State detection of bond wires in IGBT modules using eddy current pulsed thermography

Insulated gate bipolar transistor (IGBT) modules are important safety critical components in electrical power systems. Bond wire lift-off, a plastic deformation between wire bond and adjacent layers of a device caused by repeated power/thermal cycles, is the most common failure mechanism in IGBT modules. For the early detection and characterization of such failures, it is important to constantly detect or monitor the health state of IGBT modules, and the state of bond wires in particular. This paper introduces eddy current pulsed thermography (ECPT), a nondestructive evaluation technique, for the state detection and characterization of bond wire lift-off in IGBT modules. After the introduction of the experimental ECPT system, numerical simulation work is reported. The presented simulations are based on the 3-D electromagnetic-thermal coupling finite-element method and analyze transient temperature distribution within the bond wires. This paper illustrates the thermal patterns of bond wires using inductive heating with different wire statuses (lifted-off or well bonded) under two excitation conditions: nonuniform and uniform magnetic field excitations. Experimental results show that uniform excitation of healthy bonding wires, using a Helmholtz coil, provides the same eddy currents on each, while different eddy currents are seen on faulty wires. Both experimental and numerical results show that ECPT can be used for the detection and characterization of bond wires in power semiconductors through the analysis of the transient heating patterns of the wires. The main impact of this paper is that it is the first time electromagnetic induction thermography, so-called ECPT, has been employed on power/electronic devices. Because of its capability of contactless inspection of multiple wires in a single pass, and as such it opens a wide field of investigation in power/electronic devices for failure detection, performance characterization, and health monitoring.

Power converters design and analysis for high power piezoelectric ultrasonic transducers

High power piezoelectric ultrasonic transducers have been widely exploited in a variety of applications. The critical behaviour of a piezoelectric device is encapsulated in its resonant frequencies because of its maximum transmission performance at these frequencies. Therefore power electronic converters should be tuned at those resonant frequencies to transfer electrical power to mechanical power efficiently. However, structural and environmental changes cause variations in the device resonant frequencies which can degrade the system performance. Hence, estimating the device resonant frequencies within the incorporated setup can significantly improve the system performance. This paper proposes an efficient resonant frequency estimation approach to maintain the performance of high power ultrasonic applications using the employed power converter. Experimental validations indicate the effectiveness of the proposed method.

Z-source-inverter-based flexible distributed generation system solution for grid power quality improvement

Distributed generation (DG) systems are usually connected to the grid using power electronic converters. Power delivered from such DG sources depends on factors like energy availability and load demand. The converters used in power conversion do not operate with their full capacity all the time. The unused or remaining capacity of the converters could be used to provide some ancillary functions like harmonic and unbalance mitigation of the power distribution system. As some of these DG sources have wide operating ranges, they need special power converters for grid interfacing. Being a single-stage buck-boost inverter, recently proposed Z-source inverter (ZSI) is a good candidate for future DG systems. This paper presents a controller design for a ZSI-based DG system to improve power quality of distribution systems. The proposed control method is tested with simulation results obtained using Matlab/Simulink/PLECS and subsequently it is experimentally validated using a laboratory prototype.

A loop cancellation based active damping solution for constant power instability in vehicular power systems

In recent years, electric propulsion systems have increasingly been used in land, sea and air vehicles. The vehicular power systems are usually loaded with tightly regulated power electronic converters which tend to draw constant power. Since the constant power loads (CPLs) impose negative incremental resistance characteristics on the feeder system, they pose a potential threat to the stability of vehicular power systems. This effect becomes more significant in the presence of distribution lines between source and load in large vehicular power systems such as electric ships and more electric aircrafts. System transients such as sudden drop of converter side loads or increase of constant power requirement can cause complete system instability. Most of the existing research work focuses on the modeling and stabilization of DC vehicular power systems with CPLs. Only a few solutions are proposed to stabilize AC vehicular power systems with non-negligible distribution lines and CPLs. Therefore, this paper proposes a novel loop cancellation technique to eliminate constant power instability in AC vehicular power systems with a theoretically unbounded system stability region. Analysis is carried out on system stability with the proposed method and simulation results are presented to validate its effectiveness.

Virtual resistance based active damping solution for constant power instability in AC microgrids

With ever-increasing share of power electronic loads constant power instability is becoming a significant issue in microgrids, especially when they operate in the islanding mode. Transient conditions like resistive load-shedding or sudden increase of constant power loads (CPL) might destabilize the whole system. Modeling and stability analysis of AC microgrids with CPLs have already been discussed in literature. However, no effective solutions are provided to stabilize this kind of system. Therefore, this paper proposes a virtual resistance based active damping method to eliminate constant power instability in AC microgrids. Advantages and limitations of the proposed method are also discussed in detail. Simulation results are presented to validate the proposed active damping solution.

Analysis of impedance matched circuit for wireless power transfer

Typical wireless power transfer systems utilize series compensation circuit which is based on magnetic coupling and resonance principles that was first developed by Tesla. However, changes in coupling caused by gap distance, alignment and orientation variations can lead to reduce power transfer efficiencies and the transferred power levels. This paper proposes impedance matched circuit to reduce frequency bifurcation effect and improve on the transferred power level, efficiency and total harmonic distortion (THD) performance of the series compensation circuit. A comprehensive mathematical analysis is performed for both series and impedance matched circuits to show the frequency bifurcation effects in terms of input impedance, variations in transferred power levels and efficiencies. Matlab/Simulink results validate the theoretical analysis and shows the circuits’ THD performance when circuits are fed with power electronic converters.

Characterisation of the cascode gate drive of power MOSFETs in clamped inductive switching applications

This thesis proposes a novel gate drive circuit to improve the switching performance of MOSFET power switches in power electronic converters. The proposed topology exploits the cascode configuration, allowing the minimisation of switching losses in the presence of practical circuit constraints, which enables efficiency and power density improvements. Switching characteristics of the new topology are investigated and key mechanisms that control the switching process are identified. Unique analysis tools and techniques are also developed to demonstrate the application of the cascode gate drive circuit for switching performance optimisation.

Optimal reactive power dispatch based on voltage stability criteria in a large power system with AC/DC and FACTs devices

An algorithm for optimal allocation of reactive power in AC/DC system using FACTs devices, with an objective of improving the voltage profile and also voltage stability of the system has been presented. The technique attempts to utilize fully the reactive power sources in the system to improve the voltage stability and profile as well as meeting the reactive power requirements at the AC-DC terminals to facilitate the smooth operation of DC links. The method involves successive solution of steady-state power flows and optimization of reactive power control variables with Unified Power Flow Controller (UPFC) using linear programming technique. The proposed method has been tested on a real life equivalent 96-bus AC and a two terminal DC system under normal and contingency conditions.

Comparative studies of transient and steady state analysis for a typical 765kV/400kV EHV transmission system in Indian power system

This paper describes an approach for the analysis and design of 765kV/400kV EHV transmission system which is a typical expansion in Indian power grid system, based on the analysis of steady state and transient over voltages. The approach for transmission system design is iterative in nature. The first step involves exhaustive power flow analysis, based on constraints such as right of way, power to be transmitted, power transfer capabilities of lines, existing interconnecting transformer capabilities etc. Acceptable bus voltage profiles and satisfactory equipment loadings during all foreseeable operating conditions for normal and contingency operation are the guiding criteria. Critical operating strategies are also evolved in this initial design phase. With the steady state over voltages obtained, comprehensive dynamic and transient studies are to be carried out including switching over voltages studies. This paper presents steady state and switching transient studies for alternative two typical configurations of 765kV/400 kV systems and the results are compared. Transient studies are carried out to obtain the peak values of 765 kV transmission systems and are compared with the alternative configurations of existing 400 kV systems.

Circulating power test setup for a PWM rectifier motor drive

Power converters burn-in test consumes large amount of energy, which increases the cost of testing, and certification, in medium and high power application. A simple test configuration to test a PWM rectifier induction motor drive, using a Doubly Fed Induction Machine (DFIM) to circulate power back to the grid for burn-in test is presented. The test configuration makes use of only one power electronic converter, which is the converter to be tested. The test method ensures soft synchronization of DFIM and Squirrel Cage Induction Machine (SCIM). A simple volt per hertz control of the drive is sufficient for conducting the test. To synchronize the DFIM with SCIM, the rotor terminal voltage of DFIM is measured and used as an indication of speed mismatch between DFIM and SCIM. The synchronization is done when the DFIM rotor voltage is at its minimum. Analysis of the DFIM characteristics confirms that such a test can be effectively performed with smooth start up and loading of the test setup. After synchronization is obtained, the speed command to SCIM is changed in order to load the setup in motoring or regenerative mode of operation. The experimental results are presented that validates the proposed test method.

Design Of Start-up Power Circuit For Control Power Supplies With Wide Input Voltage Variation

This paper presents the design of a start up power circuit for a control power supply (CPS) which feeds power to the sub-systems of High Power Converters (HPC). The sub-systems such as gate drive card, annunciation card, protection and delay card etc; needs to be provided power for the operation of a HPC. The control power supply (CPS) is designed to operate over a wide range of input voltage from 90Vac to 270Vac. The CPS output supplies power at a desired voltage of Vout =24V to the auxiliary sub-systems of the HPC. During the starting, the power supply to the control circuitry of CPS in turn, is obtained using a separate start-up power supply. This paper discusses the various design issues of the start-up power circuit to ensure that start-up and shut down of the CPS occurs reliably. The CPS also maintains the power factor close to unity and low total harmonic distortion in input current. The paper also provides design details of gate drive circuits employed for the CPS as well as the design of on-board power supply for the CPS. Index terms: control power supply, start-up power supply, DSFC, pre-regulator

Active Power Decoupling with Reduced Converter Stress for Single-Phase Power Conversion and Interfacing

Single-phase DC/AC power electronic converters suffer from pulsating power at double the line frequency. The commonest practice to handle the issue is to provide a huge electrolytic capacitor for smoothening out the ripple. But, the electrolytic capacitors having short end of lifetimes limit the overall lifetime of the converter. Another way of handling the ripple power is by active power decoupling (APD) using the storage devices and a set of semiconductor switches. Here, a novel topology has been proposed implementing APD. The topology claims the benefit of 1) reduced stress on converter switches 2) using smaller capacitance value thus alleviating use of electrolytic capacitor in turn improving the lifetime of the converter. The circuit consists of a third leg, a storage capacitor and a storage inductor. The analysis and the simulation results are shown to prove the effectiveness of the topology.

Active Power Decoupling with Reduced Converter Stress for Single-Phase Power Conversion and Interfacing

Single-phase DC/AC power electronic converters suffer from pulsating power at double the line frequency. The commonest practice to handle the issue is to provide a huge electrolytic capacitor for smoothening out the ripple. But, the electrolytic capacitors having short end of lifetimes limit the overall lifetime of the converter. Another way of handling the ripple power is by active power decoupling (APD) using the storage devices and a set of semiconductor switches. Here, a novel topology has been proposed implementing APD. The topology claims the benefit of 1) reduced stress on converter switches 2) using smaller capacitance value thus alleviating use of electrolytic capacitor in turn improving the lifetime of the converter. The circuit consists of a third leg, a storage capacitor and a storage inductor. The analysis and the simulation results are shown to prove the effectiveness of the topology.

Optimization and Control of Power Flow in Distribution Networks

Climate change is arguably the most critical issue facing our generation and the next. As we move towards a sustainable future, the grid is rapidly evolving with the integration of more and more renewable energy resources and the emergence of electric vehicles. In particular, large scale adoption of residential and commercial solar photovoltaics (PV) plants is completely changing the traditional slowly-varying unidirectional power flow nature of distribution systems. High share of intermittent renewables pose several technical challenges, including voltage and frequency control. But along with these challenges, renewable generators also bring with them millions of new DC-AC inverter controllers each year. These fast power electronic devices can provide an unprecedented opportunity to increase energy efficiency and improve power quality, if combined with well-designed inverter control algorithms. The main goal of this dissertation is to develop scalable power flow optimization and control methods that achieve system-wide efficiency, reliability, and robustness for power distribution networks of future with high penetration of distributed inverter-based renewable generators.

Proposed solutions to power flow control problems in the literature range from fully centralized to fully local ones. In this thesis, we will focus on the two ends of this spectrum. In the first half of this thesis (chapters 2 and 3), we seek optimal solutions to voltage control problems provided a centralized architecture with complete information. These solutions are particularly important for better understanding the overall system behavior and can serve as a benchmark to compare the performance of other control methods against. To this end, we first propose a branch flow model (BFM) for the analysis and optimization of radial and meshed networks. This model leads to a new approach to solve optimal power flow (OPF) problems using a two step relaxation procedure, which has proven to be both reliable and computationally efficient in dealing with the non-convexity of power flow equations in radial and weakly-meshed distribution networks. We will then apply the results to fast time- scale inverter var control problem and evaluate the performance on real-world circuits in Southern California Edison’s service territory.

The second half (chapters 4 and 5), however, is dedicated to study local control approaches, as they are the only options available for immediate implementation on today’s distribution networks that lack sufficient monitoring and communication infrastructure. In particular, we will follow a reverse and forward engineering approach to study the recently proposed piecewise linear volt/var control curves. It is the aim of this dissertation to tackle some key problems in these two areas and contribute by providing rigorous theoretical basis for future work.

Sensorless commutation of a two-phase linear machine for marine renewable power generation

A sensorless scheme is presented for a two-phase permanent-magnet linear machine targeted for use in marine wave-power generation. This is a field where system reliability is a key concern. The scheme is able to extract the effective inductance and back-emf of the machine's phases simultaneously from measurements of the current ripple present on the power electronic converter. These measurements can then be used to estimate position. An enhancement to the scheme in the presence of spatially-varying mutual inductance between phases allows more accurate and reliable tracking from indutance-based measurements than would otherwise be expected. This scheme is able to operate at any speed including, critically, when stationary. Experimental results show promise for the scheme, although some work to reduce the level of noise would be desirable. © 2013 IEEE.