condition monitoring of igbt power modules · 04.10.2017 · power module e-hine fuel tank k iae 0...
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Condition Monitoring of IGBT Power Modulesby Real-Time Measurement of the IGBT Junction Temperature
Dr.-Ing. Marco Denk
University of BayreuthGraduated in April 2016
Doctoral thesis
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High voltagebattery
Power module E-M
achin
eFuel tank
IAEK0
Power Modules:
Central role in electric & hybrid drivetrains.
Hybrid strategies
Functionality
Efficiency
Reliability
Costs
Electric drivetrain
Motivation
Very uncertain
operating load!
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Advanced IGBT Gate Driver
To bring light into the darkness…
New IGBT Gate Driver:
Real-Time Measurement of IGBT Junction Temperature.
Recording of Load-Histories.
Monitoring of Health-State (Power Module + Cooling Sysytem)
Compact solution for Condition
Monitoring!
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Advanced IGBT Gate Driver
… the on-chip
internal gate resistor
of the IGBT is used as
a temperature sensor.
For Real-Time TJ-Measurement …
… a small identification signal is modulated on the gate voltage.
RGi = f(TJ)UGoff
UG / V
t / µs
UGon
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Advanced IGBT Gate Driver
Modified output
stage
Automatic calibration
function
Simple integrationNew IGBT Gate Driver
New IGBT Gate
Driver
Isolated interface
Target Application
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Advanced IGBT Gate Driver
During start-up … During driving …
Measured with IGBT
Gate Driver
Verification with IR cam
First working sensor system that offers deep insights into the operation of the power module.
Experimental verification
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Online Rainflow-Counting
During longer road-trials …
Temperature-ProfileLoad-History
“Temperature cycles”
Online-Rainflow
AlgorithmCompress data by 99%
Online-Rainflow
Algorithm
“Temperature cycles”
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Cooling-System
DCB-Ceramic
Baseplate
… give information about the health-state.
Health-Monitoring
Health-Monitoring:
Health-Indicator:
Increase of thermal resistances in different material layers.
Power Module
Cooling System
Temperature cycles during start-up …
Power module structure
Health-State
Health-State
SemiconductorChip-solder
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Conclusions
New IGBT Gate Driver
Junction Temperature
Load-History
Active cycles
Passive cycles
Health-State
Power Module
Cooling System
In summary …
In future …
“Early failure detection”
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Dr.-Ing. Marco Denk
University of BayreuthGraduated in April 2016
Thank you for your attention.
ISBN: 978-3-8439-2626-6
Doctoral thesis