Query: Thermo-fluid simulation for the thermal design of the IGBT module in the power convers on system

Candidate papers:

abstract: Abstract The junction temperature of the insulated gate bipolar transistor (IGBT) module, which belongs to power semiconductor devices, directly impacts on the system performance of the power conversion system (PCS) and therefore, the accurate prediction of the airflow rate passing the heat sink block of the IGBT module is very important at the thermal design stage. In this paper, the thermo fluid simulation was developed with the T Q characteristic curve to predict the junction temperature of the IGBT module and the airflow rate of the heat sink block. The porous media model was adopted in the heat sink block with fins and the filled air between fins of the heat sink block in the PCS to remove the heavily concentrated mesh problems in the heat sink block. The proposed simulation model was compared to the experimental value for the hot spot temperature on the heat sink block and the differences were within the average 4.0% margin of error in the comparison. This simulation model can be used to evaluate the suitability of the cooling design according to various operating conditions of the fan and IGBT module with benefits of the reduction in the mesh generation and the computation time. Also, this simulation model increases the flexibility of predicting the airflow rates in the PCS due to the change of the airflow passage structure in the PCS or the capacity of the fan.
author_names: Chang-Woo Han

Seung-Boong Jeong

Myung-Do Oh
title: Thermo fluid simulation for the thermal design of the IGBT module in the power conversion system
venue: Microelectron. Reliab.
year: 2016

abstract: As an increasing attention towards sustainable development of energy and environment, the power electronics (PEs) are gaining more and more attraction on various energy systems. The insulated gate bipolar transistor (IGBT) as one of the PEs with numerous advantages and potentials for development of higher voltage and current ratings, has been used in a board range of applications. However, the continuing miniaturization and rapid increasing power ratings of IGBTs have remarkable high heat flux, which requires complex thermal management. In this paper, studies of the thermal management on IGBTs are generally reviewed including analyzing, comparing, and classifying the results originating from these researches. The thermal models to accurately calculate the dynamic heat dissipation are divided into analytical models, numerical models, and thermal network models, respectively. The thermal resistances of current IGBT modules are also studied. According to the current products on a number of IGBTs, we observe that the junction to case thermal resistance generally decreases inversely in terms of the total thermal power. In addition, the cooling solutions of IGBTs are reviewed and the performance of the various solutions are studied and compared. At last, we have proposed a quick and efficient evaluation judgment for the thermal management of the IGBTs depended on the requirements on the junction to case thermal resistance and equivalent heat transfer coefficient of the test samples.
author_names: Cheng Qian

Amir Mirza Gheitaghy

Jiajie Fan

Hongyu Tang

Bo Sun

Huaiyu Ye

Guoqi Zhang
title: Thermal Management on IGBT Power Electronic Devices and Modules
venue: IEEE Access
year: 2018

abstract: The wind power industry has expanded greatly during the past few years, has served a growing market, and has spawned the development of larger wind turbines. Different designs and technical advances now make it possible to erect wind turbines offshore. The fast expansion of the wind power market faces some problems. The new designs are not always fully tested, and the designed 20 year lifetime is typically never achieved before the next generation of turbines are erected. This paper presents results from an investigation of failure statistics from four sources, i.e. two separate sources from Sweden, one from Finland, and one from Germany. Statistics reveal reliability performance of the different components within the wind turbine. The gearbox is the most critical, because downtime per failure is high compared to the other components. The statistical data for larger turbines also show trends toward higher, ever increasing failure frequency when compared to small turbines, which have a decreasing failure rate over the operational years
author_names: Johan Ribrant

Lina Bertling
title: Survey of Failures in Wind Power Systems With Focus on Swedish Wind Power Plants During 1997 2005
venue: IEEE Transactions on Energy Conversion
year: 2007

abstract: The temperature dependence and stability of three different commercially available unpackaged SiC Dmosfets have been measured. On state resistances increased to 6 or 7 times their room temperature values at 350 degC. Threshold voltages almost doubled after tens of minutes of positive gate voltage stressing at 300 degC, but approached their original values again after only one or two minutes of negative gate bias stressing. Fortunately, the change in drain current due to these threshold instabilities was almost negligible. However, the threshold approaches zero volts at high temperatures after a high temperature negative gate bias stress. The zero gate bias leakage is low until the threshold voltage reduces to approximately 150 mV, where after the leakage increases exponentially. Thermal aging tests demonstrated a sudden change from linear to nonlinear output characteristics after 24 100 h air storage at 300 degC and after 570 1000 h in N2 atmosphere. We attribute this to nickel oxide growth on the drain contact metallization which forms a heterojunction p n diode with the SiC substrate. It was determined that these state of the art SiC mosfet devices may be operated in real applications at temperatures far exceeding their rated operating temperatures.
author_names: Dean Hamilton

M R Jennings

Amador Perez-Tomas

Stephen A O Russell

Steven A Hindmarsh

Craig A J Fisher

Philip A Mawby
title: High Temperature Electrical and Thermal Aging Performance and Application Considerations for SiC Power DMOSFETs
venue: IEEE Transactions on Power Electronics
year: 2017

abstract: Modular multilevel converters (MMC) are complex systems, composed of many elements, and exposed to critical load demands in some cases. Thereby, a detailed design of its components is of preeminent importance to achieve a high system level reliability. However, the high number of devices challenges the tradeoff between cost and reliability. This article, introduces a reliability oriented design methodology, based on the cost to achieve a predefined unreliability level <inline formula><tex math notation="LaTeX"$U_x$/tex math>/inline formula> A flowchart presents the main steps of the process, including the mission profile definition, selection of power devices, thermal modeling, reliability modeling, and the reliability oriented selection. To evaluate the proposed methodology, a case study considering 17 MVA/13.8 kV MMC static synchronous compensator (STATCOM) with a real mission profile data is conducted. A <inline formula><tex math notation="LaTeX"$U_x cost$/tex math>/inline formula> map is introduced to compare various design solutions, based on power devices of different voltage classes and current capabilities.
author_names: Joao Victor Matos Farias

Allan Fagner Cupertino

Victor de Nazareth Ferreira

Heverton Augusto Pereira

Seleme Isaac Seleme

Remus Teodorescu
title: Reliability Oriented Design of Modular Multilevel Converters for Medium Voltage STATCOM
venue: IEEE Transactions on Industrial Electronics
year: 2020

abstract: The need for multidisciplinary virtual prototyping in power electronics has been well established, however, design tools capable of facilitating a rapid iterative virtual design process do not exist. A key challenge in developing such tools is identifying and developing modeling techniques which can account for 3 D geometrical design choices without unduly affecting simulation speed. This challenge has been addressed in this paper using model order reduction techniques and a prototype power electronic design tool incorporating these techniques is presented. A relevant electrothermal power module design example is then used to demonstrate the performance of the software and model order reduction techniques. Five design iterations can be evaluated, using 3 D inductive and thermal models, under typical operating and start up conditions on a desktop PC in less than 15 min. The results are validated experimentally for both thermal and electrical domains.
author_names: Paul L Evans

Alberto Castellazzi

C Mark Johnson
title: Design Tools for Rapid Multidomain Virtual Prototyping of Power Electronic Systems
venue: IEEE Transactions on Power Electronics
year: 2016

abstract: Over the last few decades, the production of Liquefied Natural Gas (LNG) has been pushing the development of electric drives with increasingly high power ratings, up to several tens of megawatts. A consolidated technology in this field entails dual star 2 pole synchronous motors fed by Load Commutated Inverters (LCI) with supply frequencies between 50 and 80 Hz. This paper presents a novel drive concept for very high power and high performance LNG applications based on a 45 MW 4 pole 100 Hz quadruple star synchronous motor supplied by four PWM multi level Voltage Source Inverters (VSI) The genesis, development and industrial implementation of this new design concept are outlined. System full load drive testing results are presented to successfully validate the proposed solution.
author_names: Alberto Tessarolo

G Zocco

C Tonello
title: Design and testing of a 45 MW 100 Hz quadruple star synchronous motor for a Liquefied Natural Gas turbo compressor drive
venue: SPEEDAM 2010
year: 2010

abstract: In recent years, global warming and environmental pollution caused a limitation of the use of natural energy and resource use has become more important Renewable resources. In the industrial sector, most of factories such as Ceramic tile production, glass, and cement of devices that are used for heat production of biofuel. After heat generation, thermal energy balance of heat production is wasted. Thermoelectric modules with exposure to ambient air temperature difference between the devices and electrical energy will generate. Ultra long life, lack of moving parts, quiet and relatively low price thermoelectric modules, they are a very attractive option for use in the field. Since the temperature above the ambient heat is transferred from wasted heat energy transferred to the surrounding environment can be used to produce electrical energy. In this study, a review of the development of Thermoelectric cooling briefly introduced first. Next, the Ceramic Tile Production Process has been summarized. To improve performance, have been described thermoelectric cooler modeling and numerical compact model. Finally, simulation results are presented. The electrical energy generated can be transmitted to electrical energy to the distribution network that the production process is simulated by MATLAB software.
author_names: Ail Madani Mohammadi
title: Renewable Energy from Thermal: Electrical Power Generation in Ceramic and TileIndustry
year: 2018

abstract: To accelerate wide industry adoption of Silicon Carbide (SiC) based technology, a three phase two level inverter based power block is designed with the latest generation high performance 1.7 kV/450 A SiC mosfet module from General Electric. The designed power block is expected to replace the currently standardized 1.7 kV/450 A Silicon (Si) insulated gate bipolar transistor (IGBT) based three phase power block. Power converters face thermal challenges when subjected to very low fundamental frequency operations (below 10 Hz) This is particularly relevant in the wind power applications. At low operating fundamental frequencies, the junction temperature of the power device experiences high peak to peak ripple, which degrades the reliability of the power modules significantly. This paper presents the thermal performance of the designed power block and draws comparisons with a similar rated Si IGBT module based power blocks, especially at low output fundamental frequency operations. Key performance indices, including power rating curves at different switching frequencies and power factors; temperature ripple at different fundamental frequencies, are examined. Simulation and experimental results are provided to validate the claims. The results indicate that the SiC mosfet module based power block can be a promising replacement for the Si IGBT based power block especially in applications where wide range of fundamental frequency operations are needed.
author_names: Sayan Acharya

Xu She

Maja Harfman Todorovic

Rajib Datta

Gary D Mandrusiak
title: Thermal Performance Evaluation of a 1.7 kV, 450 A SiC MOSFET Based Modular Three Phase Power Block With Wide Fundamental Frequency Operations
venue: IEEE Transactions on Industry Applications
year: 2019

abstract: Thermal management is becoming ever more important in passenger vehicles in the trend of vehicle electrification. Even though most of the passenger vehicles still have relatively conventional thermal management systems, advanced technologies have been increasingly developed. The internal combustion engine have had the central role in thermal management but due to the powertrain hybridization and electrification, the engines are nowadays more efficient, smaller in size, and running less frequently. Especially for plug in hybrid and electric vehicles, engines are not always used or not even available, and, thus, there is no excess heat readily available. This paper reviews the present technology for the thermal management of electrified powertrains in passenger vehicles. In this context, thermal management takes into account the cooling and heating systems for the powertrain components, and different methods to develop and improve thermal systems efficiency. This paper investigates the recent technology advances for improving energy efficiency of thermal systems. The research focus is on the hybrid and electric vehicles and especially on the challenges of improving thermal energy efficiency and performance.
author_names: Antti Lajunen

Yinye Yang

Ali Emadi
title: Recent Developments in Thermal Management of Electrified Powertrains
venue: IEEE Transactions on Vehicular Technology
year: 2018