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Power electronics play a vital role in shaping modern technological advancements, particularly in renewable energy and electric transportation. As the demand for higher efficiency and more compact components increases, so does the importance of understanding and ensuring the reliability of wide-bandgap (WBG) semiconductors, such as silicon carbide and gallium nitride. At NI Connect, NI’s Gabriel Lieser, head of power semiconductor reliability research, led a workshop shedding light on the nuances of dynamic weapon testing in power electronics, with a focus on developing tailored reliability tests for these increasingly critical semiconductor materials.
Lieser’s introduced new reliability tests tailored for WBG semiconductors, specifically SiC and GaN devices, which are increasingly critical in applications such as electric vehicles. He began by stressing the pivotal role of power electronics in modern technologies, particularly in green energy and EVs. The shift toward higher efficiency and smaller, more powerful components has driven the adoption of WBG materials. SiC and GaN devices, known for their superior performance over traditional silicon-based devices, are becoming the preferred choice in many applications. However, these new materials present unique challenges in reliability testing, necessitating the development of new testing methodologies.
The historical context provided insight into the evolution of reliability testing. Traditional tests, such as the 1,000-hour tests, were originally developed for silicon-based devices and have been standard for decades. While still valuable, they are not entirely applicable to SiC and GaN devices due to their different failure mechanisms and accelerated life factors. Thus, the industry must re-establish reliability standards tailored specifically for WBG semiconductors.
Lieser noted the importance of understanding the acceleration factors in reliability tests. For instance, squeezing 20 years of operational life into a 1,000-hour test requires an acceleration factor of 175. This necessitates precise measurement and control to ensure that test results accurately reflect long-term performance. The workshop also delved into specific failure mechanisms, such as gate stress in SiC MOSFETs and humidity-induced failures in GaN HEMTs.
In the context of SiC MOSFETs, Lieser presented real-world data from automotive-grade chips subjected to accelerated life testing. The tests revealed significant increases in on-resistance after prolonged stress, which directly impacts the efficiency and performance of EVs. Such findings underscore the necessity of incorporating these new failure modes into reliability assessments.
Temperature control emerged as a critical factor in dynamic testing. Inconsistent temperatures can lead to misleading results, such as apparent threshold voltage shifts that are temperature-induced. Additionally, preconditioning the gate threshold voltage is crucial to obtaining consistent and reliable measurements. Lieser’s team observed that improper preconditioning could result in significant measurement noise, equivalent to 100 hours of test time, thereby skewing the results.
The workshop also addressed dynamic high-temperature gate-stress testing, which simulates real-world operating conditions by applying high voltage and high temperature simultaneously. Lieser stressed the importance of maintaining a consistent test environment and recommended keeping temperature variations to a minimum to ensure reliable data.
Lieser showcased a comparative analysis of various SiC MOSFETs from different manufacturers, demonstrating the variability in their performance under stress. This variability underscores the importance of thorough testing and characterization of each device to ensure reliability in practical applications.
Lieser highlighted the need for the reliability testing community to adapt and evolve in response to the challenges posed by WBG semiconductors. By developing new testing methodologies and understanding the unique failure mechanisms of SiC and GaN devices, the industry can ensure the long-term reliability of these critical components. Lieser’s insights provided valuable guidance for professionals involved in reliability testing, stressing the importance of precise measurement, temperature control and tailored testing protocols in the evolving landscape of power electronics.
Automotive
In the fast-paced world of automotive technology, where innovation is constant and competition is fierce, ensuring the reliability and performance of new technologies is paramount. This is where qualification standards come into play, serving as the backbone of product development and market entry strategies for companies such as BMW.
Central to Lieser’s discussion was the tension between the need for thorough testing and the pressure to quickly bring new technologies to market. Accelerated lifetime testing is a crucial strategy, allowing companies to simulate years of usage in a fraction of the time. However, this approach comes with its own set of challenges, requiring careful consideration of factors such as expected performance, efficiency, range and cost implications.
Enter organizations such as JC70 and ECP, which play a pivotal role in developing industry-wide standards and fostering collaboration across the supply chain. By aligning stakeholders and building upon existing standards rather than reinventing the wheel, these organizations pave the way for a more streamlined and efficient qualification process.
Technical nuances, such as qualification methodologies and test routines, underscore the complexity of the task at hand. Yet practical solutions, such as turnkey test systems and collaborative testing facilities, offer a path forward, helping companies navigate the intricate landscape of qualification standards with more ease.
AI solutions for the evolving energy industry
The energy industry is undergoing significant transformation, driven by the dual pressures of sustaining traditional fossil fuels and advancing renewable energy sources. NI’s Brandon Brice, business development manager for energy at NI, offered insights into how AI solutions can address the evolving challenges in this sector. The energy sector is witnessing several key trends and innovations:
- Renewable energy: Growing investment in solar, wind and other renewable sources
- Internet of things: Integration of connected systems at the edge for enhanced monitoring and control
- Energy storage: Development of battery systems for residential and commercial applications
- Blockchain: Secure transactions and asset management through decentralized ledgers
- Vehicle-to-grid (V2G): Using EVs as energy resources
- Cybersecurity: Protecting connected energy systems from cyberthreats
- Quantum computing: Advancing computational capabilities for complex energy management tasks
These innovations are common across the fossil fuel and renewable energy sectors, indicating a convergence in technology application.
NI provides comprehensive solutions to address the diverse needs of the energy industry. These solutions are categorized into three areas:
- Energy generation: Involves traditional and renewable sources, such as turbines, nuclear and solar. NI offers ruggedized platforms, such as CompactRIO and Single-Board RIO, for embedded monitoring and control. These platforms provide real-time data acquisition, inline processing and headless operation capabilities essential for monitoring energy generation assets.
- Energy distribution: Focuses on inverters, grid storage and other distribution mechanisms. The same CompactRIO platforms are used for control and monitoring, ensuring stable and efficient energy distribution.
- Energy demand: Encompasses EVs, industrial equipment and consumer appliances. NI’s solutions ensure these demand-side components operate efficiently and safely within the energy ecosystem.
Additionally, SystemLink technology enables fleet tracking, remote software updates and predictive maintenance. SystemLink is NI’s core technology for asset and systems management, extending its capabilities to embedded monitoring and control systems. It provides:
- Fleet health monitoring, which tracks the condition and performance of distributed assets
- Remote software updates, which facilitate over-the-air firmware updates
- Analysis and reporting, which offer real-time data analysis and predictive maintenance insights
- Asset traceability, which ensures comprehensive tracking of all system components
Understanding the impact of grid fluctuations on energy resources is critical. Power quality issues, such as voltage disturbances, harmonic distortions and frequency variations, can affect the performance and stability of energy assets. NI provides tools to test and validate these impacts, ensuring that products can withstand grid disturbances and shut down safely if necessary.
In energy generation and distribution, the acceptance phase for deployment is crucial, especially in scenarios such as predictive health monitoring for distributed energy resources. A specific application involved CompactRIO hardware, which provided both FPGA-based processing and inline algorithms for blade health monitoring. This capability was instrumental in securing customer buy-in, particularly for applications requiring control and monitoring at high-voltage DC stations.
In the embedded space, the platform’s versatility extends to various energy-generation resources, such as oil and gas, where it serves as a controller for monitoring and control applications. By leveraging the platform’s capabilities, customers can deliver tailored solutions for predictive maintenance, asset traceability and data analysis.
Furthermore, the platform’s modularity and scalability are evident in its use cases, ranging from battery testing to V2G applications. For instance, in DC fast-charging scenarios, it can emulate batteries while supporting different charging protocols. Similarly, in V2G setups, the platform enables power flow reversal for grid support.
Designing products that perform reliably under varying grid conditions is critical, especially in regions with unstable power. To address this, we must consider regional voltage differences and how products behave in diverse grid environments. The modular and scalable 9300 battery cycler and 9510 grid simulator allow testing up to 2.4 MW for DC and 1.2 MW for AC, respectively.
Testing and compliance are critical aspects addressed by the platform, especially concerning grid stability and regulatory standards, such as UL 1741 and IEC 62116. With the ability to simulate grid fluctuations and validate product responses, it ensures reliability and compliance across diverse operating conditions and geographical regions.
Use cases include DC fast charging, in which simulated batteries and grid conditions test charger protocols, and V2G scenarios, which ensure products operate correctly when providing backup power. Additionally, testing DC-to-AC inverters in stationary storage systems confirms seamless integration with renewable energy sources. NI’s versatile power electronics portfolio supports diverse applications, from vehicle-to-home power transfer to isolated energy pods, demonstrating its commitment to robust, region-specific product performance testing.
The energy industry is at a pivotal point, requiring robust and adaptable technologies to navigate its evolving landscape. NI’s AI-driven solutions and comprehensive ecosystem support innovation and ensure future-proof capabilities. By leveraging these technologies, energy companies can maintain efficient, reliable and secure operations in both traditional and renewable sectors.
Advancements in battery-cell testing: addressing challenges and implementing solutions
In powertrain testing, particularly battery testing, addressing challenges and implementing effective solutions are paramount. At NI Connect, NI’s Felipe Quintana, principal systems engineer, presented insightful strategies and techniques aimed at tackling the complexities of cell testing in both validation and manufacturing environments.
The presentation underscored the critical importance of thorough cell testing in ensuring battery cell performance, safety and longevity. Key challenges identified included the time-consuming nature of testing, lack of standardization in testing methodologies and limited non-destructive testing techniques. Failure to address these challenges could result in detrimental impacts on performance, safety and environmental sustainability.
To overcome these challenges, Quintana introduced three common cell quality testing techniques: DC internal resistance (DCR), AC internal resistance (ACR) and electrochemical impedance spectroscopy (EIS). Each technique offers unique insights into cell behavior and can be applied across various cell form factors and chemistries:
- DCR testing focuses on obtaining the resistance of the cell, providing valuable insights into its state of health. However, it may disrupt the electrochemical state of the cell, and it has limitations in characterizing capacitive components.
- ACR testing, conducted at a fixed frequency, offers a quicker alternative to DCR testing and provides insights into both the resistive and capacitive components of the cell’s impedance.
- EIS represents the pinnacle of cell testing, offering a comprehensive frequency sweep analysis to map impedance across a wide frequency range. While time-consuming, EIS provides invaluable insights into cell behavior and can aid in defect detection and model fitting.
Quintana also noted the advantages of utilizing an AI solution provider for cell testing needs. Leveraging PXI-based solutions offers flexibility, scalability and unmatched measurement quality. Additionally, the integration capabilities of AI solutions enable seamless deployment across various production environments.
NI’s Steven Dusing, technical manager, further elaborated on the implementation of cell testing solutions in low-volume production and high-volume manufacturing settings. Through close collaboration with AI solution providers, DMC offers expertise in system integration, material handling and automation to streamline the testing process and maximize throughput.
Advancements in battery cell testing are crucial for ensuring the reliability and performance of battery-powered devices, from EVs to portable electronics. Addressing challenges and implementing cutting-edge testing techniques allow companies to uphold the highest quality and safety standards in their products.
The post Addressing Complexities in Power Electronics: Insights from NI Connect Workshops appeared first on Power Electronics News.
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