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The submitted manuscript has been prepared by the Oak Ridge National
Laboratory, Oak Ridge, Tennessee 37831, managed by UT- Battelle for the
U.S. Department of Energy under contract DE-AC05-00OR22725.The
manuscript is authored by a contractor of the U.S. Government under contract
DE-AC05-00OR22725. Accordingly, the US Government retains a non-
exclusive, royalty-free license to publish from the contribution, or allow Figure 1. Block diagram of the steps involved in lifetime estimation of power
others to do so, for U.S. Government purposes. semiconductors.
Stress
σ B
D
E
H
C Strain, ε
A
I
a) b)
Figure 2. "Rainflow" on a) a load sequence and b) its stress-strain plot.
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363K
403K
443K
523K
a) b)
Figure 4. Stress-strain graph variation with temperature of a) solder [32] b) aluminum specimen [31].
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TABLE I
A STEP BY STEP ANALYSIS OF RAINFLOW ALGORITHM WITH AND WITHOUT EQUIVALENT TEMPERATURE CALCULATION
APPLIED TO THE EXAMPLE PROFILE IN FIG. 2.
Conventional rainflow
Start and Cycle formed Equivalent temp calculation
end Points (Range ) using
extreme considered Four-point Start and Mean Equiv. start Mean
Amplitude Amplitude
points rainflow end times temp and end times Temp
1-2 77.96-36.93 - 3-9 - - 3-9 - -
2-3 36.93-72.03 No 9-18 - - 9-18 - -
3-4 72.03-42.71 No 18-21 - - 18-21 - -
4-5 42.7-70.7 Yes 21-24 28 56.7 21-24 28 56.58
3-6 72.04-42.17 Yes 18-27 29.87 57.10 18-21.05 29.87 58.7
2-7 36.9-76.46 No 9-30 - - 9-19.15 - -
7-8 76.46-39.82 No 30-36 - - 19.15-36 - -
8-9 39.82-60.8 No 36-42 - - 36-42 - -
9-10 60.8-47.58 Yes 42-48 13.22 54.19 42-48 13.22 55.3
8-11 39.82-71.54 No 36-51 - - 36-43.34 - -
11-12 71.54-57.48 Yes 51-57 14.06 64.51 43.34-57 14.06 64.82
12-13 57.48-75.8 No 57-60 - - 57-44.04 - -
TABLE II
LIST OF PARAMETERS AND DESCRIPTIONS
Il load current of the system
Ia inverter Phase current
Φ power factor angle of the load
Rfd on state resistances of diode
Roni on state resistances of IGBT
Von_d forward voltage drop across the diode
Von_i forward voltage drop across the IGBT
turn on switching losses from test
E on_test
conditions
E off_test turn off switching losses from test
DC voltage across the switch during the
VDC
current operation
DC voltage across the switch with the
VDC_test
test conditions from the datasheet
current across the IGBT during test
Ictest
conditions
fsw switching frequency
TABLE III.
Figure 6. STATCOM model connected to grid. LIST OF IGBT AND DIODE PARAMETERS FOR LOSS
CALCULATION
Analytical model for power calculation is discussed in section Ron Von Eon Eoff (mJ)
IGBT 4 mΩ 1.8 V 22 mJ 15
V. Diode 11 mΩ 1.0 V 32(reverse recovery)
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The IGBT current and temperature distribution while supplier’s power cycling data to that of (4), the constants are
maintaining unity power factor of the power system is shown derived as α equals -6.14, for mean temperature, Tm of 25 oC,
in Fig. 8 and Fig. 9, respectively. The temperature varies from and A=1300. The constant values were obtained by curve
40oC to a maximum of 100oC. fitting the manufacturer’s data for power cycling to (5).
This temperature profile of a semiconductor is applied to Linear accumulation of the fatigue damage is considered.
fast rainflow algorithm [30] in conjunction equivalent The degradation is given by [1]
temperature calculation [26]. The remaining useful life and N (ΔT , Tm )
lifetime estimation methodology are described in detail in D=∑ (6)
[30]. N f (ΔT , Tm )
The relation between the life in terms of number of cycles Using (5) and (6), the degradation is 6.8×10-3 for the load
and the mean temperature, and the amplitude of temperature is profile shown in Fig. 7. The total cycles for the load profile
given by the Arrhenius-Coffin-Manson’s lifetime model are 533 using four-point rainflow algorithm [25].T
proposed by Held et al [6] as shown in (5) Degradation is calculated with and without equivalent
Q temperature calculation, and the histogram plots are shown in
( )
α
N f (Tm , ΔT j ) = A × ΔT j × exp RTm
(5) Fig. 10 a) and b) respectively. For conventional rainflow
algorithm calculation, the degradation accounts for 0.029%
where A, α are constants and are module dependent, R is the degradation for the month while the degradation calculation
gas constant (8.314 J1mol.K), Tm is the mean junction with equivalent temperature calculation accounts for 0.033%.
temperature in one power cycle in Kelvin, and the internal This emphasizes the importance of equivalent temperature
energy is Q = 7.8 × 104 JMol-l (or about 0.8eV). ΔTj is the based lifetime calculation for semiconductors in long-term
variation of the junction temperature. By curve fitting the calculations.
Figure 7. Arc furnace based industrial load power factor variation monitored for every 15 minutes for a period of month.
Figure 8. Inverter current in amperes for unity power factor of the load.
Figure 9. IGBT temperature variation for the reactive compensation of the load.
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a) b)
Figure 10. Rainflow histogram of load profile in Fig. 7 with a) conventional calculation and b) equivalent temperature calculation.
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