Frédéric Richardeau

Survey on Fault Operation on Multilevel Inverters

This paper is related to faults that can appear in multilevel (ML) inverters, which have a high number of components. This is a subject of increasing importance in high-power inverters. First, methods to identify a fault are classified and briefly described for each topology. In addition, a number of strategies and hardware modifications that allow for operation in faulty conditions are also presented. As a result of the analyzed works, it can be concluded that ML inverters can significantly increase their availability and are able to operate even with some faulty components.

Architecture Complexity and Energy Efficiency of Small Wind Turbines

The power characteristics of wind turbines are nonlinear. It is particularly true for vertical-axis turbines whose provided power is very sensitive to the load. Thus, controlling the operating point is essential to optimize the energetic behavior. Several control strategies (maximum power point tracking) can be used for the energy conversion. If the wind-turbine characteristic Cp(lambda) is supposed to be a priori known, it can be used for optimal control of the torque, speed, or system output power. On the contrary, if this characteristic is unknown, an operational seeking algorithm such as fuzzy logic has to be implemented. Several structures with different associated complexity degrees can be used, in particular, the structure of the ac-dc conversion, which can be either a pulsewidth-modulation voltage-source rectifier or a simple diode bridge. A comparative study of the corresponding control strategies and architectures is proposed in this paper regarding the tradeoffs between structure complexity and energy efficiency. The analysis is based on simulations and experiments

Ageing and Failure Modes of IGBT Modules in High-Temperature Power Cycling

This paper presents an experimental study on the ageing of insulated-gate bipolar transistor (IGBT) power modules. The aim is to identify the effects of power cycling on these devices with high baseplate temperatures (60 °C to 90 °C) and wide temperature swings (60 °C to 100 °C). These values for thermal stresses have been defined according to automotive applications. The test conditions are provided by two types of test benches that will be described in this paper. The changes in electrical and thermal indicators are observed regularly by a monitoring system. At the end of the test (reaching damage criterion or failure), different analyses are performed (acoustic scanning and SEM imaging), and the damage is listed systematically. Nineteen samples of 600-V 200-A IGBT modules were thus aged using five different power-cycling protocols. The final summary of results shows that ageing mechanisms mainly concern wire bonds and emitter metallization, with gradual impact depending on protocol severity.

Multicell converters: derived topologies

Multicell converters were introduced ten years ago and, over this period, their properties have been thoroughly analyzed. Since then, this concept has lead to some other innovative topologies which are briefly presented in this paper. Different ways to introduce soft switching in multicell converters are investigated. The concept of distributing power over several switches, giving more degrees of freedom and using less passive components, is extended further with the stacked multicell topology. Finally, direct AC-AC converters using the multicell approach are described.

Fault management of multicell converters

Component counts and oversimplified reliability rules may lead to the conclusion that multilevel converters are less safe than two-level converters, just because they use more components. A better approach might be to consider that they use a different arrangement of components and also that the consequence of faults may be very different. This paper is focused on the study of the consequences of faults in hard-switching and soft-switching multicell converters. Solutions to minimize the consequences of major faults are described.

Evaluation of

The supervision of semiconductor power devices in operation demonstrates an obvious interest to improve the operating safety of electronic power converters used in critical applications. Unfortunately, this is a significant challenge due to the variability of stress conditions on the one hand and to the difficulty to implement accurate measurement systems in power stages on the other. Using VCE measurement as a real-time supervision method is evaluated here by using aging test results obtained on insulated gate bipolar transistor (IGBT) modules stressed by power cycling. These results are related to the aging of bond wires and metallization, on the top part of the module. Results were obtained in original test benches whose characteristics are overviewed briefly in the first part of this paper, along with a description of test conditions. The second part presents selected results extracted from a larger work and focusing on the VCE evolution with respect to degradations of the modules top part. Their analysis highlights the potential of VCE measurement. The last part proposes the principle of a specific system able to achieve real-time VCE supervision in the test benches in operation.

V_{\rm ce}

Multilevel converters have many power devices and drivers. Thus, a direct reliability calculation based only on the first failure occurrence on one of the components clearly leads them to be devalued compared to two-level converters. However, taking into account that symmetrical multilevel converters such as the X-level active neutral point clamped (ANPC) family are based on imbricated and/or stacked switching cells on the one hand, with an additional center tap at the dc bus in three-phase operation on the other hand, several redundancies clearly appear which can be managed to increase the global reliability. For the first time, a general and theoretical methodology used to calculate reliability laws and failure rates and applied to compare two-, three-, and five-level topologies is proposed. Results show that the fault handling of three- and five-level three-phase topologies permits a great increase in reliability over a “relatively” short time duration, in addition to other benefits.

Monitoring as a Real-Time Method to Estimate Aging of Bond Wire-IGBT Modules Stressed by Power Cycling

The test and the characterization of medium or high-power electronic converters, under nominal operating conditions, are made difficult by the requirement of high-power electrical source and load. In addition, the energy lost during the test may be very significant. The opposition method, which consists of an association of two identical converters supplied by the same source, one operating as a generator, the other as a receptor, can be a better way to do these test. Another advantage is the possibility to realize accurate measurements of the different losses in the converters under test. In the first part of this paper, the characteristics of the method concerning loss measurements are compared to those of the electrical or calorimetric methods, then it is shown how it can be applied to different types of power electronic converters, choppers, switched mode power supplies, and pulsewidth modulation inverters. In the second part, different examples of studies conducted by the authors, and using this method, are presented. They have varying goals, from the test of soft-switching inverters to the characterization of integrated gate-commutated thyristor (IGCT) devices mounted into 2-MW choppers.

Reliability Calculation of Multilevel Converters: Theory and Applications

The imbricated-cell multilevel converter is well suited to high power applications. It allows the series connection of n switches with natural voltage sharing between these switches enabled through the connection of n-1 flying capacitors. This paper deals with the application of soft-switching on this topology; to date, only the hard-switching mode has been studied. The use of soft switching enables an increase of the switching frequency (resulting in the size reduction of the flying capacitors) without a decrease of the converter efficiency. Of the soft switching methods considered, the Auxiliary Resonant Commutated Pole (ARCP) technique was chosen due to the relative ease in which it can be incorporated into the converter topology. Furthermore, this technique offers numerous advantages: loss reduction, no added stress to the switches and compatibility with PWM control. The main properties of the ARCP multicell converter are the same as the hard-switched topology: an increase of the apparent output switching frequency and natural self-balancing of the flying-capacitor voltages. This paper presents the results of both simulations performed and measurements taken from an experimental set-up in order to study the viable system functioning. The introduction of soft-switching strongly complicates the theoretical study of the balancing mechanisms, however. As a result, the authors depend on simulations to validate the natural balancing effect during soft switching. Lastly, a general method of loss measurement is presented. Results show that the converter losses are reduced by at least 30%.

Use of opposition method in the test of high-power electronic converters

Power-factor-corrector (PFC) converters are now commonly used in low-power supply systems connected to AC networks. In addition to their basic PFC properties, they constitute the best technical solution to directly obtain the compatibility with a large range of AC voltages provided by different distribution networks around the world (typically, from 85 to 265 V rms). It is the main application of these converters. This function is achieved with an additional cost and volume, and this extra price to pay needs to be minimized. In this context, we first recall the main approaches of the design of conventional PFCs based on the boost converter topology. We emphasize the different critical points of the sizing that mainly concern the input choke and the silicon devices, in regard with the choice of the switching frequency. Few ways of improvement are then presented for these conventional PFCs. In a second part, always in the context of a large input voltage range, we consider the possibility to introduce the multi-level concept to reduce the input choke and filters. A solution using a multi-level flying capacitor two-cell converter is presented. It is shown that it can lead to a significant increase of the performances, with several options of sizing which can be suited to different requirements of the applications.