Prognostics and health management of power electronics

Prognostics and health management (PHM) is a major tool enabling systems to evaluate their reliability in real-time operation. Despite ground-breaking advances in most engineering and scientific disciplines during the past decades, reliability engineering has not seen significant breakthroughs or noticeable advances. Therefore, self-awareness of the embedded system is also often required in the sense that the system should be able to assess its own health state and failure records, and those of its main components, and take action appropriately. This thesis presents a radically new prognostics approach to reliable system design that will revolutionise complex power electronic systems with robust prognostics capability enhanced Insulated Gate Bipolar Transistors (IGBT) in applications where reliability is significantly challenging and critical. The IGBT is considered as one of the components that is mainly damaged in converters and experiences a number of failure mechanisms, such as bond wire lift off, die attached solder crack, loose gate control voltage, etc. The resulting effects mentioned are complex. For instance, solder crack growth results in increasing the IGBT’s thermal junction which becomes a source of heat turns to wire bond lift off. As a result, the indication of this failure can be seen often in increasing on-state resistance relating to the voltage drop between on-state collector-emitter. On the other hand, hot carrier injection is increased due to electrical stress. Additionally, IGBTs are components that mainly work under high stress, temperature and power consumptions due to the higher range of load that these devices need to switch. This accelerates the degradation mechanism in the power switches in discrete fashion till reaches failure state which fail after several hundred cycles. To this end, exploiting failure mechanism knowledge of IGBTs and identifying failure parameter indication are background information of developing failure model and prognostics algorithm to calculate remaining useful life (RUL) along with ±10% confidence bounds. A number of various prognostics models have been developed for forecasting time to failure of IGBTs and the performance of the presented estimation models has been evaluated based on two different evaluation metrics. The results show significant improvement in health monitoring capability for power switches.Furthermore, the reliability of the power switch was calculated and conducted to fully describe health state of the converter and reconfigure the control parameter using adaptive algorithm under degradation and load mission limitation. As a result, the life expectancy of devices has been increased. These all allow condition-monitoring facilities to minimise stress levels and predict future failure which greatly reduces the likelihood of power switch failures in the first place

Robust condition monitoring for modern power conversion

The entire US electrical grid contains assets valued at approximately $800 billion, and many of these assets are nearing the end of their design lifetimes. In addition, there is a growing dependence upon power electronics in mission-critical assets (i.e. for drives in power plants and naval ships, wind farms, and within the oil and natural-gas industries). These assets must be monitored. Diagnostic algorithms have been developed to use certain key performance indicators (KPI) to detect incipient failures in electric machines and drives. This work was designed to be operated in real-time on operational machines and drives. For example the technique can detect impending failures in both mechanical and electrical components of a motor as well as semiconductor switches in power electronic drives. When monitoring power electronic drives, one is typically interested in the failure of power semiconductors and capacitors. To detect incipient faults in IGBTs, for instance, one must be able to track KPIs such as the on-state voltage and gate charge. This is particularly challenging in drives where one must measure voltages on the order of one or two volts in the presence of significant EMI. Sensing techniques have been developed to allow these signals to be reliably acquired and transmitted to the controller. This dissertation proposes a conservative approach for condition monitoring that uses communications and cloud-based analytics for condition monitoring of power conversion assets. Some of the potential benefits include lifetime extension of assets, improved efficiency and controllability, and reductions in operating costs especially with remotely located equipment

Prognostics of Insulated Gate Bipolar Transistors

Insulated gate bipolar transistors (IGBTs) are the devices of choice for medium and high power, low frequency applications. IGBTs have been reported to fail under excessive electrical and thermal stresses in variable speed drives and are considered as reliability problems in wind turbines, inverters in hybrid electric vehicles and railway traction motors. There is a need to develop methods to detect anomalous behavior and predict the remaining useful life (RUL) of IGBTs to prevent system downtime and costly failures. In this study, a framework for prognostics of IGBTs was developed to provide early warnings of failure and predict the remaining useful life. The prognostic framework was implemented on non punch through (NPT) IGBTs. Power cycling of IGBTs was performed and the gate-emitter voltage, collector-emitter voltage, collector-emitter current and case temperature was monitored in-situ during aging. The on-state collector-emitter current (ICE(ON)) and collector-emitter voltage (VCE(ON)) were identified as precursors to IGBT failure. Electrical characterization and X-ray analysis was performed before and after aging to map degradation in the devices to observed trends in the precursor parameters. A Mahalanobis distance based approach was used for anomaly detection. The initial ICE(ON) and VCE(ON) parameters were used to compute the healthy MD distance. This healthy MD distance was transformed and the mean and standard deviation of the transformed MD data was obtained. The μ+3σ upper bound obtained from the transformed healthy MD was then used as a threshold for anomaly detection. This approach was able to detect anomalous behavior in IGBTs before failure. Upon anomaly detection, a particle filter approach was used for predicting the remaining useful life of the IGBTs. A system model was developed using the degradation trend of the VCE(ON) parameter. This model was obtained by a least squares regression of the IGBT degradation curve. The tracking and prediction performance of the model with the particle filter was demonstrated

Application of coupled electro-thermal and physics-of-failure-based analysis to the design of accelerated life tests for power modules

In the reliability theme a central activity is to investigate, characterize and understand the contributory wear-out and overstress mechanisms to meet through-life reliability targets. For power modules, it is critical to understand the response of typical wear-out mechanisms, for example wire-bond lifting and solder degradation, to in-service environmental and load-induced thermal cycling. This paper presents the use of a reduced-order thermal model coupled with physics-of-failure-based life models to quantify the wear-out rates and life consumption for the dominant failure mechanisms under prospective in-service and qualification test conditions. When applied in the design of accelerated life and qualification tests it can be used to design tests that separate the failure mechanisms (e.g. wire-bond and substrate-solder) and provide predictions of conditions that yield a minimum elapsed test time. The combined approach provides a useful tool for reliability assessment and estimation of remaining useful life which can be used at the design stage or in-service. An example case study shows that it is possible to determine the actual power cycling frequency for which failure occurs in the shortest elapsed time. The results demonstrate that bond-wire degradation is the dominant failure mechanism for all power cycling conditions whereas substrate-solder failure dominates for externally applied (ambient or passive) thermal cycling

Variable selection for wind turbine condition monitoring and fault detection system

With the fast growth in wind energy, the performance and reliability of the wind power generation system has become a major issue in order to achieve cost-effective generation. Integration of condition monitoring system (CMS) in the wind turbine has been considered as the most viable solution, which enhances maintenance scheduling and achieving a more reliable system. However, for an effective CMS, large number of sensors and high sampling frequency are required, resulting in a large amount of data to be generated. This has become a burden for the CMS and the fault detection system. This thesis focuses on the development of variable selection algorithm, such that the dimensionality of the monitoring data can be reduced, while useful information in relation to the later fault diagnosis and prognosis is preserved. The research started with a background and review of the current status of CMS in wind energy. Then, simulation of the wind turbine systems is carried out in order to generate useful monitoring data, including both healthy and faulty conditions. Variable selection algorithms based on multivariate principal component analysis are proposed at the system level. The proposed method is then further extended by introducing additional criterion during the selection process, where the retained variables are targeted to a specific fault. Further analyses of the retained variables are carried out, and it has shown that fault features are present in the dataset with reduced dimensionality. Two detection algorithms are then proposed utilising the datasets obtained from the selection algorithm. The algorithms allow accurate detection, identification and severity estimation of anomalies from simulation data and supervisory control and data acquisition data from an operational wind farm. Finally an experimental wind turbine test rig is designed and constructed. Experimental monitoring data under healthy and faulty conditions is obtained to further validate the proposed detection algorithms

Effect of water on electrical properties of Refined, Bleached, and Deodorized Palm Oil (RBDPO) as electrical insulating material

This paper describes the properties of refined, bleached, deodorized palm oil (RBDPO) as having the potential to be used as insulating liquid. There are several important properties such as electrical breakdown, dielectric dissipation factor, specific gravity, flash point, viscosity and pour point of RBDPO that was measured and compared to commercial mineral oil which is largely in current use as insulating liquid in power transformers. Experimental results of the electrical properties revealed that the average breakdown voltage of the RBDPO sample, without the addition of water at room temperature, is 13.368 kV. The result also revealed that due to effect of water, the breakdown voltage is lower than that of commercial mineral oil (Hyrax). However, the flash point and the pour point of RBDPO is very high compared to mineral oil thus giving it advantageous possibility to be used safely as insulating liquid. The results showed that RBDPO is greatly influenced by water, causing the breakdown voltage to decrease and the dissipation factor to increase; this is attributable to the high amounts of dissolved water

PV System Design and Performance

Photovoltaic solar energy technology (PV) has been developing rapidly in the past decades, leading to a multi-billion-dollar global market. It is of paramount importance that PV systems function properly, which requires the generation of expected energy both for small-scale systems that consist of a few solar modules and for very large-scale systems containing millions of modules. This book increases the understanding of the issues relevant to PV system design and correlated performance; moreover, it contains research from scholars across the globe in the fields of data analysis and data mapping for the optimal performance of PV systems, faults analysis, various causes for energy loss, and design and integration issues. The chapters in this book demonstrate the importance of designing and properly monitoring photovoltaic systems in the field in order to ensure continued good performance