DC-link capacitors are an important part in the majority of power electronic converters which contribute to cost, size and failure rate on a considerable scale. From capacitor users' viewpoint, this paper presents a review on the improvement of reliability of dc link in power electronic converters from two aspects: 1) reliability-oriented dc-link design solutions; 2) conditioning monitoring of dc-link capacitors during operation. Failure mechanisms, failure modes and lifetime models of capacitors suitable for the applications are also discussed as a basis to understand the physics-of-failure. This review serves to provide a clear picture of the state-of-the-art research in this area and to identify the corresponding challenges and future research directions for capacitors and their dc-link applications.

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Reliability of Capacitors for DC-Link Applications in Power Electronic Converters—An Overview

A novel life-cycle monitoring and voltage-managing device for dc-link electrolytic capacitors in pulsewidth modulation converters is presented. The system performs online identification of the capacitor's equivalent series resistance (ESR) in order to detect the life-cycle status and permit preventive maintenance. The ESR detection is based on the capacitor's ac losses calculated from voltage/current measurements using a simple low-cost microcontroller. The unit is designed as small printed circuit board located directly at the capacitor's screw terminals in order to simplify the required temperature sensing and to minimize wiring effort. The minimized energy consumption allows a power supply taken out of the capacitor to be tested. Besides life-cycle monitoring, the unit further facilitates energy-efficient voltage balancing for capacitors in series arrangements avoiding any power resistors typically used in balancing circuits. Instead, the unit controls the capacitor voltage by influencing its power consumption. Each individual monitoring unit (one per each power capacitor of the converter) transfers the ESR results to the converter's main controller and receives control commands via a common optoisolated fieldbus. Alternatively, this data transfer is performed using wireless near-field communication leading to a completely autonomous monitoring unit without any wiring for power supply and data transmission.

Life-Cycle Monitoring and Voltage-Managing Unit for DC-Link Electrolytic Capacitors in PWM Converters

This paper presents a low-cost method to realize a real-time condition monitoring and a predictive-maintenance system of an electrolytic capacitor used in uninterruptible power supplies (UPSs). This method consists in detecting the changes in real time of the equivalent series resistance and the capacitance C values of the electrolytic capacitors. Simulation and experimental results are presented to illustrate the proposed monitoring technique. The proposed method can be used in UPS where waveforms are continuously varying in amplitude, frequency, and temperature. The proposed online failure prediction method has the merits of using only the existent resources in UPS and with the use of known algorithms.

https://hal.archives-ouvertes.fr/hal-00536644/document

A Real-Time Predictive-Maintenance System of Aluminum Electrolytic Capacitors Used in Uninterrupted Power Supplies

Capacitors are one type of reliability-critical components in power electronic systems. In the last two decades, many efforts in academic research have been devoted to the condition monitoring of capacitors to estimate their health status. Industry applications are demanding more reliable power electronics products with preventive maintenance. Nevertheless, most of the developed capacitor condition monitoring technologies are rarely adopted by industry due to the complexity, increased cost, and other relevant issues. An overview of the prior-art research in this area is therefore needed to justify the required resources and the corresponding performance of each key method. It serves to provide a guideline for industry to evaluate the available solutions by technology benchmarking, as well as to advance the academic research by discussing the history development and the future opportunities. Therefore, this paper first classifies the capacitor condition monitoring methods into three categories, then the respective technology evolution in the last two decades is summarized. Finally, the state-of-the-art research and the future opportunities targeting for industry applications are given.

A Review of the Condition Monitoring of Capacitors in Power Electronic Converters

Reliability of Capacitors for DC-Link Applications in Power Electronic Converters

The object of this paper is to present an economic electronic module integrated on an electrolytic capacitor that is able to indicate the moment when it must be changed. First, with a switchmode power supply as an example, the high probability of electrolytic capacitor failure with respect to other power components is noted. Second, the authors recall that the increase of the equivalent series resistance (ESR) of the capacitor is the best indicator of their faulty state. From the measurements of the voltage ripple and the capacitor current, one can deduce the ESR; the latter is compared to the ESR value of the sound capacitor deduced from the component case temperature. Thus, the capacitor deterioration can be diagnosed.

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F. Perisse

Papers

Realization of a smart electrolytic capacitor circuit