Methodology for Dynamic Stability and Robustness Analysis of Commercial-Power-Module-Based DC-Distributed Systems

El propósito de esta tesis es presentar una metodología para realizar análisis de la dinámica en pequeña señal y el comportamiento de sistemas de alimentación distribuidos de corriente continua (CC), formados por módulos comerciales. Para ello se hace uso de un método sencillo que indica los márgenes de estabilidad menos conservadores posibles mediante un solo número. Este índice es calculado en cada una de las interfaces que componen el sistema y puede usarse para obtener un índice global que indica la estabilidad del sistema global. De esta manera se posibilita la comparación de sistemas de alimentación distribuidos en términos de robustez. La interconexión de convertidores CC-CC entre ellos y con los filtros EMI necesarios puede originar interacciones no deseadas que dan lugar a la degradación del comportamiento de los convertidores, haciendo el sistema más propenso a inestabilidades. Esta diferencia en el comportamiento se debe a interacciones entre las impedancias de los diversos elementos del sistema. En la mayoría de los casos, los sistemas de alimentación distribuida están formados por módulos comerciales cuya estructura interna es desconocida. Por ello los análisis presentados en esta tesis se basan en medidas de la respuesta en frecuencia del convertidor que pueden realizarse desde los terminales de entrada y salida del mismo. Utilizando las medidas de las impedancias de entrada y salida de los elementos del sistema, se puede construir una función de sensibilidad que proporciona los márgenes de estabilidad de las diferentes interfaces. En esta tesis se utiliza el concepto del valor máximo de la función de sensibilidad (MPC por sus siglas en inglés) para indicar los márgenes de estabilidad como un único número. Una vez que la estabilidad de todas las interfaces del sistema se han evaluado individualmente, los índices obtenidos pueden combinarse para obtener un único número con el que comparar la estabilidad de diferentes sistemas. Igualmente se han analizado las posibles interacciones en la entrada y la salida de los convertidores CC-CC, obteniéndose expresiones analíticas con las que describir en detalle los acoplamientos generados en el sistema. Los estudios analíticos realizados se han validado experimentalmente a lo largo de la tesis. El análisis presentado en esta tesis se culmina con la obtención de un índice que condensa los márgenes de estabilidad menos conservativos. También se demuestra que la robustez del sistema está asegurada si las impedancias utilizadas en la función de sensibilidad se obtienen justamente en la entrada o la salida del subsistema que está siendo analizado. Por otra parte, la tesis presenta un conjunto de parámetros internos asimilados a impedancias, junto con sus expresiones analíticas, que permiten una explicación detallada de las interacciones en el sistema. Dichas expresiones analíticas pueden obtenerse bien mediante las funciones de transferencia analíticas si se conoce la estructura interna, o utilizando medidas en frecuencia o identificación de las mismas a través de la respuesta temporal del convertidor. De acuerdo a las metodologías presentadas en esta tesis se puede predecir la estabilidad y el comportamiento de sistemas compuestos básicamente por convertidores CC-CC y filtros, cuya estructura interna es desconocida. La predicción se basa en un índice que condensa la información de los márgenes de estabilidad y que permite la obtención de un indicador de la estabilidad global de todo el sistema, permitiendo la comparación de la estabilidad de diferentes arquitecturas de sistemas de alimentación distribuidos. ABSTRACT The purpose of this thesis is to present dynamic small-signal stability and performance analysis methodology for dc-distributed systems consisting of commercial power modules. Furthermore, the objective is to introduce simple method to state the least conservative margins for robust stability as a single number. In addition, an index characterizing the overall system stability is obtained, based on which different dc-distributed systems can be compared in terms of robustness. The interconnected systems are prone to impedance-based interactions which might lead to transient-performance degradation or even instability. These systems typically are constructed using commercial converters with unknown internal structure. Therefore, the analysis presented throughout this thesis is based on frequency responses measurable from the input and output terminals. The stability margins are stated utilizing a concept of maximum peak criteria, derived from the behavior of impedance-based sensitivity function that provides a single number to state robust stability. Using this concept, the stability information at every system interface is combined to a meaningful number to state the average robustness of the system. In addition, theoretical formulas are extracted to assess source and load side interactions in order to describe detailed couplings within the system. The presented theoretical analysis methodologies are experimentally validated throughout the thesis. In this thesis, according to the presented analysis, the least conservative stability margins are provided as a single number guaranteeing robustness. It is also shown that within the interconnected system the robust stability is ensured only if the impedance-based minor-loop gain is determined at the very input or output of each subsystem. Moreover, a complete set of impedance-type internal parameters as well as the formulas according to which the interaction sensitivity can be fully explained and analyzed, is provided. The given formulation can be utilized equally either based on measured frequency responses, time-domain identified internal parameters or extracted analytic transfer functions. Based on the analysis methodologies presented in this thesis, the stability and performance of interconnected systems consisting of converters with unknown internal structure, can be predicted. Moreover, the provided concept to assess the least conservative stability margins enables to obtain an index to state the overall robust stability of distributed power architecture and thus to compare different systems in terms of stability.

Power cycling lifetime estimation of IGBT power modules based on chip temperature modeling

In this doctoral thesis, methods to estimate the expected power cycling life of power semiconductor modules based on chip temperature modeling are developed. Frequency converters operate under dynamic loads in most electric drives. The varying loads cause thermal expansion and contraction, which stresses the internal boundaries between the material layers in the power module. Eventually, the stress wears out the semiconductor modules. The wear-out cannot be detected by traditional temperature or current measurements inside the frequency converter. Therefore, it is important to develop a method to predict the end of the converter lifetime. The thesis concentrates on power-cycling-related failures of insulated gate bipolar transistors. Two types of power modules are discussed: a direct bonded copper (DBC) sandwich structure with and without a baseplate. Most common failure mechanisms are reviewed, and methods to improve the power cycling lifetime of the power modules are presented. Power cycling curves are determined for a module with a lead-free solder by accelerated power cycling tests. A lifetime model is selected and the parameters are updated based on the power cycling test results. According to the measurements, the factor of improvement in the power cycling lifetime of modern IGBT power modules is greater than 10 during the last decade. Also, it is noticed that a 10 C increase in the chip temperature cycle amplitude decreases the lifetime by 40%. A thermal model for the chip temperature estimation is developed. The model is based on power loss estimation of the chip from the output current of the frequency converter. The model is verified with a purpose-built test equipment, which allows simultaneous measurement and simulation of the chip temperature with an arbitrary load waveform. The measurement system is shown to be convenient for studying the thermal behavior of the chip. It is found that the thermal model has a 5 C accuracy in the temperature estimation. The temperature cycles that the power semiconductor chip has experienced are counted by the rainflow algorithm. The counted cycles are compared with the experimentally verified power cycling curves to estimate the life consumption based on the mission profile of the drive. The methods are validated by the lifetime estimation of a power module in a direct-driven wind turbine. The estimated lifetime of the IGBT power module in a direct-driven wind turbine is 15 000 years, if the turbine is located in south-eastern Finland.

Lifetime Modeling of SiC Power Modules in Automotive Traction Inverters

This thesis presents a model-based software implementation for the estimation of the damage of a power module inside and automotive traction inverter with few hardware test setup performed to support the simulation with real-life data.

Piirilevyn suunnittelu suurelle virralle DC/DC-muuntimeen

Ajoneuvoissa, kuten busseissa, käytetään yleensä 24 VDC järjestelmiä ja tämä ei muutu myöskään sähköajoneuvojen kohdalla. Sähköajoneuvoissakin tarvitaan siis 24 VDC matalajänniteakustoja valoille, pyyhkijöille ja muille matalan jännitteen järjestelmille. Lisäksi sähköajoneuvoissa on esimerkiksi ilmastointi ja paineilmankompressori, jotka tarvitsevat taajuusmuuttajan pyörittämään niitä. Tässä työssä suunnitellaan suuren virran piilevy DC/DC-muuntimeen, joka on osa ajoneuvokäyttöön suunnitellun invertterin ja DC/DC-muuntimen yhdistelmälaitetta. Työn pääpaino on piirilevyn suunnittelussa, mutta työssä kerrotaan lyhyesti koko laitteen kytkentä ja käyttötarkoitus. Työssä kerrotaan myös tehopiirilevylle tulevien komponenttien valinta, mitoitus ja jäähdytys. Käydään läpi suuren virran piirilevysuunnittelun mitoitusperiaatteet ja mitä seikkoja siinä erityisesti tulee ottaa huomioon. Lisäksi käsitellään piirilevyn liityntöjä ja virtakiskojen lämpenemää virranahtautumisen takia. Suunniteltua piirilevyä mitataan ja sen toimintaa kokeillaan prototyyppilaitteessa. Protoyyppilaitteella havaitaan virtakiskojen lämpenevän liikaa ja huomataan ongelma kytkenssä. Kytkentää korjattiin ja toimintaa analysoitiin uudestaan, jonka jälkeen havaittiin piirilevyn lämpenemän tippuneen 20 °C. Lopputuloksena piirilevyn lämpenemä, korjatulla kytkennällä, on suunnitellun mukainen. Lopussa esitetään piirilevyn korvaamista moduuliratkaisulla laitteen parantamiseksi sarjatuotantoon.

Modelo matemático para otimização dos custos de um sistema híbrido eólico-solar : aplicação no bombeamento de petróleo

This work purposes the application of a methodology to optimize the implantation cost of an wind-solar hybrid system for oil pumping. The developed model is estimated the implantation cost of system through Multiple Linear Regression technique, on the basis of the previous knowledge of variables: necessary capacity of storage, total daily energy demand, wind power, module power and module number. These variables are gotten by means of sizing. The considered model not only can be applied to the oil pumping, but also for any other purposes of electric energy generation for conversion of solar, wind or solar-wind energy, that demand short powers. Parametric statistical T-student tests had been used to detect the significant difference in the average of total cost to being considered the diameter of the wind, F by Snedecor in the variance analysis to test if the coefficients of the considered model are significantly different of zero and test not-parametric statistical by Friedman, toverify if there is difference in the system cost, by being considered the photovoltaic module powers. In decision of hypothesis tests was considered a 5%-significant level. The configurations module powers showed significant differences in total cost of investment by considering an electrical motor of 3 HP. The configurations module powers showed significant differences in total cost of investment by considering an electrical motor of 5 HP only to wind speed of 4m/s and 6 m/s in wind of 3 m, 4m and 5 m of diameter. There was not significant difference in costs to diameters of winds of 3 m and 4m. The mathematical model and the computational program may be used to others applications which require electrical between 2.250 W and 3.750 W. A computational program was developed to assist the study of several configurations that optimizes the implantation cost of an wind-solar system through considered mathematical model

Practical Characterization of Input-Parallel-Connected Converters with a Common Input Filter

The paper presents a method to analyze robust stability and transient performance of a distributed power system consisting of commercial converter modules interconnected through a common input filter. The method is based on the use of four transfer functions, which are measurable from the converter input and output terminals. It is shown that these parameters provide important information on the power module sensitivity to the interactions caused by the external impedances. Practical characterization for the described system structure is performed introducing special transfer functions utilized for the interactions assessment. Experimental results are provided to support the presented analysis procedure.

BETs: Propellant less de orbiting of space debris by bare electrodynamic tethers

As a fundamental contribution to limiting the increase of debris in the Space environment, a three-year project started on 1 November 2010 financed by the European Commission under the FP-7 Space Programme. It aims at developing a universal system to be carried on board future satellites launched into low Earth orbit (LEO), to allow de-orbiting at end of life. The operational system involves a conductive tape-tether left bare of insulation to establish anodic contact with the ambient plasma as a giant Langmuir probe. The project will size the three disparate dimensions of a tape for a selected de-orbit mission and determine scaling laws to allow system design for a general mission. It will implement control laws to restrain tether dynamics in/off the orbital plane; and will carry out plasma chamber measurements and numerical simulations of tether-plasma interaction. The project also involves the design and manufacturing of subsystems: electron-ejecting plasma contactors, an electric control and power module, interface elements, tether and deployment mechanisms, tether tape/end-mass as well as current collection plus free-fall, and hypervelocity impact tests.

An universal system to de-orbit satellites at end of life

A 3-year Project financed by the European Commission is aimed at developing a universal system to de-orbit satellites at their end of life, as a fundamental contribution to limit the increase of debris in the Space environment. The operational system involves a conductive tapetether left bare to establish anodic contact with the ambient plasma as a giant Langmuir probe. The Project will size the three disparate dimensions of a tape for a selected de-orbit mission and determine scaling laws to allow system design for a general mission. Starting at the second year, mission selection is carried out while developing numerical codes to implement control laws on tether dynamics in/off the orbital plane; performing numerical simulations and plasma chamber measurements on tether-plasma interaction; and completing design of subsystems: electronejecting plasma contactor, power module, interface elements, deployment mechanism, and tether-tape/end-mass. This will be followed by subsystems manufacturing and by currentcollection, free-fall, and hypervelocity impact tests.

In situ diagnostics and prognostics of wire bonding faults in IGBT modules for electric vehicle drives

This paper presents a diagnostic and prognostic condition monitoring method for insulated-gate bipolar transistor (IGBT) power modules for use primarily in electric vehicle applications. The wire-bond-related failure, one of the most commonly observed packaging failures, is investigated by analytical and experimental methods using the on-state voltage drop as a failure indicator. A sophisticated test bench is developed to generate and apply the required current/power pulses to the device under test. The proposed method is capable of detecting small changes in the failure indicators of the IGBTs and freewheeling diodes and its effectiveness is validated experimentally. The novelty of the work lies in the accurate online testing capacity for diagnostics and prognostics of the power module with a focus on the wire bonding faults, by injecting external currents into the power unit during the idle time. Test results show that the IGBT may sustain a loss of half the bond wires before the impending fault becomes catastrophic. The measurement circuitry can be embedded in the IGBT drive circuits and the measurements can be performed in situ when the electric vehicle stops in stop-and-go, red light traffic conditions, or during routine servicing.

Sistema de armazenamento de energia com base em baterias e no ondulador de tensão trifásico

Dissertação para obtenção do grau de Mestre em Engenharia Electrotécnica Ramo de Automação e Eletrotécnica Ramo de Automação e Eletrónica Industrial

Real-time reliability test for a CPV module based on a power degradation model

Models based on degradation are powerful and useful tools to evaluate the reliability of those devices in which failure happens because of degradation in the performance parameters. This paper presents a procedure for assessing the reliability of concentrator photovoltaic (CPV) modules operating outdoors in real-time conditions. With this model, the main reliability functions are predicted. This model has been applied to a real case with a module composed of GaAs single-junction solar cells and total internal reflection (TIR) optics

SOPHIA CPV module round robin: power rating at CSOC

Within the European funded project SOPHIA, a Round Robin measurement on CPV module has been initiated. Seven different test laboratories located in Europe between 48°N and 37°N perform measurements of four SOITEC CPV modules. The modules are electrically characterized with different measurement equipment under various climatic conditions. One pyrheliometer and one spectral sensor based on component cells are shipped together with the modules. This ensures that the irradiance and spectrum, two factors with high impact on CPV module performance, are measured with the identical equipment at each site. The round robin activity is performed in closeco-operation with the IEC TC82 WG7 power rating team in order to support the work on the CPV module power rating draft standard 62670-3. The resultingrated module power outputs at CSOC (Concentrator Standard Operating Conditions) are compared amongst the power rating methods and amongst the test labs. In this manner, a deviation in rated power output between different test labs and power rating methods is determined.

Análisis de sistemas eléctricos en microsatélites. Desarrollo de módulos para una Concurrent Design Facility (CFD)para el desarrollo y análisis de misiones espaciales = Analysis of microsatellites power subsystems (battery testing). Development and programming of a new Propulsion Module for a space mission Concurrent Design Facility (CDF)

El objetivo de este proyecto es recoger y explicar el conjunto de tareas realizadas durante el proceso de colaboración llevado a cabo en el Instituto de Microgravedad “Ignacio Da Riva” durante el curso académico 2014/2015, las cuales han conformado las prácticas externas cursadas en la titulación de Grado en Ingeniería Aeroespacial, y el Trabajo de Fin de Grado de la misma titulación. En este documento se pretende,además, poner de manifiesto la rigurosidad con la que se trabaja en el ámbito espacial y la importancia de los protocolos y procedimientos para asegurar un resultado adecuado en los trabajos realizados. Una parte importante del proyecto detalla los procesos de monitorización y mantenimiento de la batería del satélite universitario UPMSat-2 cuyo lanzamiento está previsto para el año próximo y el cual será el segundo satélite del mundo en incorporar una batería de Ión-Litio.

Análisis de sistemas eléctricos en microsatélites. Desarrollo de módulos para una Concurrent Design Facility (CDF) para desarrollo y análisis de misiones espaciales = Analysis of microsatellites power subsystems (battery testing). Development and programming of a new Orbit Design Module for a space mission Concurrent Design Facility (CDF)

El presente proyecto se ha realizado durante las prácticas curriculares que han tenido lugar en el Instituto Universitario de Microgravedad “Ignacio Da Riva” (IDR/UPM). A lo largo de estas prácticas se han llevado a cabo trabajos en diversos campos, todos relacionados con el UPMSat-2, desde el subsistema de potencia (placas solares y baterías) hasta el desarrollo de módulos para la Sala de Diseño Concurrente (Concurrent Design Facility, CDF). En la realización de las mismas se ha trabajado en equipo, junto con otros dos alumnos. El objetivo del proyecto es recopilar las tareas realizadas, proporcionando el desarrollo teórico necesario para llevar a cabo todas ellas. Al ser un trabajo con varias partes claramente diferenciadas, se ha optado por comenzar con unas páginas dedicadas a las misiones espaciales. A continuación el trabajo se adentra en el subsistema de potencia de un satélite, particularizando para el UPMSat-2. Finalmente, se proporciona la teoría necesaria para el desarrollo del módulo de misión de la CDF del IDR/UPM, software que se ha desarrollado y tiene reservado un espacio al final, en el cual se describe el programa y se realizan comparaciones de los resultados que proporciona frente a casos reales.

Análisis en sistemas eléctricos en microsatélites. Desarrollo de módulos para una Concurrent Design Facility (CDF) para desarrollo y análisis de misiones espaciales = Analysis of microsatellites power subsystems (battery testing). Development and programming of a new Orbit Design Module for a space mission Concurrent Design Facility (CDF)

El objetivo de este trabajo de fin de grado es la exposición de los resultados y conclusiones, fruto de las tareas desarrolladas durante las practicas curriculares en el Instituto Universitario de Microgravedad “Ignacio Da Riva” (IDR/UPM) el presente curso académico. La estructura del trabajo se compone de dos bloques diferenciados entre sí: el seguimiento de una batería y el desarrollo de un módulo para una CDF.