CN113267690A - Aging evaluation method for power module of traction converter - Google Patents
Aging evaluation method for power module of traction converter Download PDFInfo
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Abstract
The invention provides a method for evaluating the aging of a power module of a traction converter, which adopts the technical scheme that the method comprises the steps of carrying out parameter test on the power module of the traction converter and comparing the parameters with a rated value and a maximum value; if the parameter of the power module exceeds the rated value but does not exceed the maximum value, calculating the junction temperature of the power module under the actual working condition; performing on-site sampling test on the power module, acquiring the number of sample life times of the power module according to the junction temperature, calculating the number of model life times according to an existing life model, and acquiring a corrected life model according to the number of sample life times and the number of model life times; and obtaining the cycle life times of the power module according to the junction temperature by correcting the life model, and calculating the expected life times of the power module according to the cycle life times. The method solves the problem that the aging state of the power module cannot be accurately evaluated by the conventional method for evaluating the aging of the power module of the traction converter.
Description
Technical Field
The invention belongs to the technical field of converters, and particularly relates to a method for evaluating aging of a power module of a traction converter.
Background
The traction converter provides power for rail transit vehicles, is known as the heart of the vehicles, a power module in the traction converter bears the core electric energy conversion function, and the aging state of the traction converter is directly related to the safe and reliable operation of trains.
At present, the evaluation method of the power module in rail transit vehicles at home and abroad is simpler, and a parameter test method is generally adopted, namely, the parameter of the module is tested and then compared with the value in a manual, so that the state of the power module is judged. According to the actual test situation, although the parameters of many modules are attenuated, the parameters of many modules do not exceed the calibration range specified by the manual, so that the aging state of the modules cannot be evaluated by the current maintenance regulations.
In recent years, in some domestic and foreign documents, it has been proposed to calculate the remaining life of a power module based on a life model. The evaluation method is to calculate the expected life based on a life model of a new module, wherein the life model is generally obtained by long-time test tests of a component supplier, and a test object is a new module. For a module which runs for many years, due to the fact that parameter states of the module obviously change, a life model is not applicable, and in addition, enough samples can not be tested again on site to obtain the life model, so that the method is difficult to be applied to the aging state evaluation of a site operation module.
Disclosure of Invention
The embodiment of the application provides a method for evaluating the aging of a power module of a traction converter, which is used for at least solving the problem that the aging state of the power module cannot be accurately evaluated by the conventional method for evaluating the aging of the power module of the traction converter.
The embodiment of the application provides a method for evaluating the aging of a power module of a traction converter, which comprises the following steps: a module parameter testing step, namely performing parameter testing on a power module of the traction converter and comparing the parameters with a rated value and a maximum value; calculating the actual junction temperature, namely calculating the junction temperature of the power module under the actual working condition if the parameter of the power module exceeds the rated value but does not exceed the maximum value; a life model correction step, namely performing field sampling test on the power module, acquiring the number of times of the life of a sample of the power module according to the junction temperature, calculating the number of times of the life of the model according to an existing life model, and acquiring a corrected life model according to the number of times of the life of the sample and the number of times of the life of the model; and an aging state evaluation step, namely acquiring the cycle life times of the power module according to the corrected life model and the junction temperature, and calculating the expected life times of the power module according to the cycle life times.
Preferably, the actual junction temperature calculating step calculates the junction temperature according to the following formula:
Tj＝Ploss*Zth+Ta
in the formula, TjIs the junction temperature, Z, of the power modulethIs the thermal impedance of the power module, TaIs ambient temperature, PlossIs the power consumption of the power module.
Preferably, the power consumption includes a conduction loss of the power module, and the conduction loss is calculated according to the following formula:
Pcond,s＝Is×Vce
in the formula, Pcond，sTo conduction loss, IsIs the voltage at which the power module operates, VceIs the voltage at which the power module operates.
Preferably, the power consumption includes a switching loss of the power module, and the switching loss is obtained by a linear interpolation method.
Preferably, the lifetime model correcting step further includes: selecting a preset number of power modules as samples, testing the service life times of the power modules at the same junction temperature, and calculating an average value to obtain the service life times of the samples.
Preferably, the modified life model is obtained according to the following formula:
in the formula, Nf_oldNumber of sample Life times, Nf_newThe number of model life times, A and n are model parameters.
Preferably, the aging state evaluating step further includes: discretizing the junction temperature to obtain the cycle number of each junction temperature period, and obtaining the cycle life number through the corrected life model.
Preferably, the aging state evaluating step further includes: and obtaining the expected life times under the action of different junction temperature periods according to the junction temperature, the cycle times and the cycle life times.
Preferably, the aging state evaluating step further includes: and obtaining the expected life times under the action of different junction temperature cycles by adopting a linear fatigue damage accumulation theory.
Preferably, the evaluation method further includes a health state evaluation step of calculating a difference between the expected life times and a design life, and judging the health state of the power module according to the difference and a preset difference ratio.
Compared with the related art, the method for evaluating the aging of the power module of the traction converter can evaluate the aging state of the module of a train running for many years under the condition of lacking historical operation data and a large number of test samples, provides judgment on whether the module is suitable for continuous operation, overhaul and reuse or replacement, and has important significance on overhaul, maintenance and service life extension of the train running for decades.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the application and together with the description serve to explain the application and not to limit the application. In the drawings:
fig. 1 is a flowchart of a method for evaluating aging of a power module of a traction converter according to the present invention;
Detailed Description
In order to make the objects, technical solutions and advantages of the present application more apparent, the present application will be described and illustrated below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present application and are not intended to limit the present application. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments provided in the present application without any inventive step are within the scope of protection of the present application.
It is obvious that the drawings in the following description are only examples or embodiments of the present application, and that it is also possible for a person skilled in the art to apply the present application to other similar contexts on the basis of these drawings without inventive effort. Moreover, it should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another.
Reference in the specification to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the specification. The appearances of the phrase in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Those of ordinary skill in the art will explicitly and implicitly appreciate that the embodiments described herein may be combined with other embodiments without conflict.
Unless defined otherwise, technical or scientific terms referred to herein shall have the ordinary meaning as understood by those of ordinary skill in the art to which this application belongs. Reference to "a," "an," "the," and similar words throughout this application are not to be construed as limiting in number, and may refer to the singular or the plural. The present application is directed to the use of the terms "including," "comprising," "having," and any variations thereof, which are intended to cover non-exclusive inclusions; for example, a process, method, system, article, or apparatus that comprises a list of steps or modules (elements) is not limited to the listed steps or elements, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Embodiments of the invention are described in detail below with reference to the accompanying drawings:
fig. 1 is a flowchart of a method for evaluating aging of a power module of a traction converter according to the present invention, please refer to fig. 1, where the method for evaluating aging of a power module of a traction converter according to the present invention includes the following steps:
s1: the method comprises the steps of performing a parameter test on a power module of the traction converter, and comparing the parameter with a rated value and a maximum value.
S2: and if the parameter of the power module exceeds the rated value but does not exceed the maximum value, calculating the junction temperature of the power module under the actual working condition.
Optionally, the junction temperature is calculated according to the following formula:
Tj＝Ploss*Zth+Ta
in the formula, TjIs the junction temperature, Z, of the power modulethIs the thermal impedance of the power module, TaIs ambient temperature, PlossIs the power consumption of the power module.
Optionally, the power consumption includes a conduction loss of the power module, and the conduction loss is calculated according to the following formula:
Pcond,s＝Is×Vce
in the formula, Pcond，sTo conduction loss, IsIs the voltage at which the power module operates, VceIs the voltage at which the power module operates.
The power consumption comprises the switching loss of the power module, and the switching loss is obtained through a linear interpolation mode.
In specific implementation, the module is tested for key parameters on an IGBT dynamic and static test platform. Since the power module manual specifies the parameter ranges. And (4) regarding the module with the test result exceeding the maximum value of the parameter as failed, regarding the module with the parameter in a reasonable range near the rated value as normal, and regarding the module with the parameter exceeding the rated value but not exceeding the maximum value and capable of normally operating, continuing the subsequent steps for evaluation.
In a specific implementation, if the parameter exceeds the rated value but does not exceed the maximum value, the junction temperature is calculated; in a specific implementation, the service life of a power module is mainly influenced by the variation of the junction temperature inside the power module. Thus, the more accurate the measured junction temperature is calculated, the more accurate the resulting evaluation results. Junction temperature is a key factor influencing life evaluation, and is calculated according to the following formula because the junction temperature cannot be directly measured:
Tj＝Ploss*Zth+Ta
in the formula, TjIs the junction temperature, Z, of the power modulethIs the thermal impedance of the power module, TaIs ambient temperature, PlossIs the power consumption of the power module.
In a specific implementation, the power consumption of the power module includes two parts, namely conduction loss and switching loss. The conduction loss is calculated according to the following formula:
Pcond,s＝Is×Vce
in the formula, Pcond，sTo conduction loss, IsIs the voltage at which the power module operates, VceIs the voltage at which the power module operates.
In a specific implementation, the switching loss is obtained by a linear interpolation method, and the formula is as follows:
in the formula, Psw,IIs the switching loss, P, of the IGBT of the power moduleon,IIs the turn-on loss, P, of the IGBT of the power moduleoff,ITurn-off loss, f, of the power module IGBTswIs the switching frequency, I, of the IGBT of the power modulenomIs the test current, U, of the IGBT of the power modulenomIs the test voltage, T, of the IGBT of the power modulevjIs the test junction temperature of the power module IGBT,
is the operating current, U, of the IGBT of the power moduledcIs the operating voltage of the IGBT of the power module, Eon(Inom,Unom,Tvj) Is the turn-on energy of the IGBT of the power module, Eoff(Inom,Unom,Tvj) Is the turn-off energy of the power module IGBT.
From the above calculations, it can be seen that the internal junction temperature of the power module is dominated by Ploss、Eon、Eoff、ZthSeveral factors influence, and these parameters are influenced by factors such as the actual operating condition of converter, ambient temperature, humidity to a great extent. The calibration values on the manual are obtained under ideal test conditions, and the difference from the actual working conditions is often far, so that the finally calculated junction temperature error is large. The module is subjected to stress test under actual working conditions, so that the parameter test is more accurate. In specific implementation, the tested sample comprises actual influence factors such as a driving plate, heat-conducting silicone grease, a cold plate and the like, so that the test is more accurate.
S3: and carrying out field sampling test on the power module, acquiring the number of the service lives of the samples of the power module according to the junction temperature, calculating the number of the service lives of a model according to the existing service life model, and acquiring a corrected service life model according to the number of the service lives of the samples and the number of the service lives of the model.
Optionally, a preset number of the power modules are selected as samples, the number of times of the life of the power modules at the same junction temperature is tested, and an average value is calculated to obtain the number of times of the life of the samples.
Optionally, the modified life model is obtained according to the following formula:
in the formula, Nf_oldNumber of sample Life times, Nf_newThe number of model life times, A and n are model parameters.
In an implementation, a life model of the power module is the basis for life prediction. For the IGBT, the weak link is the connection part of materials, the failure is mainly material fatigue and aging caused by thermal stress generated by temperature change, and the general service life model is as follows:
Nf＝A×(ΔTj)-n
wherein, Delta TjIs the change in junction temperature, and a and-n are model parameters.
The model is obtained by extracting a large number of samples and carrying out long-term reliability experiments when the parts are produced and manufactured. For the old module which runs for years, the parameters of the module are changed, and the parameters of the life model are completely different from those of the new module. Because the failure mechanism of the power module does not change in the operation process, the service life model of the old device is obtained by testing a small amount of samples and correcting the model according to the test result, so that the aging state of the operation module can be evaluated.
In the specific implementation, more than 6 samples are taken from the field module for testing, and the same delta T is usedjThen, the number of life times is Nf_old_1、Nf_old_2、Nf_old_3、Nf_old_4、Nf_old_5、Nf_old_6Taking the average value as Nf_old。
In an implementation, the Δ T is calculated by a lifetime model calculationjNumber of life times of Nf_new。
In the specific implementation, considering that the failure mechanism is not changed, the actual test result is adopted to correct the calculation result, and thus the life model of the batch of power modules is obtained as follows:
in the formula, Nf_oldNumber of sample Life times, Nf_newThe number of model life times, A and n are model parameters.
The invention provides a method for correcting a service life model of a power module under the condition of unchanging a failure mechanism, and the acquisition of the service life model needs to adopt a large number of samples to carry out statistical experiments, so that the time is long. The method can obtain the service life model of the old module in a short time by using less samples.
S4: and acquiring the cycle life times of the power module according to the junction temperature through the corrected life model, and calculating the expected life times of the power module according to the cycle life times.
Optionally, discretizing the junction temperature to obtain the cycle number of each junction temperature period, and obtaining the cycle life number through the corrected life model.
Optionally, the expected lifetime times under different junction temperature periods are obtained according to the junction temperature, the cycle times and the cycle lifetime times.
Optionally, the expected life times under the action of different junction temperature cycles are obtained by using a linear fatigue damage accumulation theory.
In specific implementation, the actual junction temperature curve of the module obtained by calculation and test is discretized to obtain the variation delta T of each specific junction temperaturejNumber of cycles WiAnd querying the junction temperature delta T from the corrected life modeljNumber of cycles ofi。
In specific implementation, the method adopts a linear fatigue damage accumulation theory, namely Miner's theorem, and changes the IGBT junction temperature variation delta Tj and the occurrence frequency W of the delta Tj in each running period of the trainiAnd the number of IGBT cycle life times N under the delta TjiSubstitution formula
I.e., how many cycles the module can operate.
The present application provides a detailed description of step S4.
The existing data are shown in the following table:
| ΔTj | Wi | Ni |
| 10 | 11 | 4678680 |
| 20 | 38 | 3742944 |
| 30 | 96 | 2994355 |
| 40 | 102 | 2395484 |
| 50 | 80 | 1916387 |
| 60 | 23 | 1533110 |
| 70 | 10 | 1226488 |
| 80 | 6 | 981190 |
adopting a linear fatigue damage accumulation theory, namely Miner's theorem, and changing the IGBT junction temperature variation delta Tj and the occurrence frequency W of the delta Tj in each running period of the trainiAnd the number of IGBT cycle life times N under the delta TjiSubstitution formula
Can obtain the product
In a specific implementation, if a certain operation item takes the time of station stopping, end changing and the like into consideration, and one cycle period is 240s, the operation life of the module is 6322 × 240/3600 — 421 h.
S5: and calculating a difference value between the expected life times and the design life, and judging the health state of the power module according to the ratio of the difference value to a preset difference value.
In a particular implementation, if the module parameters are in the normal range and the calculated remaining life exceeds a1 above the new design life, then the module is in a healthy state; if the calculated remaining life is below A2 of the design life, the module is a recommended replacement state and the remaining interval is an emphasis observation state. Wherein, A1 and A2 can be determined according to historical operating conditions of various places.
The method adopts the means of combining the measured data with the calculated data and combining the theoretical calculation with the experiment, and not only considers the parameters of the module, but also considers the influences of the network pressure, the heat-conducting silicone grease, the radiator and the driving circuit in the calculation and test processes, so that the aging evaluation result is based on the operation condition.
It should be noted that the steps illustrated in the above-described flow diagrams or in the flow diagrams of the figures may be performed in a computer system, such as a set of computer-executable instructions, and that, although a logical order is illustrated in the flow diagrams, in some cases, the steps illustrated or described may be performed in an order different than here.
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present application, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the concept of the present application, which falls within the scope of protection of the present application. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. The method for evaluating the aging of the power module of the traction converter is applied to rail transit and comprises the following steps:
a module parameter testing step, namely performing parameter testing on a power module of the traction converter and comparing the parameters with a rated value and a maximum value;
calculating the actual junction temperature, namely calculating the junction temperature of the power module under the actual working condition if the parameter of the power module exceeds the rated value but does not exceed the maximum value;
a life model correction step, namely performing field sampling test on the power module, acquiring the number of times of the life of a sample of the power module according to the junction temperature, calculating the number of times of the life of the model according to an existing life model, and acquiring a corrected life model according to the number of times of the life of the sample and the number of times of the life of the model;
and an aging state evaluation step, namely acquiring the cycle life times of the power module according to the corrected life model and the junction temperature, and calculating the expected life times of the power module according to the cycle life times.
2. The method for evaluating the aging of a power module of a traction converter as claimed in claim 1, wherein the step of calculating the actual junction temperature calculates the junction temperature according to the following formula:
Tj＝Ploss*Zth+Ta
in the formula, TjIs the junction temperature, Z, of the power modulethIs the thermal impedance of the power module, TaIs ambient temperature, PlossIs the power consumption of the power module.
3. The traction converter power module degradation assessment method according to claim 2, wherein the power consumption comprises a conduction loss of the power module, the conduction loss being calculated according to the following formula:
Pcond,s＝Is×Vce
in the formula, Pcond，sTo conduction loss, IsIs the voltage at which the power module operates, VceIs the voltage at which the power module operates.
4. The traction converter power module degradation evaluation method of claim 2, wherein the power consumption comprises a switching loss of the power module, and the switching loss is obtained by linear interpolation.
5. The traction converter power module degradation assessment method of claim 1, wherein said lifetime model modification step further comprises: selecting a preset number of power modules as samples, testing the service life times of the power modules at the same junction temperature, and calculating an average value to obtain the service life times of the samples.
6. The traction converter power module degradation assessment method according to claim 5, wherein said modified life model is obtained according to the following formula:
in the formula, Nf_oldNumber of sample Life times, Nf_newThe number of model life times, A and n are model parameters.
7. The traction converter power module degradation assessment method of claim 1, wherein the degradation state assessment step further comprises: discretizing the junction temperature to obtain the cycle number of each junction temperature period, and obtaining the cycle life number through the corrected life model.
8. The traction converter power module degradation assessment method of claim 7, wherein the degradation state assessment step further comprises: and obtaining the expected life times under the action of different junction temperature periods according to the junction temperature, the cycle times and the cycle life times.
9. The traction converter power module degradation assessment method of claim 8, wherein the degradation state assessment step further comprises: and obtaining the expected life times under the action of different junction temperature cycles by adopting a linear fatigue damage accumulation theory.
10. The method of claim 9, further comprising a health assessment step of calculating a difference between the expected life times and a design life and determining the health of the power module based on the difference and a predetermined difference ratio.
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