Reliability of Power Electronic Converter Systems.pdf

Reliability of Power Electronic Converter Systems.pdf

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IETPOWERANDENERGYSERIES80ReliabilityofPowerElectronicConverterSystemsOthervolumesinthisseries:

Volume1PowerCircuitBreakerTheoryandDesignC.H.Flurscheim（Editor）Volume4IndustrialMicrowaveHeatingA.C.MetaxasandR.J.MeredithVolume7InsulatorsforHighVoltagesJ.S.T.LoomsVolume8VariableFrequencyACMotorDriveSystemsD.FinneyVolume10SF6SwitchgearH.M.RyanandG.R.JonesVolume11ConductionandInductionHeatingE.J.DaviesVolume13StatisticalTechniquesforHighVoltageEngineeringW.HauschildandW.MoschVolume14UninterruptiblePowerSuppliesJ.PlattsandJ.D.StAubyn（Editors）Volume15DigitalProtectionforPowerSystemsA.T.JohnsandS.K.SalmanVolume16ElectricityEconomicsandPlanningT.W.BerrieVolume18VacuumSwitchgearA.GreenwoodVolume19ElectricalSafety:

AGuidetoCausesandPreventionofHazardsJ.MaxwellAdamsVolume21ElectricityDistributionNetworkDesign,2ndEditionE.LakerviandE.J.HolmesVolume22ArtificialIntelligenceTechniquesinPowerSystemsK.Warwick,A.O.EkwueandR.Aggarwal（Editors）Volume24PowerSystemCommissioningandMaintenancePracticeK.HarkerVolume25EngineersHandbookofIndustrialMicrowaveHeatingR.J.MeredithVolume26SmallElectricMotorsH.Moczala,J.Draeger,H.Krauss,H.Shock,andS.TillnerVolume27AC-DCPowerSystemAnalysisJ.ArrillagaandB.C.SmithVolume29HighVoltageDirectCurrentTransmission,2ndEditionJ.ArrillagaVolume30FlexibleACTransmissionSystems（FACTS）Y.-H.Song（Editor）Volume31EmbeddedGenerationN.Jenkins,R.Allan,P.Crossley,D.Kirschen,andG.StrbacVolume32HighVoltageEngineeringandTesting,2ndEditionH.M.Ryan（Editor）Volume33OvervoltageProtectionofLow-VoltageSystems,RevisedEditionP.HasseVolume36VoltageQualityinElectricalPowerSystemsJ.Schlabbach,D.Blume,andT.StephanblomeVolume37ElectricalSteelsforRotatingMachinesP.BeckleyVolume38TheElectricCar:

DevelopmentandFutureofBattery,HybridandFuel-CellCarsM.WestbrookVolume39PowerSystemsElectromagneticTransientsSimulationJ.ArrillagaandN.WatsonVolume40AdvancesinHighVoltageEngineeringM.HaddadandD.WarneVolume41ElectricalOperationofElectrostaticPrecipitatorsK.ParkerVolume43ThermalPowerPlantSimulationandControlD.FlynnVolume44EconomicEvaluationofProjectsintheElectricitySupplyIndustryH.KhatibVolume45PropulsionSystemsforHybridVehiclesJ.MillerVolume46DistributionSwitchgearS.StewartVolume47ProtectionofElectricityDistributionNetworks,2ndEditionJ.GersandE.HolmesVolume48WoodPoleOverheadLinesB.WareingVolume49ElectricFuses,3rdEditionA.WrightandG.NewberyVolume50WindPowerIntegration:

ConnectionandSystemOperationalAspectsB.Fox,D.Flynn,L.Bryans,N.Jenkins,D.Milborrow,M.OMalley,R.Watson,andO.Anaya-LaraVolume51ShortCircuitCurrentsJ.SchlabbachVolume52NuclearPowerJ.WoodVolume53ConditionAssessmentofHighVoltageInsulationinPowerSystemEquipmentR.E.JamesandQ.SuVolume55LocalEnergy:

DistributedGenerationofHeatandPowerJ.WoodVolume56ConditionMonitoringofRotatingElectricalMachinesP.Tavner,L.Ran,J.PenmanandH.SeddingVolume57TheControlTechniquesDrivesandControlsHandbook,2ndEditionB.DruryVolume58LightningProtectionV.Cooray（Editor）Volume59UltracapacitorApplicationsJ.M.MillerVolume62LightningElectromagneticsV.CoorayVolume63EnergyStorageforPowerSystems,2ndEditionA.Ter-GazarianVolume65ProtectionofElectricityDistributionNetworks,3rdEditionJ.GersVolume66HighVoltageEngineeringTesting,3rdEditionH.Ryan（Editor）Volume67MulticoreSimulationofPowerSystemTransientsF.M.UriateVolume68DistributionSystemAnalysisandAutomationJ.GersVolume69TheLighteningFlash,2ndEditionV.Cooray（Editor）Volume70EconomicEvaluationofProjectsintheElectricitySupplyIndustry,3rdEditionH.KhatibVolume78NumericalAnalysisofPowerSystemTransientsandDynamicsA.Ametani（Editor）Volume77Wide-AreaMonitoringofInterconnectedPowerSystemsA.R.MessinaVolume79Vehicle-to-Grid:

LinkingElectricVehiclestoTheSmartGridJ.LuandJ.Hossain（Editors）Volume905PowerSystemProtection,4volumesReliabilityofPowerElectronicConverterSystemsEditedbyHenryShu-hungChung,HuaiWang,FredeBlaabjergandMichaelPechtTheInstitutionofEngineeringandTechnologyPublishedbyTheInstitutionofEngineeringandTechnology,London,UnitedKingdomTheInstitutionofEngineeringandTechnologyisregisteredasaCharityinEngland&Wales（no.211014）andScotland（no.SC038698）.TheInstitutionofEngineeringandTechnology2016Firstpublished2015ThispublicationiscopyrightundertheBerneConventionandtheUniversalCopyrightConvention.Allrightsreserved.Apartfromanyfairdealingforthepurposesofresearchorprivatestudy,orcriticismorreview,aspermittedundertheCopyright,DesignsandPatentsAct1988,thispublicationmaybereproduced,storedortransmitted,inanyformorbyanymeans,onlywiththepriorpermissioninwritingofthepublishers,orinthecaseofreprographicreproductioninaccordancewiththetermsoflicencesissuedbytheCopyrightLicensingAgency.Enquiriesconcerningreproductionoutsidethosetermsshouldbesenttothepublisherattheundermentionedaddress:

TheInstitutionofEngineeringandTechnologyMichaelFaradayHouseSixHillsWay,StevenageHerts,SG12AY,UnitedKingdomwww.theiet.orgWhiletheauthorsandpublisherbelievethattheinformationandguidancegiveninthisworkarecorrect,allpartiesmustrelyupontheirownskillandjudgementwhenmakinguseofthem.Neithertheauthorsnorpublisherassumesanyliabilitytoanyoneforanylossordamagecausedbyanyerrororomissioninthework,whethersuchanerrororomissionistheresultofnegligenceoranyothercause.Anyandallsuchliabilityisdisclaimed.ThemoralrightsoftheauthorstobeidentifiedasauthorsofthisworkhavebeenassertedbytheminaccordancewiththeCopyright,DesignsandPatentsAct1988.BritishLibraryCataloguinginPublicationDataAcataloguerecordforthisproductisavailablefromtheBritishLibraryISBN978-1-84919-901-8（hardback）ISBN978-1-84919-902-5（PDF）TypesetinIndiabyMPSLimitedPrintedintheUKbyCPIGroup（UK）Ltd,CroydonContents1Reliabilityengineeringinpowerelectronicconvertersystems11.1Performancefactorsofpowerelectronicsystems11.1.1Powerelectronicconvertersystems11.1.2Designobjectivesforpowerelectronicconverters31.1.3Reliabilityrequirementsintypicalpowerelectronicapplications41.2Reliabilityengineeringinpowerelectronics61.2.1Keytermsandmetricsinreliabilityengineering61.2.2Historicaldevelopmentofpowerelectronicsandreliabilityengineering111.2.3Physicsoffailureofpowerelectroniccomponents151.2.4DFRofpowerelectronicconvertersystems171.2.5Acceleratedtestingconceptsinreliabilityengineering201.2.6Strategiestoimprovethereliabilityofpowerelectronicconvertersystems231.3Challengesandopportunitiesinresearchonpowerelectronicsreliability241.3.1Challengesinpowerelectronicsreliabilityresearch251.3.2Opportunitiesinpowerelectronicsreliabilityresearch25References262Anomalydetectionandremaininglifepredictionforpowerelectronics312.1Introduction312.2Failuremodels322.2.1Time-dependentdielectricbreakdownmodels332.2.2Energy-basedmodels342.2.3Thermalcyclingmodels352.3FMMEAtoidentifyfailuremechanisms362.4Data-drivenmethodsforlifeprediction392.4.1Thevariablereductionmethod402.4.2DefinefailurethresholdbyMahalanobisdistance422.4.3K-nearestneighborclassification462.4.4Remaininglifeestimation-basedparticlefilterparameter482.4.5Data-drivenanomalydetectionandprognosticsforelectroniccircuits512.4.6Canarymethodsforanomalydetectionandprognosticsforelectroniccircuits522.5Summary53Acknowledgements53References533ReliabilityofDC-linkcapacitorsinpowerelectronicconverters593.1CapacitorsforDC-linksinpowerelectronicconverters593.1.1ThetypeofcapacitorsusedforDC-links593.1.2ComparisonofdifferenttypesofcapacitorsforDC-links603.1.3Reliabilitychallengesforcapacitorsinpowerelectronicconverters633.2Failuremechanismsandlifetimemodelsofcapacitors643.2.1Failuremodes,failuremechanisms,andcriticalstressorsofDC-linkcapacitors643.2.2LifetimemodelsofDC-linkcapacitors663.2.3AcceleratedlifetimetestingofDC-linkcapacitorsunderhumidityconditions683.3Reliability-orienteddesignforDClinks693.3.1SixtypesofcapacitiveDC-linkdesignsolutions703.3.2Areliability-orienteddesignprocedureofcapacitiveDC-links723.4ConditionmonitoringofDC-linkcapacitors75References774Reliabilityofpowerelectronicpackaging834.1Introduction834.2Reliabilityconceptsforpowerelectronicpackaging844.3Reliabilitytestingforpowerelectronicpackaging854.3.1Thermalshocktesting864.3.2Temperaturecycling864.3.3Powercyclingtest874.3.4Autoclave884.3.5Gatedielectricreliabilitytest884.3.6Highlyacceleratedstresstest894.3.7High-temperaturestoragelife（HSTL）test894.3.8Burn-intest894.3.9Othertests904.4Powersemiconductorpackageormodulereliability904.4.1Solderjointreliability914.4.2Bondwirereliability914.5Reliabilityofhigh-temperaturepowerelectronicmodules944.5.1Powersubstrate95viReliabilityofpowerelectronicconvertersystems4.5.2High-temperaturedieattachreliability964.5.3Dietopsurfaceelectricalinterconnection974.5.4Encapsulation984.6Summary99Acknowledgements99References995Modellingforthelifetimepredictionofpowersemiconductormodules1035.1Acceleratedcyclingtests1055.2Dominantfailuremechanisms1065.3Lifetimemodelling1085.3.1Thermalmodelling1085.3.2Empiricallifetimemodels1105.3.3Physics-basedlifetimemodels1125.3.4LifetimepredictionbasedonPClifetimemodels1175.4Physics-basedlifetimeestimationofsolderjointswithinpowersemiconductormodules1185.4.1Stressstrain（hysteresis）solderbehaviour1195.4.2Constitutivesolderequations1215.4.3Clechsalgorithm1235.4.4Energy-basedlifetimemodelling1235.5Exampleofphysics-basedlifetimemodel