CN110726923A - Accelerated life test method for motor controller circuit board - Google Patents
Accelerated life test method for motor controller circuit board Download PDFInfo
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- CN110726923A CN110726923A CN201810778640.3A CN201810778640A CN110726923A CN 110726923 A CN110726923 A CN 110726923A CN 201810778640 A CN201810778640 A CN 201810778640A CN 110726923 A CN110726923 A CN 110726923A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/28—Testing of electronic circuits, e.g. by signal tracer
- G01R31/2801—Testing of printed circuits, backplanes, motherboards, hybrid circuits or carriers for multichip packages [MCP]
- G01R31/281—Specific types of tests or tests for a specific type of fault, e.g. thermal mapping, shorts testing
- G01R31/2817—Environmental-, stress-, or burn-in tests
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Abstract
The invention provides an accelerated life test method of a motor controller circuit board, which comprises the steps of obtaining the temperature cycle change times of the conventional life test of the motor controller circuit board, calculating the temperature cycle change times of the accelerated life test according to the temperature cycle change times, and finally carrying out the accelerated life test on a motor controller sample piece to be tested to judge whether the motor controller circuit board sample piece to be tested is invalid or not. The invention can accurately detect some functions of the motor controller circuit board to further judge the service life of the motor controller circuit board, and simulate the operation condition of the motor controller circuit board by using the set temperature change curve, thereby greatly shortening the service life test period of the motor controller circuit board, reducing the test cost, improving the service life test efficiency of the motor controller circuit board, improving the reliability of service life detection of the motor controller circuit board, finding the problems of the motor controller circuit board in advance, solving the problems in time and ensuring the reliable operation of the whole vehicle.
Description
Technical Field
The invention belongs to the technical field of new energy automobiles, and particularly relates to an accelerated life test method for a motor controller circuit board.
Background
The motor controller is a core component of the new energy automobile, and has the main functions of controlling the driving motor to work, providing power for the automobile, providing an auxiliary braking function when the automobile is braked, and recycling braking energy. The motor controller is a power control unit, the inside contains the three-phase full-bridge inverter circuit who comprises a plurality of IGBT power modules, motor controller is in the course of the work, can produce a large amount of heats because of IGBT switching loss and conduction loss, high-voltage distribution parts such as bus capacitance and the contactor inside the controller in addition also can produce more heats in the course of the work, these heats are mostly taken away by cooling circulation system, but still can partly pass through the casing, the air radiates to the controller inside, and the controller is a confined space structurally, can cause the hot chamber effect of controller like this, make the controller work in the cavity inside temperature can reach 70 ℃, especially on some circuit boards that have heating device inside the controller, if the local temperature of drive plate can reach 90 ℃ the highest. In addition, in winter, especially in severe cold areas, the temperature can be reduced to-20 ℃ or even-40 ℃ after the controller stops working. The design life of the motor controller for the vehicle is generally required to reach 10 years, and as mentioned above, the motor controller is required to bear high and low temperature cold and heat shock for a long time in work.
If the publication number is "CN 207449665U", the name is "a Chinese patent of electric automobile motor controller", the motor controller that this patent discloses includes the casing and sets up the upper cover at the casing top, is provided with the IGBT module in the casing, is provided with IGBT control circuit board above the IGBT module. Because there are many electronic device and connector on the inside circuit board of motor controller, the used material of materials such as circuit board, connector and electronic components is various, and the coefficient of expansion of various materials also has great difference, and the controller influences the reliable operation of vehicle because of bearing high low temperature impact for a long time, and the expanded thermal contraction influences, and the circuit board takes place pad fracture, device damage scheduling problem, consequently, needs detect the life-span and the function of circuit board.
Disclosure of Invention
The invention aims to provide an accelerated life test method of a motor controller circuit board, which is used for solving the problem of low vehicle operation reliability caused by the fact that the service life of the motor controller circuit board is not detected in the prior art.
In order to achieve the purpose, the invention provides an accelerated life test method of a motor controller circuit board, which comprises the following steps:
1) acquiring the temperature cycle change times of a conventional life test of a motor controller circuit board, and calculating the temperature cycle change times of an accelerated life test according to the temperature cycle change times, the temperature change range under the conventional life test and the temperature change range under the accelerated test;
2) selecting a motor controller sample piece to be tested, carrying out accelerated life test on a circuit board of the motor controller sample piece to be tested according to a temperature change curve determined by a temperature change range under the accelerated life test until the temperature cycle change times of the accelerated life test are reached, carrying out circuit function test on the circuit board of the motor controller sample piece to be tested, and judging that the motor controller sample piece to be tested fails if the test fails; or if the set welding point aging characteristics appear on the circuit board of the motor controller sample piece to be tested in the acceleration test process, performing circuit function test, if the test is passed, continuing the test until the temperature cycle change times of the acceleration life test is reached, and if the test is not passed, judging that the test is invalid.
Further, the number of temperature cycle changes of the accelerated life test is represented as:
wherein N isLabNumber of temperature cycles for accelerated life test, NprufNumber of temperature cycles, Δ T, for routine life testingpraxTemperature variation range, Δ T, for routine life testLabK is a model index for the temperature change range under the accelerated life test.
The temperature change curve is defined as that the circuit board of the motor controller sample piece to be tested is placed at a first set temperature for a first set time, and then the circuit board of the motor controller sample piece to be tested is placed at a second set temperature for a second set time.
In order to prevent the circuit board of the motor controller sample piece to be tested from being subjected to large thermal shock, after the circuit board of the motor controller sample piece to be tested is placed at the first set temperature for the first set time, the circuit board of the motor controller sample piece to be tested is placed at the second set temperature for the second set time after the circuit board of the motor controller sample piece to be tested is placed at the first set temperature for the third set time.
As a further limitation on the welding spot aging characteristic, the set welding spot aging characteristic means that the length of the visible crack of the circuit board sample of the motor controller to be tested is longer than the set length of the welding surface or the visible crack and the crack of the circuit board sample of the motor controller to be tested are completely cracked.
Further, after the accelerated life test is finished, if the function test of the circuit board of the motor controller sample piece to be tested is judged to pass, the welding spot aging characteristic of the circuit board of the motor controller sample piece to be tested is detected, and if the set welding spot aging characteristic does not appear on the circuit board of the motor controller sample piece to be tested, the motor controller sample piece is judged to be not failed.
Further, if the circuit board of the motor controller sample piece to be tested is judged to have the set welding point aging characteristic, slicing analysis is carried out on the circuit board of the motor controller sample piece to be tested, if the length of the crack on the slice is judged to be larger than the set length of the welding surface, the motor controller sample piece to be tested is judged to be invalid, and if not, the motor controller sample piece to be tested is judged to be invalid.
The invention has the beneficial effects that:
the method comprises the steps of firstly obtaining the temperature cycle change times of the conventional life test of the motor controller circuit board, then calculating the temperature cycle change times of the accelerated life test according to the temperature cycle change times and related parameters, and finally carrying out the accelerated life test on the motor controller sample piece to be tested to judge whether the motor controller circuit board sample piece to be tested is invalid. The invention can accurately detect some functions of the motor controller circuit board to further judge the service life of the motor controller circuit board, and simulate the operation condition of the motor controller circuit board by using the set temperature change curve, thereby greatly shortening the service life test period of the motor controller circuit board, reducing the test cost, improving the service life test efficiency of the motor controller circuit board, improving the reliability of service life detection of the motor controller circuit board, finding the problems of the motor controller circuit board in advance, solving the problems in time and ensuring the reliable operation of the whole vehicle.
Drawings
Fig. 1 is a schematic diagram of a cold-hot impact curve of a motor controller circuit board according to the present invention.
Detailed Description
The following further describes embodiments of the present invention with reference to the drawings:
the invention combines the operating temperature and environment of the motor controller and the material characteristic of the motor controller to obtain the relationship between the service life of the circuit board and the temperature change, and completes the accelerated service life verification and evaluation of the circuit board of the motor controller by setting an accelerated service life verification model and setting a temperature change cycle. Based on the above, the invention provides an accelerated life test method for a motor controller circuit board, which comprises the following steps:
1) acquiring the temperature cycle change times of the conventional life test of the motor controller circuit board, and calculating the temperature cycle change times of the accelerated life test according to the temperature cycle change times, the temperature change range under the conventional life test and the temperature change range under the accelerated test;
2) selecting a motor controller sample piece to be tested, carrying out accelerated life test on a circuit board of the motor controller sample piece to be tested according to a temperature change curve determined by a temperature change range under the accelerated life test until the temperature cycle change times of the accelerated life test are reached, carrying out circuit function test on the circuit board of the motor controller sample piece to be tested, and judging that the motor controller sample piece to be tested fails if the test fails; or if the circuit board of the motor controller sample piece to be tested has set welding point aging characteristics in the process of the accelerated test, performing circuit function test, if the test is passed, continuing the test until the temperature cycle change times of the accelerated life test is reached, and if the test is not passed, judging that the test is invalid.
The set welding point aging characteristic means that the length of the visible crack of the circuit board sample piece of the motor controller to be tested is larger than the set length of the welding surface, or the visible crack of the circuit board sample piece of the motor controller to be tested is larger than the crack of the welding surface, and the crack is completely cracked.
The number of temperature cycle changes in the accelerated life test is represented as:
wherein N isLabNumber of temperature cycles for accelerated life test, NprufNumber of temperature cycles, Δ T, for routine life testingpraxTemperature variation range, Δ T, for routine life testLabK is a model index for the temperature change range under the accelerated life test.
The temperature variation curve of this embodiment refers to a time period for which the circuit board of the sample piece of the motor controller to be tested is placed at the first set temperature for the first set time, and then a time period for which the circuit board of the sample piece of the motor controller to be tested is placed at the second set temperature for the second set time. Here, after the circuit board of the sample motor controller device under test is left at the first set temperature for the first set time, the circuit board of the sample motor controller device under test is left at the second set temperature for the second set time after the third set time.
After the accelerated life test is finished, if the function test of the circuit board of the motor controller sample piece to be tested is judged to be passed, detecting the solder joint aging characteristic of the circuit board of the motor controller sample piece to be tested, and if the circuit board of the motor controller sample piece to be tested is judged not to have the set solder joint aging characteristic, judging that the motor controller sample piece does not fail; and if the circuit board of the motor controller sample piece to be tested is judged to have the set welding point aging characteristic, carrying out slicing analysis on the circuit board of the motor controller sample piece to be tested, if the length of the crack on the slice is judged to be larger than the set length of the welding surface, judging that the motor controller sample piece to be tested is invalid, and if not, judging that the motor controller sample piece to be tested is not invalid.
The following steps are combined with the operating environment temperature of the motor controller to detect the service life of the circuit board of the motor controller, and the method comprises the following steps:
1) number of temperature cycles required for life NpraxDetermination of (1):
in the embodiment, the running condition of the urban bus is adopted to estimate the times of cold and hot shock, the bus is supposed to run at the first station and the last station for 8 times every day, the water temperature is basically unchanged during the midway rest, the typical water temperature is 40 ℃, the maximum internal temperature of the driver during running is 90 ℃, and the average ambient temperature is 25 ℃. The bus runs 365 days per year, and the motor controller experiences 2 temperature changes: 8 temperature changes 50 ℃ and 1 temperature change 65 ℃ (cold start).
(1) Under the condition that the motor controller has a service life of 10 years, the temperature changes by 50 ℃ and 29200 times; the temperature was changed 65 ℃ and 3650 times.
(2) Under the condition that the motor controller has a 15-year service life, the temperature changes by 50 ℃ and 43800 times; the temperature was changed to 65 ℃ and 5475 times. The data are shown in Table 1:
TABLE 1 Life time and number of cycles
Compared with the urban public transport working condition, the temperature impact frequency under the high-speed working condition is lower, and the service life requirement of the public transport working condition is met by the circuit board welding spots, so that the service life requirement of the high-speed working condition is met inevitably.
2) Determination of the number of temperature cycles of the accelerated test:
the key part influencing the service life of the motor controller is a circuit board welding spot, and when the circuit board of the motor controller is designed, the following requirements are required for the circuit board welding spot: number of temperature cycles N under design requirementsprax29200; the reliability R is 0.9; confidence PA0.9; the number n of samples is 10.
The service life of the welding point of the circuit board follows Weibull distribution, beta is a Weibull shape parameter and is related to a failure mechanism, and the value of typical welding point fatigue failure is 3; n is a radical ofprufThe number of the specific temperature changes required to be tested under the actual temperature change, namely the number of the conventional temperature cycle changes.
Using the Coffin-Manson model:
wherein the model index k is 2.65, the fatigue constant of the lead-free solder, and delta TpraxThe actual temperature variation range is 50 ℃ or 65 ℃; delta TLabThe temperature range for the test was 170 deg.C (maximum temperature 125 deg.C, minimum temperature-45 deg.C). From the above data, N can be obtainedLabThe number is as follows: 1849 cycles correspond to a 10 year lifetime and 2775 cycles correspond to a 15 year lifetime, as shown in Table 2.
TABLE 2 accelerated life test temperature cycle number of changes
3) Temperature cycling settings:
the factors influencing the welding points of the circuit board are mainly temperature cold and heat changes, the service life of the welding points is verified by adopting a cold and heat impact method, the whole circuit board is cooled to the low temperature of-45 ℃, kept for a certain time and then rapidly heatedHeating to 125 deg.C, and maintaining for a certain time to complete a temperature cycle. The circuit board is placed in a temperature surge tank, the cold and hot shocks include a high temperature period and a low temperature period, and the test sample is exposed to a first temperature TaHolding at-45 deg.C for a first set time and then exposing the test piece to a second temperature TbThe second set time is maintained at 125 ℃, and the first set time and the second set time are equal and are t1As another embodiment, the first set time and the second set time may not be equal to each other; placing a motor controller circuit board at a first set temperature t1After the time, a third set time t is needed2Placing the circuit board of the motor controller sample piece to be tested at a second set temperature t1Time, the third setting time t of the present embodiment2No more than 0.5 minute, and the next cycle, the test piece was exposed to a low temperature TaAt the time of transition t2Not exceeding 0.5 minute. One cycle comprises 2 exposure times t1And 2 transition times t2FIG. 1 is a graph of temperature change versus time, FIG. 1A-beginning of the first cycle; b-end of first cycle and start of second cycle. In general, it is difficult to rapidly change the temperature of the temperature surge tank from one temperature to another, and therefore, the present embodiment requires t or less1The temperature of the temperature impact box reaches the required temperature value within 10 hours, if the temperature is less than or equal to t1And if the temperature of the temperature impact box does not reach the required temperature value within 10 hours, judging that the test fails.
4) Accelerated life test and evaluation:
(1) randomly extracting 10 sample pieces with the number of 1# -10#, fixing the circuit board in a fixture, and placing the fixture into a temperature impact box.
(2) Loading the cold and hot impact specified in the step 3).
(3) And (5) regularly monitoring the change condition of the welding spot of the sample piece and recording test data. The specific cycle times and the corresponding years can be customized, for example, if the welding spot is found to have a cracking trend, the detection frequency needs to be strengthened subsequently. The specific cycle number and the corresponding year are shown in Table 2.
(4) Detection in the test: if the circuit board of the motor controller sample piece to be tested has a welding spot aging grade of 4-5, the circuit board of the motor controller sample piece to be tested needs to be subjected to circuit function testing, and if the circuit function testing is passed, the circuit board is put back to continue testing until the testing is finished; and if the circuit function test fails, determining that the circuit is not qualified. The aging levels 4-5 refer to the set welding point aging characteristics.
(5) Detection after the test: firstly, testing the circuit function, if the circuit function of the motor controller fails, judging that the motor controller fails, namely, the motor controller sample piece to be tested fails; if the function of the motor controller circuit passes, the aging degree of the welding spot of the circuit board of the motor controller sample piece to be detected is detected, if the aging degree of the welding spot of the circuit board of the motor controller sample piece to be detected is judged to be within a set range, the motor controller sample piece is judged not to be invalid, and the aging degree of the circuit board of the motor controller to be detected is judged by performing visual inspection through a stereo microscope.
Solder joint aging, as observed by a stereomicroscope, is defined as follows:
level 0: smooth and bright, does not become grey-dark and has no dark cracks;
level 1: the surface is dark, rough and crackless;
and 2, stage: the surface has (dark) cracks, and the length of the corresponding welding surface is less than 25 percent of the cracks;
and 3, level: cracks are obviously visible on the surface, and 25-50% of the cracks correspond to the length of the welding surface;
4, level: cracks are obviously visible on the surface, and the cracks are larger than 50% of the length of the corresponding welding surface, but are not completely disconnected;
and 5, stage: cracks are obviously visible on the surface, and the surface is completely cracked.
If the aging grade of the circuit board of the motor controller is detected to be 0-3 grade, subsequent slice analysis is not needed, and the circuit board is directly judged to be qualified; if the aging grade of the circuit board of the motor controller is detected to be 4-5 grades, slicing analysis and examination under a metallographic microscope are needed, and if the length of the cracks on the slices is determined to be larger than 50% of the length of the corresponding welding surface, the judgment is unqualified; if < 50%, the product is qualified.
The invention provides a principle, a test and a rating method for testing and verifying the cold and hot impact accelerated life of a welding spot of a circuit board of a motor controller, and the problems existing in the design of the circuit board are found in advance through accelerated verification, so that the reliability of the motor controller is improved, the test period is greatly shortened, and the test cost is reduced.
The specific embodiments are given above, but the present invention is not limited to the above-described embodiments. The basic idea of the present invention lies in the above basic scheme, and it is obvious to those skilled in the art that no creative effort is needed to design various modified models, formulas and parameters according to the teaching of the present invention. Variations, modifications, substitutions and alterations may be made to the embodiments without departing from the principles and spirit of the invention, and still fall within the scope of the invention.
Claims (7)
1. An accelerated life test method of a motor controller circuit board is characterized by comprising the following steps:
1) acquiring the temperature cycle change times of a conventional life test of a motor controller circuit board, and calculating the temperature cycle change times of an accelerated life test according to the temperature cycle change times, the temperature change range under the conventional life test and the temperature change range under the accelerated life test;
2) selecting a motor controller sample piece to be tested, carrying out accelerated life test on a circuit board of the motor controller sample piece to be tested according to a temperature change curve determined by a temperature change range under the accelerated life test until the temperature cycle change times of the accelerated life test are reached, carrying out circuit function test on the circuit board of the motor controller sample piece to be tested, and judging that the motor controller sample piece to be tested fails if the test fails; or if the set welding point aging characteristic appears on the circuit board of the motor controller sample piece to be tested in the accelerated life test process, performing circuit function test, if the test is passed, continuing the test until the temperature cycle change times of the accelerated life test is reached, and if the test is not passed, judging that the test is invalid.
2. The accelerated life test method of a motor controller circuit board according to claim 1, wherein the number of temperature cycle changes of the accelerated life test is represented as:
wherein N isLabNumber of temperature cycles for accelerated life test, NprufNumber of temperature cycles, Δ T, for routine life testingpraxTemperature variation range, Δ T, for routine life testLabK is a model index for the temperature change range under the accelerated life test.
3. The accelerated life test method of a motor controller circuit board according to claim 1 or 2, wherein the temperature variation curve refers to a time period for which the circuit board of the motor controller sample to be tested is placed at a first set temperature for a first set time, and then a time period for which the circuit board of the motor controller sample to be tested is placed at a second set temperature for a second set time.
4. The accelerated life test method of a motor controller circuit board according to claim 3, wherein after the circuit board of the motor controller sample to be tested is placed at the first set temperature for the first set time, the circuit board of the motor controller sample to be tested is placed at the second set temperature for the second set time after a third set time.
5. The accelerated life test method of a motor controller circuit board according to claim 1, wherein the set solder joint aging characteristic means that the length of the visible crack of the sample piece of the motor controller circuit board to be tested is longer than the set length of the soldering surface or the sample piece of the motor controller circuit board to be tested has a visible crack and the crack is completely cracked.
6. The accelerated life test method of the motor controller circuit board according to claim 5, wherein after the accelerated life test is finished, if the function test of the circuit board of the motor controller sample piece to be tested is judged to pass, the solder joint aging characteristic of the circuit board of the motor controller sample piece to be tested is detected, and if the set solder joint aging characteristic of the circuit board of the motor controller sample piece to be tested is judged not to occur, the motor controller sample piece is judged not to fail.
7. The accelerated life test method of a motor controller circuit board according to claim 6, wherein if the circuit board of the motor controller sample piece to be tested is judged to have the set solder joint aging characteristic, the circuit board of the motor controller sample piece to be tested is subjected to slice analysis, if the length of the crack on the slice is judged to be greater than the set length of the soldering surface, the motor controller sample piece to be tested is judged to be failed, otherwise, the motor controller sample piece to be tested is judged to be not failed.
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| CN112729794A (en) * | 2020-12-23 | 2021-04-30 | 宝能(广州)汽车研究院有限公司 | Service life verification method and verification platform of motor controller |
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