Advancing power electronics thermal stress and reliability is a critical factor in power electronics equipment. NREL aims to improve thermal stress and reliability of power electronics technologies

O'Keefe, M. P.

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PEEM Thermal Stress and ReliabilityMichael Patrick O’KeefeEmail: michael_okeefe@nrel.govPhone: 303.275.4268Organization: National Renewable Energy LaboratoryTeam members:  Kevin BennionKen KellySreekant NarumanchiProject Duration:  FY08 to FY10DOE FreedomCAR and Vehicle Technologies ProgramAdvanced Power Electronics and Electric Machines Projects FY08 Kickoff MeetingNational Transportation Research Center Knoxville, TennesseeNovember 8, 2007This presentation does not contain any proprietary or confidential informationNREL-PR-540-42341DOE FreedomCAR APEEM Projects FY08 Kickoff Meeting2The Problem• Fundamental concerns related to PEEM component usage and reliability• Existing methods of addressing reliability are cost and time intensive• For the DOE: Lack of method to quantify 15 year life targetDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting3Description of Technology• Flexible reliability modeling tool(s) for automotive power electronics• Allow life/ reliability to be addressed earlier in the design phaseTODAYFUTUREAnalysis Development Validationdevelopment timecosteffortDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting4Uniqueness of Project and Impacts• Develop critical areas not being addressed• Integrate, leverage, and coordinate– testing at ORNL, ANL, and INL– thermal modeling at NREL– physics of failure experts– knowledge from automotive OEMs and suppliers• Impacts– Assess 15 year life target for DOE R&D– Empower designers and integrators to address life/ reliability earlier in the design cycleDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting5Accomplishments to Date(for projects funded in prior FYs)• Project discussions initiated in FY07• Discussion of project with industry ongoing• Thermal system models builtTemperatures HeatGenerationMG2 Shaft Torque and SpeedVehicle TestData PSATPriusModelORNL Inverter Loss Map?Reliability?DOE FreedomCAR APEEM Projects FY08 Kickoff Meeting6Reynell, M. 1990Source: U.S. Air Force Avionics Integrity Program• Develop a computer tool that can be used by industry and DOE program to predict reliability of PEEM components• Use the tool to assess one aspect of the life target for an APEEM projectMAJOR CAUSES OF ELECTRONIC FAILURES(note: not POWER electronics)Project Objective for FY08DOE FreedomCAR APEEM Projects FY08 Kickoff Meeting7Technical Approach for FY08• Develop detailed plan of action for project (03/2007)• Milestone: submit report on project plan (06/2007)• Integrate one working model into the tool suite (09/2008)DOE FreedomCAR APEEM Projects FY08 Kickoff Meeting8Vision for Reliability ToolSilicon chipSolderDirect Bond CopperCu, AlN, CuThermal greaseBase plate, heat sinkPin finsCoolantflowQ  heat User specifies heat input, loadingsmaterials and architectureDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting9Thermal models can map loads to stressorsThermal Loading(HEAT GENERATION)Design Information(Geometry & Materials)STRESSORSTemperatures, Stresses, StrainsFEA orFast NetworkModelDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting10Failure ModesLife is predicted with physics of failure modelsLife PredictionModel Based on Physics of Failurephysics of failure identifying & understand physical process of failureSTRESSORSTemperatures, Stresses, StrainsDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting11Timeline2007Oct Nov Dec2008Jan Feb Mar Apr May Jun Jul Aug SepIDENTIFY AREA TOADDRESS BUILD FIRST TOOLMILESTONE:RESEARCH PLANDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting12The Challenges/Barriers• Integration and coordination of various engineering software tools• Validation of models (availability of data)• Complexity of problem• Validation of predictionsDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting13Beyond FY08• FY09– Application of tool to APEEM program– Expansion of tool to cover more areas– Validation activities• FY10– Finish validation and development activitiesDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting14Summary• Develop Automotive PEEM Reliability Tool• Process:– Starting slow– Create a working example early on– Adjust as we go– Identify opportunities to validate– Review progress periodically with DOE and National Laboratory team, OEMs, suppliers and other stake holdersDOE FreedomCAR APEEM Projects FY08 Kickoff Meeting15?

PEEM Thermal Stress and Reliability

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PEEM Thermal Stress and Reliability

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