CN109613352A - Method, device and system for testing service life of power module in converter - Google Patents
Method, device and system for testing service life of power module in converter Download PDFInfo
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- G—PHYSICS
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Abstract
The invention discloses a method, a device and a system for testing the service life of a power module in a converter. The service life testing method comprises the following steps: controlling the power module to operate under a preset over-temperature pressure condition; obtaining the total time length of the power module from the beginning of operation to the failure of operation; taking the product of the total duration and the life acceleration factor as the operating life of the power module; wherein, the preset over-temperature pressure condition comprises: the ambient temperature in which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is higher than a preset threshold; the value of the life acceleration factor is determined by a preset over-temperature pressure condition. By adopting the embodiment of the invention, the service life test period of the converter power module can be shortened.
Description
Technical Field
The invention relates to the technical field of converters, in particular to a method, a device and a system for testing the service life of a power module in a converter.
Background
Wind power generation is the most mature technology and the most developed renewable energy technology in new energy, and a wind power converter is a core component of electric energy grid connection of a wind generating set, so that the research on the service life of the wind power converter is very important. The service life test of the converter is mainly the service life test of the power module in the converter, however, the service life test of the power module in the converter has the characteristic of long duration period, and the implementation of the service life test in the field of wind power converters is greatly limited due to the consideration of cost and project schedule.
Disclosure of Invention
The embodiment of the invention provides a method, a device and a system for testing the service life of a power module in a converter, which can effectively shorten the service life test duration period of the power module of the converter.
In a first aspect, an embodiment of the present invention provides a method for testing a lifetime of a power module in a converter, where the method includes:
controlling the power module to operate under a preset over-temperature pressure condition;
obtaining the total time length of the power module from the beginning of operation to the failure of operation;
taking the product of the total duration and the life acceleration factor as the operating life of the power module; wherein,
the preset over-temperature pressure conditions comprise: the ambient temperature in which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is higher than a preset threshold;
the value of the life acceleration factor is determined by a preset over-temperature pressure condition.
In a possible embodiment of the first aspect, the fluctuations are periodic fluctuations.
In one possible embodiment of the first aspect, the plurality of temperatures includes a first temperature and a second temperature, the first temperature being higher than the second temperature; when the power module operates under the preset over-temperature pressure condition, the time period that the ambient temperature is equal to the first temperature is the same as the time period that the ambient temperature is equal to the second temperature.
In one possible embodiment of the first aspect, the preset over-temperature pressure condition further comprises: the operating conditions of the power modules are different at different ambient temperatures.
In one possible embodiment of the first aspect, the plurality of temperatures includes a first temperature and a second temperature, the first temperature being higher than the second temperature; when the environment temperature is a first temperature, the output current of the power module is not equal to 0; when the ambient temperature is the second temperature, the output current of the power module is equal to 0.
In a possible implementation manner of the first aspect, when the power module adopts the water cooling device to dissipate heat, the ambient temperature refers to a temperature at a water inlet of the water cooling device; when the power module adopts the air cooling device to dissipate heat, the ambient temperature refers to the temperature at the air inlet of the air cooling device.
In a possible implementation manner of the first aspect, when determining the value of the life acceleration factor, a fatigue life Coffin-Manson model is established according to a preset over-temperature pressure condition, and the value of the life acceleration factor is calculated according to the Coffin-Manson model.
In a possible embodiment of the first aspect, the number of power modules is two, and the two power modules are operated alternately during the test.
The embodiment of the invention provides a device for testing the service life of a power module in a converter, which comprises:
the control processing module is used for controlling the power module to operate under the preset over-temperature pressure condition;
the timing processing module is used for acquiring the total time length of the power module from the beginning of operation to the failure of operation;
the service life result processing module is used for taking the product of the total duration and the service life acceleration factor as the operation service life of the power module;
wherein, the preset over-temperature pressure condition comprises: the ambient temperature in which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is higher than a preset threshold; the value of the life acceleration factor is determined by a preset over-temperature pressure condition.
In a third aspect, an embodiment of the present invention provides a life test system for a power module in a current transformer, where the life test system is based on the above life test method for the power module in the current transformer, and includes: the system comprises a closed cabinet body, a heat dissipation system and a main controller; the closed cabinet body is used for accommodating the power module; the heat dissipation system is connected with the power module and used for dissipating heat of the power module; the main controller is connected with the power module and the heat dissipation system, and is used for executing the service life test method of the power module in the converter.
In one possible embodiment of the third aspect, the life test system further comprises a converter controller, and the converter controller is communicatively connected to the main controller.
In a possible implementation manner of the third aspect, the life test system further includes a reactor, and the reactor is connected with the power module through a contactor; and the main controller controls the contactor to be switched on or switched off according to a preset over-temperature pressure condition so as to enable the power module to normally operate or stop operating.
In one possible implementation manner of the third aspect, the number of the power modules is two, and the number of the contactors is two, wherein the first power module is connected with the reactor through the first contactor, and the second power module is connected with the reactor through the second contactor; the main controller respectively controls the first contactor to be connected and the second contactor to be disconnected according to a preset over-temperature pressure condition, so that the first power module normally operates and the second power module stops operating; and controlling the first contactor to be switched off and the second contactor to be switched on so as to stop the first power module and normally operate the second power module.
In the embodiment of the invention, in order to carry out accelerated life test on the power module, the power module needs to be controlled and controlled to operate under the condition of the preset over-temperature pressure, and because the over-temperature pressure condition based on high temperature fluctuation can greatly shorten the time from the operation start to the operation failure of the power module compared with the normal temperature pressure, the technical scheme in the embodiment of the invention can quickly finish the life test of the power module of the converter, has the advantages of saving cost and avoiding delaying project progress, is beneficial to promoting the life test of the power module in the converter, evaluating the service life of the power module, and finding out the weakest design point of the operation of the power module in time and adjusting the design point.
Drawings
The present invention may be better understood from the following description of specific embodiments thereof taken in conjunction with the accompanying drawings, in which like or similar reference characters identify like or similar features.
Fig. 1 is a failure schematic diagram of a power module according to an embodiment of the present invention;
fig. 2 is a schematic flowchart of a method for testing a lifetime of a power module in a converter according to an embodiment of the present invention;
fig. 3 is a parameter diagram illustrating a temperature cycle test performed on a power module in a converter according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a device for testing a lifetime of a power module in a converter according to an embodiment of the present invention;
fig. 5 is a schematic structural diagram of a life test system for a power module in a current transformer according to an embodiment of the present invention;
fig. 6 is a schematic structural diagram of a life test system for a power module in a current transformer according to another embodiment of the present invention.
Detailed Description
Features and exemplary embodiments of various aspects of the present invention will be described in detail below. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present invention.
The power module in the converter mainly comprises an Insulated Gate Bipolar Transistor (IGBT), a thin film capacitor, a reactor, a Printed Circuit Board Assembly (PCBA) including active electronic devices and passive electronic devices, and the inventor of the present application finds that: the temperature fluctuation of the IGBT copper substrate can cause the peeling of the welding layer inside the IGBT or the occurrence of cavities, and the crusting thermal resistance is increased; the operation life rule of the film capacitor is that the core temperature is 10K higher per liter, and the life is doubled; the insulation characteristic of the silicon steel reactor is reduced along with the temperature rise; the heat-conducting silicone grease filled between the IGBT module and the radiator is used for ensuring the reliable contact between the IGBT module and the radiator and improving the heat dissipation efficiency, but the heat-conducting silicone grease is volatilized due to high temperature fluctuation and high continuous temperature, so that the heat dissipation failure is finally caused, and therefore, the temperature is closely related to the service life of the converter power module.
Fig. 1 is a failure schematic diagram of a power module according to an embodiment of the present invention. Wherein the abscissa represents the ambient pressure (e.g., voltage pressure, temperature pressure, ambient pressure, etc.) to which the power module is subjected, F0 represents the normal pressure, F1 represents the overpressure threshold, F2 represents the safety pressure threshold, and the ordinate represents the inverse of the life acceleration factor associated with the ambient pressure.
When the power module is subjected to an environmental pressure between F0 and F1, the failure is in the form of loss failure, mainly manifested as converter failure due to aging of the life of the electronic components, which belongs to a later failure mode.
When the environmental pressure to which the power module is subjected is between F1 and F2, the failure mode is usually an overpressure failure, which mainly means that the working condition of the power module exceeds the designed pressure, and belongs to the early failure mode.
In fig. 1, SA1 indicates a failure distribution region where the power module is subjected to an environmental pressure of F0, that is, when the power module is not subjected to life acceleration processing, and the life acceleration factor is 1. SA2 indicates that the ambient pressure to which the power module is subjected is F1, i.e., the failure distribution region in which the power module has not been subjected to life acceleration processing, and the inverse of the life acceleration factor is 1/60, that is, if the operating life of the power module measured at the pressure of F1 is 100 hours, the rated operating life of the power module under normal pressure should be calculated as 100 × 60 — 6000 hours.
Therefore, experiments can be designed to enable the power module converter power module to work in an over-pressure area, so that the service life of the power module is shortened by a certain life acceleration factor.
In addition, the applicant finds two temperature failure mechanisms in the power module loss failure research: the mechanism is loss failure caused by high temperature and constant temperature; the second mechanism is loss failure caused by high temperature fluctuation pressure. Because the phenomenon of temperature fluctuation appears more in the actual working condition of the wind power converter, and high temperature fluctuation is easier to cause the failure of electronic devices such as a semiconductor module, a heat dissipation system, a capacitor and the like.
Therefore, when the accelerated life test is carried out on the power module, high temperature fluctuation can be selected as an over-temperature pressure condition, and the environment temperature of the power module is controlled to fluctuate according to the preset temperature difference.
Based on the above, the embodiment of the invention provides a method, a device and a system for testing the service life of a power module in a converter.
Fig. 2 is a schematic flowchart of a method for testing a lifetime of a power module in a converter according to an embodiment of the present invention. As shown in fig. 2, the life test method includes steps 101 to 103.
In step 101, the power module is controlled to operate under a preset over-temperature pressure condition.
In step 102, the total length of time that the power module has elapsed from the start of operation to the failure of operation is obtained.
In step 103, the product of the total duration and the lifetime acceleration factor is taken as the operating lifetime of the power module.
Wherein the value of the life acceleration factor is determined by a preset over-temperature pressure condition. The preset over-temperature pressure conditions comprise: the ambient temperature in which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is above a preset threshold to meet characteristic requirements of high temperature fluctuations.
In the embodiment of the invention, in order to carry out accelerated life test on the power module, the power module needs to be controlled to operate under the condition of the preset over-temperature pressure, and because the over-temperature pressure condition based on high temperature fluctuation can greatly shorten the time from the operation start to the operation failure of the power module compared with the normal temperature pressure, the technical scheme in the embodiment of the invention can quickly complete the life test of the power module of the converter, has the advantages of saving cost and avoiding delaying project progress, is beneficial to promoting the life test of the power module in the converter, evaluating the service life of the power module, and finding out the weakest design point of the operation of the power module in time and adjusting the design point.
Further, in order to simplify the control process of the power module accelerated life test, the high temperature fluctuation may be periodic fluctuation, i.e. the fluctuation frequency and the fluctuation amplitude are fixed.
In an alternative embodiment, the ambient temperature to which the power module is exposed may be set to fluctuate between two temperatures, such as a first temperature T1 and a second temperature T2, T1> T2, and the period of time that the ambient temperature equals T1 is the same as the period of time that the ambient temperature equals T2 when the power module is operating under preset over-temperature pressure conditions.
Further, the operating conditions of the power module are different at different ambient temperatures. For example, when the ambient temperature is T1, the output current of the power module is not equal to 0; when the ambient temperature is T2, the output current of the power module is equal to 0, so that the power module can be continuously switched between a dynamic state and a static state, thereby accelerating the loss failure time of the power module.
In actual operation, the power module is installed in the closed cabinet body, a water cooling device or an air cooling device can be adopted to dissipate heat of the power module, and a water path of the water cooling device or an air channel of the air cooling device is communicated with the cabinet body where the power module is located. When the power module adopts a water cooling device for heat dissipation, the ambient temperature refers to the temperature at the water inlet of the water cooling device; when the power module adopts the air cooling device to dissipate heat, the ambient temperature refers to the temperature at the air inlet of the air cooling device.
The following describes the selection of parameters when the power module is subjected to a temperature cycle test, taking a water-cooled heat dissipation device as an example. Fig. 3 is a parameter diagram of a temperature cycle test performed on a power module in a converter according to an embodiment of the present invention. Wherein the horizontal axis represents time, the vertical axis represents the reciprocal of the acceleration factor, the curve S1 represents the output current of the power module, the curve S2 represents the temperature of the water inlet, and the curve S3 represents the cabinet temperature.
In the example of fig. 3, one fluctuation period is 30 minutes, in the first 15 minutes, the temperature of the water inlet is constant at 80 ℃, the output current of the power module is increased from 0 to the rated value Io, the power module is in an operating state, and the heat dissipation of the power module is slow due to the overhigh temperature of the water inlet; in the last 15 minutes, the water temperature of the water inlet is constant at 20 ℃, the output current of the power module is 0, the power module does not work, and the accumulated heat of the power module can be smoothly dissipated due to the lower temperature of the water outlet and is reduced to 20 ℃ after the fluctuation period is finished.
It should be noted that, although fig. 3 shows that two temperature reference values, namely 80 ℃ and 20 ℃, are included in a fluctuation cycle, and the duration of 80 ℃ is equal to the duration of 20 ℃ (15 minutes), in practical applications, a person skilled in the art may set a plurality of temperature reference values, for example, three, four, seven or more, and set the durations corresponding to the temperature reference values in a fluctuation cycle according to actual needs, and is not limited herein.
In addition, because in a fluctuation period, the power module needs to be in an idle state for a period of time, and the intermittent working mode can cause the reactor connected with the power module to be subjected to temperature cycle impact to accelerate the failure of the reactor, therefore, two power modules can be tested simultaneously, the two power modules are connected into the same reactor, and the reactor can be connected into the working power module alternately during testing, so that the reactor is prevented from being subjected to temperature cycle impact.
According to the embodiment of the invention, when the value of the life acceleration factor is determined, a fatigue life Coffin-Manson model is established according to a preset over-temperature pressure condition, and the value of the life acceleration factor is calculated according to the Coffin-Manson model. The following is a detailed description of the model of the accelerated failure factor introduced by the embodiments of the present invention.
When accelerated life testing is performed on a power module for temperature-pressure cycling, a simplified Coffin-Manson model (1) may be selected:
wherein, AFCoffTo be a life spanAn acceleration factor;
ΔTtestthe actual temperature fluctuation difference during the accelerated life test is obtained;
ΔToperpresetting temperature fluctuation difference during accelerated life test;
Ftestthe actual temperature fluctuation frequency during the life test is accelerated;
Fopera preset temperature fluctuation frequency which is an actual temperature fluctuation;
e is activation energy, which is related to the used material;
r is Boltzmann's constant, value 0.000086159;
Tmax testthe maximum absolute temperature value is the highest absolute temperature value in the accelerated life test;
Tmax operto speed up the actual maximum absolute temperature at the life test,
a. m and E are related to the operation condition of the product and the material of the evaluated product.
According to equation (1), the actual reduced rated life T of the power module can be obtainedoper：
Toper＝Ttest×AFCoff(2)
Further, when the power module is subjected to the accelerated life test, the delta T can be increasedtestAnd Tmax testTo shorten the test time.
Fig. 4 is a schematic structural diagram of a device for testing the lifetime of a power module in a converter according to an embodiment of the present invention, and as shown in fig. 4, the device for testing the lifetime of a power module includes a control processing module 401, a timing processing module 402, and a lifetime result processing module 403.
The control processing module 401 is configured to control the power module to operate under a preset over-temperature pressure condition. The timing processing module 402 is used to obtain the total time that the power module has elapsed from the start of operation to the failure of operation. The lifetime result processing module 403 is configured to take the product of the total duration and the lifetime acceleration factor as the operating lifetime of the power module.
Wherein, the value of the life time acceleration factor is determined by a preset over-temperature pressure condition, and the preset over-temperature pressure condition comprises: the ambient temperature at which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is above a preset threshold.
Fig. 5 is a schematic structural diagram of a life test system of a power module in a current transformer according to an embodiment of the present invention, which is based on the above life test method of the power module in the current transformer, and as shown in fig. 5, the life test system includes a closed cabinet, a heat dissipation system 503, and a main controller 504.
Wherein the enclosure is used to contain power modules, fig. 5 shows two groups of power modules 501 and 502, which are respectively installed in the enclosure 1 and the enclosure 2.
The heat dissipation system 503 is respectively communicated with the cabinet body to which the two groups of power modules 501 and 502 belong, and the heat dissipation system may be a water cooling device or an air cooling device.
The main controller 504 is connected to the power modules 501 and 502 and the heat dissipation system 503, respectively, and the main controller 504 executes the life test method of the power modules in the converter as described above.
It should be noted that the power module may include a combination device formed by a network side three-phase power module and a machine side three-phase power module, or may be a single network side three-phase power module or a machine side three-phase power module, which is not limited herein.
Fig. 6 is a schematic structural diagram of a life test system of a power module in a converter according to another embodiment of the present invention, which is used to show a specific implementation form of the life test system.
Fig. 6 shows two groups of power modules in common, each group of power modules includes a grid-side power module and a machine-side power module, converter controllers corresponding to the two groups of power modules are respectively CPU1 and CPU2, and CPU1 and CPU2 are used as main bodies of a test, and implement a test control process together with PLC main control.
The water temperature control system shown in fig. 6 includes a water temperature control execution system and a corresponding controller CPU 3.
Fig. 6 also shows a reactor 601, the reactor 601 is connected with two groups of power modules through contactors Q1 and Q2, respectively, and the PLC master control is configured to control Q1 to be turned on and Q2 to be turned off according to a preset over-temperature pressure condition, so that the power modules in the enclosure 1 operate normally and the power modules in the enclosure 2 stop operating; and controls the Q1 to be switched off and the Q2 to be switched on, so that the power module in the closed cabinet 1 stops running and the power module in the closed cabinet 2 runs normally.
The load of the converter power module shown in fig. 6 is a star-connected reactor, in order to prevent the power supply system and the load reactor from temperature cycle impact in each test period, two contactors Q1 and Q2 are added in the system, and through PLC master control, two groups of converter power modules work alternately, so that the power supply and the test load of the test system can work continuously.
It should be noted that. The PLC master is a central processing unit of the entire accelerated life test system, and may communicate with the inverter controller CPU1, the CPU2, and the water temperature controller CPU2, respectively, in a data serial manner. The PLC master control can also control the starting and stopping of the power module, the switching of the reactor and the temperature of the cooling system, and can perform the functions of storing running data, recording running time, alarming the system and the like.
It should also be clear that the embodiments in this specification are described in a progressive manner, and that the same or similar parts in the various embodiments are referred to each other, and each embodiment focuses on differences from the other embodiments. For the device embodiments, reference may be made to the description of the method embodiments in the relevant part. Embodiments of the invention are not limited to the specific steps and structures described above and shown in the drawings. Those skilled in the art may make various changes, modifications and additions to, or change the order between the steps, after appreciating the spirit of the embodiments of the invention. Also, a detailed description of known process techniques is omitted herein for the sake of brevity.
The functional blocks shown in the above-described structural block diagrams may be implemented as hardware, software, firmware, or a combination thereof. When implemented in hardware, it may be, for example, an electronic circuit, an Application Specific Integrated Circuit (ASIC), suitable firmware, plug-in, function card, or the like. When implemented in software, the elements of an embodiment of the invention are the programs or code segments used to perform the required tasks. The program or code segments may be stored in a machine-readable medium or transmitted by a data signal carried in a carrier wave over a transmission medium or a communication link. A "machine-readable medium" may include any medium that can store or transfer information. Examples of a machine-readable medium include electronic circuits, semiconductor memory devices, ROM, flash memory, Erasable ROM (EROM), floppy disks, CD-ROMs, optical disks, hard disks, fiber optic media, Radio Frequency (RF) links, and so forth. The code segments may be downloaded via computer networks such as the internet, intranet, etc.
Embodiments of the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. For example, the algorithms described in the specific embodiments may be modified without departing from the basic spirit of the embodiments of the present invention. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the embodiments of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (13)
1. A method for testing the service life of a power module in a converter is characterized by comprising the following steps:
controlling the power module to operate under a preset over-temperature pressure condition;
obtaining the total time length of the power module from the beginning of operation to the failure of operation;
taking the product of the total duration and a life acceleration factor as the operating life of the power module; wherein,
the preset over-temperature pressure condition comprises the following steps: the ambient temperature in which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is above a preset threshold;
the value of the life acceleration factor is determined by the preset over-temperature pressure condition.
2. The method of claim 1, wherein the fluctuations are periodic fluctuations.
3. The method of claim 1, wherein the plurality of temperatures includes a first temperature and a second temperature, the first temperature being higher than the second temperature; when the power module operates under the preset over-temperature pressure condition, the duration that the ambient temperature is equal to the first temperature is the same as the duration that the ambient temperature is equal to the second temperature.
4. The method of claim 1, wherein the preset over-temperature pressure condition further comprises: and under different ambient temperatures, the operating conditions of the power module are different.
5. The method of claim 4, wherein the plurality of temperatures includes a first temperature and a second temperature, the first temperature being higher than the second temperature;
when the environment temperature is the first temperature, the output current of the power module is not equal to 0; when the environment temperature is the second temperature, the output current of the power module is equal to 0.
6. The method of claim 1,
when the power module adopts a water cooling device for heat dissipation, the environment temperature refers to the temperature at the water inlet of the water cooling device;
when the power module adopts an air cooling device for heat dissipation, the environment temperature refers to the temperature at the air inlet of the air cooling device.
7. The method according to claim 1, wherein when determining the value of the life acceleration factor, a fatigue life Coffin-Manson model is established according to the preset over-temperature pressure condition, and the value of the life acceleration factor is calculated according to the Coffin-Manson model.
8. The method of claim 1, wherein the number of power modules is two, and wherein the two power modules are operated alternately during the test.
9. A life test device of power module in converter, characterized by includes:
the control processing module is used for controlling the power module to operate under the condition of preset over-temperature pressure;
the timing processing module is used for obtaining the total time length of the power module from the beginning of operation to the failure of operation;
a life result processing module for taking the product of the total duration and the life acceleration factor as the operation life of the power module;
wherein,
the preset over-temperature pressure condition comprises the following steps: the ambient temperature in which the power module is located fluctuates between a plurality of temperatures, wherein at least one temperature of the plurality of temperatures is above a preset threshold;
the value of the life acceleration factor is determined by the preset over-temperature pressure condition.
10. A life test system for a power module in a current transformer, the life test system comprising: the system comprises a closed cabinet body, a heat dissipation system and a main controller; wherein,
the closed cabinet body is used for accommodating a power module;
the heat dissipation system is connected with the power module and used for dissipating heat of the power module;
the main controller is connected with the power module and the heat dissipation system, and is used for executing a life test method of the power module in the current transformer based on any one of claims 1-8.
11. The system of claim 10, further comprising a converter controller communicatively coupled to the master controller.
12. The system of claim 10, further comprising a reactor connected to the power module through a contactor;
and the main controller controls the contactor to be switched on or switched off according to the preset over-temperature pressure condition so as to enable the power module to normally operate or stop operating.
13. The system of claim 12,
the number of the power modules is two, and the number of the contactors is two, wherein the first power module is connected with the reactor through a first contactor, and the second power module is connected with the reactor through a second contactor;
the main controller respectively controls the first contactor to be connected and the second contactor to be disconnected according to the preset over-temperature pressure condition, so that the first power module normally operates and the second power module stops operating; and controlling the first contactor to be switched off and the second contactor to be switched on so as to stop the first power module from operating and enable the second power module to normally operate.
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