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

Advances in power electronics enable efficient and flexible processing of electric power in the application of renewable energy sources, electric vehicles, adjustable-speed drives, etc. More and more efforts are devoted to better power electronic systems in terms of reliability to ensure high availability, long lifetime, sufficient robustness, low maintenance cost and low cost of energy. However, the reliability predictions are still dominantly according to outdated models and terms, such as MIL-HDBK-217H handbook models, Mean-Time-To-Failure (MTTF), and Mean-Time-Between-Failures (MTBF). A collection of methodologies based on Physics-of-Failure (PoF) approach and mission profile analysis are presented in this paper to perform reliability-oriented design of power electronic systems. The corresponding design procedures and reliability prediction models are provided. Further on, a case study on a 2.3 MW wind power converter is discussed with emphasis on the reliability critical components IGBTs. Different aspects of improving the reliability of the power converter are mapped. Finally, the challenges and opportunities to achieve more reliable power electronic systems are addressed.

Design for reliability of power electronic systems

In electric vehicle (EV) inverter systems, direct-current-link capacitors, which are bulky, heavy, and susceptible to degradation from self heating, can become a critical obstacle to high power density. This paper presents a comprehensive method for the analysis and comparative evaluation of dc-link capacitor applications to minimize the volume, mass, and capacitance. Models of equivalent series resistance that are valid over a range of frequency and operating temperature are derived and experimentally validated. The root-mean-square values and frequency spectra of the capacitor current are analyzed with respect to three modulation strategies and various operating conditions over practical ranges of load power factor and modulation index in EV drive systems. The modeling and analysis also consider the self-heating process and resulting core temperature of the dc-link capacitors, which impacts their lifetimes. Based on an 80-kW permanent-magnet (PM) motor drive system, the application of electrolytic capacitors and film capacitors has been evaluated by both simulation and experimental tests. The inverter power density is improved from 2.99 kW/L to 13.3 kW/L, without sacrificing the system performance in terms of power loss, core temperature, and lifetime.

http://web.mit.edu/parmstr/www/pubs/TVT.2012.2206082.pdf

Analysis and Evaluation of DC-Link Capacitors for High-Power-Density Electric Vehicle Drive Systems

Traction inverters are crucial components of modern electrified automotive powertrains. Advances in power electronics have enabled lower cost inverters with high reliability, efficiency, and power density, suitable for mass market consumer automotive applications. This paper presents an independent review of the state-of-the-art traction inverter designs from several production vehicles across multiple manufacturers. Future trends in inverter design are identified based on industry examples and academic research. Wide bandgap devices and trends in device packaging are discussed along with active gate driver implementations, current and future trends in system integration, and advanced manufacturing techniques.

Automotive Traction Inverters: Current Status and Future Trends

In this paper, a novel scheme for the estimation of the equivalent series resistance (ESR) of the dc-link electrolytic capacitor in three-phase ac/dc pulsewidth-modulation converters is proposed for condition monitoring. First, a controlled ac current component is injected into the input. Then, it induces ac voltage ripples on the dc output. By manipulating these ac voltage and current components with digital filters, the value of the ESR can be calculated, where the recursive least squares algorithm is used for reliable estimation results. In addition, the value of the ESR is corrected by considering the temperature effect, for which a simple temperature-sensing circuit has been designed. The simulation and experimental results show that the estimation error of the ESR is within a reasonable range, thereby enabling the determination of the appropriate time for the replacement of the capacitor.

Fault Diagnosis of DC-Link Capacitors in Three-Phase AC/DC PWM Converters by Online Estimation of Equivalent Series Resistance

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.

M A Vogelsberger

Papers

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