considering IGBT modules, electrolytic capacitors and electrochemical storage degradation. The lifetime information is used to estimate BESS's Net-Present-Value (NPV), evaluating the benefits of deploying PE-based BESS in the European grid. A comparison between different countries, Germany, the Netherlands, and the U.K., is performed, considering the PFR implementation and remuneration differences. The analysis shows that the BESS management strategy can extend its lifetime and that the component that exhibits the shortest lifetime is the electrochemical storage. The PE components are subject to low wear due to the low power utilization and, therefore, small thermal swings while performing PFR. In conclusion, the provision of PFR by means of BESS has been found to be profitable in all three countries. However, in the Netherlands, the potential NPV has been estimated to be 47% and 76% higher than in Germany and the U.K., respectively.

A Single Channel IGBT Gate Drivers for Medium Voltage Converters

This article treats the gate driver system for IGBT modules in Medium-Voltage (MV) applications. The study focuses principally on two functions of an IGBT gate driver: an impulse signal transmission and a power transmission. For each function, the suitable topology is proposed. Then, for safety and device's protection reason, all gate driver functions must sustain the high and very high galvanic insulation voltage capabilities. For low-cost design, the insulation system can be achieved with the help of the insulating material in a pot core planar transformer. Therefore, for each function, the optimized design of a pot-core transformer and its associated electronics components is performed with the help of a virtual prototyping tool (a genetic algorithm: GA code in MATLAB<SUP>TM</SUP>). The first section focuses on optimization design of a selected topology for an impulse signal transmission function. A bi-objective (maximize the output voltage v_out and minimize the input current i_mos) problem of this function that leads to a Pareto front is presented. Several Pareto fronts’ results are obtained assuming different insulation layers thickness. The second part focuses on optimization design of a selected topology for a power transmission function. Maximize the converter efficiency (η_con) and minimize the output power (P_out) are considered as a bi-objective. Thus, numerous Pareto fronts’ results are achieved for a few different insulation thicknesses. Finally, the prototype of a single channel IGBT gate driver is invented to validate the proposed design.

АНАЛИЗ НАДЕЖНОСТНОГО СОСТОЯНИЯ СИЛОВОЙ ЭЛЕКТРОНИКИ ПУТЕМ КОНТРОЛЯ ТЕПЛОЭЛЕКТИЧЕСКИХ ПАРАМЕТРОВ

The article discusses an approach to creating a simulation mathematical model of the operation of power IGBT modules for the subsequent analysis of data used to assess the operational state and determine the residual life. Methods for calculating the main controlled parameters are presented, modes of operation of IGBT devices as part of converter equipment are considered.

A real-time aging monitoring method of parallel-connected IGBT modules

A parallel connection of electronic devices in the energy system is currently the only and the most effective way to expand the power capacity. For a circuit containing loads, a minor change of the conduction resistance of electronic devices is not suitable for measurement, but for each parallel branch, its change will be more obvious through current distribution. In this paper, we proposed a current-based method for condition monitoring of the aging process of the electronic modules. The aging information on the package is analyzed and calculated to quantifiable convert to its conduction resistance and then to the current distribution of each branch. By detecting and comparing the value of the current, the aging process can be monitored in real-time. The proposed method has the advantages of low cost and easy implementation. More in detail, it does not need for multi-point monitoring of case temperature, or complicated circuit design for minor changes in voltage monitoring. Finally, the accuracy of the proposed method is validated by simulations and experimental results show a good agreement. Index TermsIGBT, Condition monitoring, Aging process, Parallel connection.

High Power Wireless Power Transfer with Inductive Coupling

This paper describes the design of a high power wireless power transfer with a coupled series resonant circuit. Coils distance is 600 mm and a nominal power is 20 kW. The transfer is provided by the inductive coupling of the resonant circuit with 800 mm diameter coils. The resonant circuit is powered by an inverter with IGBT modules working on frequency 130 kHz. The functionality of the realized device is verified by measurements, the evaluation of which is at the end of the article.

Power Electronics Reliability: State of the Art and Outlook

This article aims to provide an update of the reliability aspects of research on power electronic components and hardware systems. It introduces the latest advances in the understanding of failure mechanisms, testing methods, accumulated damage modeling, and mission-profile-based reliability prediction. Component-level examples (e.g., Si IGBT modules, SiC MOSFETs, GaN devices, capacitors, and magnetic components) are used for illustration purposes in addition to system-level studies. The limitations and associated open questions are discussed to identify future research opportunities in power electronics reliability.