Comparison of counting algorithms and empiric lifetime models to analyze the load-profile of an IGBT power module in a hybrid car

Denk, Marco; Bakran, Mark-M.

doi:10.1109/edpc.2013.6689758

Cited by 12 publications

(9 citation statements)

References 6 publications

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“…Their valuing as half temperature cycles leads to a reduced operational lifetime consumption compared to the Rainflow algorithm [6]. This applies equally to the passive cycles.…”

Section: Substitutability Of the Rainflow Methodmentioning

confidence: 99%

“…In the following investigations it should be analyzed whether the Rainflow method can be substituted with an easy to implement halfcycle or maximum-edge algorithm [6]. For this purpose the capability of the three algorithms to convert the presented load-profile into a distribution of defined temperature cycles is investigated.…”

Section: Substitutability Of the Rainflow Methodmentioning

confidence: 99%

“…In view of the state of the art the lifetime calculation on the basis of the presented load-profile demands the storage of each cycle with its amplitude Δ , its minimum temperature ,min , and its heating time on [6]. To store the calculated temperature cycles on the system controller with a minimum storage capacity a four-dimensional frequency distribution should be used [7].…”

Section: Temperature Cycle Storagementioning

confidence: 99%

“…The recorded load history of test vehicles or first field returns can be used to create an experience base and to optimize the load-profiles and the lifetime calculation approach of IGBT power modules. This paper shows new results of the IGBT driver and the recording algorithm and combines it with the results of the following publications [5][6][7]. In the following the state-of-the-art approach to calculate the lifetime of an IGBT power module is briefly summarized.…”

Section: Introductionmentioning

confidence: 99%

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Online Junction Temperature Cycle Recording of an IGBT Power Module in a Hybrid Car

Denk

Bakran

2015

Advances in Power Electronics

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The accuracy of the lifetime calculation approach of IGBT power modules used in hybrid-electric powertrains suffers greatly from the inaccurate knowledge of application typical load-profiles. To verify the theoretical load-profiles with data from the field this paper presents a concept to record all junction temperature cycles of an IGBT power module during its operation in a test vehicle. For this purpose the IGBT junction temperature is measured with a modified gate driver that determines the temperature sensitive IGBT internal gate resistor by superimposing the negative gate voltage with a high-frequency identification signal. An integrated control unit manages the measurement during the regular switching operation, the exchange of data with the system controller, and the automatic calibration of the sensor system. To calculate and store temperature cycles on a microcontroller an online Rainflow counting algorithm was developed. The special feature of this algorithm is a very accurate extraction of lifetime relevant information with a significantly reduced calculation and storage effort. Until now the recording concept could be realized and tested within a laboratory voltage source inverter. Currently the IGBT driver with integrated junction temperature measurement and the online cycle recording algorithm is integrated in the voltage source inverter of first test vehicles. Such research will provide representative load-profiles to verify and optimize the theoretical load-profiles used in today's lifetime calculation.

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“…Their valuing as half temperature cycles leads to a reduced operational lifetime consumption compared to the Rainflow algorithm [6]. This applies equally to the passive cycles.…”

Section: Substitutability Of the Rainflow Methodmentioning

confidence: 99%

Section: Substitutability Of the Rainflow Methodmentioning

confidence: 99%

Section: Temperature Cycle Storagementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Online Junction Temperature Cycle Recording of an IGBT Power Module in a Hybrid Car

Denk

Bakran

2015

Advances in Power Electronics

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“…The rest lifetime of semiconductor devices and converters can only be estimated by a model that takes into account the load profile, current status, and the mission profile [3][4][5][6][7]. Moreover, the traditional lifetime model cannot calculate online the rest lifetime.…”

Section: Introductionmentioning

confidence: 99%

Study on lifetime prediction considering fatigue accumulative effect for die‐attach solder layer in an IGBT module

Lai

Chen

et al. 2018

IEEJ Transactions Elec Engng

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An accurate lifetime model is needed in power electronic systems as a cost-effective means of improving reliability and performance assessment, which have long been highly desired to reduce the maintenance cost and to make the product more competitive in the market. Die-attach solder layer fatigue has been identified as one of the root causes of failure of power electronic modules. This paper presents "physics-of-failure lifetime model", which takes fatigue accumulative effect into consideration and can quantify the effect of long-term small-temperature cycling to device fatigue life cycle to estimate the lifetime of the power module. First, small T j power cycling tests were designed to obtain the effects of T j on aged and un-aged modules. They indicated that the traditional lifetime models were not accurate in predicting the lifetime of power modules. Therefore, a new time-domain crack propagation model based on the cumulative damage in the die-attach solder layer is proposed, which includes time-dependent material properties and temperature profiles. Moreover, power cycling experiments and simulations are conducted to demonstrate the method by comparing the number of cycles to failure.

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Reliability Oriented Design of Dual Active Bridge Converter for Power Supply on Heavy-Vehicles

Shah

Bhattacharya

2018

2018 IEEE Energy Conversion Congress and Exposition (ECCE)

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Comparison of counting algorithms and empiric lifetime models to analyze the load-profile of an IGBT power module in a hybrid car

Cited by 12 publications

References 6 publications

Online Junction Temperature Cycle Recording of an IGBT Power Module in a Hybrid Car

Online Junction Temperature Cycle Recording of an IGBT Power Module in a Hybrid Car

Study on lifetime prediction considering fatigue accumulative effect for die‐attach solder layer in an IGBT module

Reliability Oriented Design of Dual Active Bridge Converter for Power Supply on Heavy-Vehicles

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