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Reliability analysis of power MOSFET’s with the help of compact models and circuit simulation
(2002)
High temperature reliability on automotive power modules verified by power cycling tests up to 150°C
(2003)
This paper proposes an ultra-low inductance half-bridge switching cell with substrate integrated 650V GaN bare dies. A vertical parallel-plate waveguide structure with 100 μm layer thickness results in a commutation loop inductance of 0.5 nH resulting in a negligible drain-source voltage overshoot in the inductive load standard pulse test. On the other hand reliable circuit operation requires an assessment of the isolation strength of the thin dielectric layer in the main commutation loop, because critical high local electric fields might occur between the pads. Measurements of the dielectric breakdown voltage followed by a statistical failure analysis provide a characteristic life of 14.7 kV and a 10% quantile of 13.5kV in the Weibull fitted data. This characteristic life depends strongly on the ambient temperature and drops to 4.1kV at 125°C. Additionally, ageing tests show an increasing in dielectric breakdown voltage after 500h, 1000h and 2000h at 125°C high-temperature storage due to resin densification processes.
Power cycling and temperature endurance test of a GaN switching cell with substrate integrated chips
(2019)
We present a reliability study of a half-bridge switching cell with substrate integrated 650 V GaN HEMTs. Power Cycling Testing with a ΔTj of 100 K has revealed thermo-mechanically induced failures of contact vias after more than 220 kcycles. The via failure mode of contact opening is confirmed by reverse-bias pulsed IV-measurements to be primarily triggered by a ΔTj imposed thermal gradient and not by a high Tj. The chip electrical characteristics, however, remained unaffected during Power Cycling. Furthermore, a High Temperature Storage test at 125 °C for 5000 h has shown no changes in the electrical performance of substrate integrated GaN HEMTs.
Wide-bandgap semiconductors such as Silicon Carbide (SiC) or Gallium Nitride (GaN) enable fast switching and high switching frequencies of power electronics. However, this potential can not be exploited due to limitations caused by parasitic elements of packaging and interconnections. This paper shows a possibility to minimize parasitic elements of a half-bridge switching cell with 650 V GaN dies integrated into a printed circuit substrate. A sub-nH commutation loop of 0.5 nH inductance gives superior switching characteristics compared to circuits with packaged dies. Simulation and experimental results of an inverse double pulse test confirm our expectations. This study further reveals additional benefits of the proposed technology in terms of mechanical stability and thermal interfacing to heat sinks compared to circuits with packaged dies.
Design of a Low Multi-Loop Inductance Three Level Neutral Point Clamped Converter with GaN HEMTs
(2020)
This work shows a numerical and experimental analysis of a Neutral-Point-Clamp (NPC) three level inverter featuring an ultra low inductance printed circuit board (PCB) design in consideration of the mutual inductive and capacitive couplings. The commutation loops in this design are found to be strongly dependent on the vertical thickness of the used prepregs and the core. For vertical thicknesses ≤ 100 μm capacitive coupling must be taken into account in the switching cell design. Experimental measurements of a test set-up with a total PCB thickness of 400 μm results in commutation loop inductances from 1.4 nH up to 3.1 nH. In this set-up, switching tests without external gate resistor showed only a maximum voltage overshoot of 7% at 800 V. Based on a numerical analysis of the NPC cell we propose a further switching performance improvement with significant smaller parasitic inductance due to the application of novel printed circuit technologies such as the integration of bare dies into the printed circuit board or polyimide as an interlayer dielectric material.
The automotive industry is pushing power electronic packaging to higher operating and heatsink temperatures while still requiring very high power densities due to limited space. Currently, the power electronics that is implemented within the engine compartment of the vehicle must operate with heatsink temperatures of approximately 85/spl deg/C and this temperature can be expected to increase to 125/spl deg/C in the near future. The high temperature operation of the power electronic structure is fundamentally limited by the employed materials maximum temperatures. A packaging concept is introduced that describes a structure realisation that enables the materials to operate at high ambient temperatures without exceeding their individual maximum temperatures. This in turn allows the complete power electronic structure to operate at a higher system temperature. In this paper, the packaging concept that can be used to meet these difficult requirements of high temperature and high power-density is introduced, discussed and implemented. Two case studies are considered and implemented to illustrate the packaging concept.
A reinforcement of concrete structures is needed because of the low tensile strength of concrete. Corrosion of the usually used steel reinforcments cause issues during time. Therfore, alternative reinforcements produced from non-corosive materials - like polymer fibers - become more interesting. A polymer fiber has to reach high mechanical properties and a good bonding ability to concrete. Both properties can be influenced by the selection of polymer and the used production process. Two polymers, polypropylene and aliphatic polyketone are tested within this study. First mono-material fibers of each material are produced and tested, later the materials are combined in a core-shell fiber. All fibers are produced by standard extrusion or coextrusion and a later drawing process. The mechanical properties are determined by tensile tests. The calculation of interfacial shear strength from single fiber pull-out tests allows an evaluation of the bonding ability. Additionally, fiber surface before and after pull-out is examined using reflected light microscopy. Contact angle measurements are done to evaluate possible influences of the surface energy and polarity. Density measurements are used to compare weight potential of the different mono-material and core-shell fibers. The results show good mechanical properties for all fiber materials. The interfacial shear strength is ≈ 2-3 times higher for fibers with polyketone compared to the ones with polypropylene at the fibers surface, which can be explained by higher surface energy and polarity of the polyketone compared to polypropylene and different surface deformation during pull-out. Lower densities are reached by fibers containing polypropylene.
Corrosion of steel reinforcements in concrete constructions is a big topic for the building industry. Polymeric materials are a possible alternative due to their ability to withstand corrosion. To replace steel reinforcements, fibers with high mechanical properties and a good bonding ability between fiber and concrete are needed. Today different approaches for concrete reinforcement by polymer fibers have been investigated. The bonding ability of the fibers can be increased by mechanical anchoring, e.g. crimped or embossed fibers, as well as by a chemical bonding between concrete and fiber surface. To realize the requirements of high mechanical properties and a good bonding behavior, a fiber that is drawn from a co-extruded filament shall be produced and tested. The filament owns an innovative core-shell-structure. The core maintains the fiber-stiffness and the tensile strength while the shell allows using another material to affect the bonding behavior of the fiber. This study shows the usage of fibers with differing shell materials to examine their influence on the mechanical properties of the fiber in total and the adhesion abilities to concrete. As core material, an unfilled polypropylene (PP) is used. The shell materials are varied using different polymers e.g. polypropylene or ethylene acrylic acid copolymer, as well as two PP based compounds filled with wood particles and calcium carbonate blended with a maleic anhydride based coupling agent. The mechanical properties of the fibers are tested by fiber tensile tests to compare the younǵs modulus and the tensile strength. The influence of the shell phase on the bonding ability to concrete is evaluated by the interfacial shear strength calculated from single fiber pull-out tests. Microscopy is used to interpret changes before and after pull-out. The results depict incredible positive effects and allow new insights in possible materials for fiber reinforced concrete constructions.
Increasing demand for energy-efficient means of transport has steadily intensified the trend towards lightweight components. Thermoplastic glass fiber composites (organo sheets) play a major role in the production of functional automotive components. Organo sheets are cut, shaped and functionalized by injection molding to produce hybrid components, such as those used in car door modules. The cutting process produces a considerable amount of production waste, which has thus far been thermally recycled. This study develops a closed mechanical recycling process and analyzes the different steps of the process. The offcuts were shredded using two shredding methods and implemented directly in the injection-molding process. Using tensile tests and impact bending tests, the material properties of the recycled materials were compared with the virgin material. In addition, fiber length degradation via the injection-molding process and the influence of the waterjet-cutting process on the mechanical properties are investigated. Recycled offcuts are both comparable to new material in terms of mechanical properties and usability, and are also economically and ecologically advantageous. Recycling polypropylene waste with glass fiber reinforcement in a closed loop is an effective way to reduce industrial waste in a sustainable and economical production process.
A calculation method for a robust servo controller design depending on the sampling time and the processing dead time was developed for mechanically stiff drives. With a test stand for high dynamic and high positioning accuracy, the theoretical calculations for the high bandwidth improvements are verified. The test stand includes a voice coil motor and a power electronic with Gallium Nitride (GaN) power semiconductors for switching frequencies of more than 100kHz.
A discrete-time design method for a robust current controller of a servo drive has been developed. It takes the sampling time, the processing dead time and the dynamic behavior of the A/D converter into account. The theoretical calculations are verified using a test stand for high dynamics. The test stand includes a voice coil motor and power electronics with Gallium Nitride (GaN) power semiconductors for switching frequencies of more than 100 kHz. The bandwidth of the current control loop can be improved from typically 1 kHz to 1.5 kHz with insulated-gate bipolar transistor (IGBT) power semiconductors in state-of-the-art motion control systems to 10 kHz and more.
The dynamic behavior and position stability of servo drives are influenced by many parameters. One major influencing parameter is the pulse width modulation (PWM) frequency. With inverters based on wide bandgap semiconductors, the PWM frequency can be increased. This enables a substantial increase in the current control bandwidth. The paper focuses on the influence of the PWM frequency on the dynamics of control loops and position stability, which are derived from theoretical correlations. The theory is verified using a test bench for high dynamic and position stability. The test bench is equipped with a voice coil motor and power electronic with gallium nitride (GaN) power semiconductors for switching frequencies of 100kHz and over. The achieved position stability, measured with a laser-based comparator at the tool center point, is lower than "+-1nm" with a standard deviation of "0.16nm" at a PWM frequency of "f_PWM=100kHz".
A parallel design concept of Delta-Sigma modulators that optimizes the resolution and the bandwidth for a highly dynamic position control in industrial applications. The idea is realized on a printed circuit board and tested by using a comprehensive measurement setup. The effective number of bits is increased by 2.5 bits at a fixed frequency. For a constant resolution, the design approach allows smaller filter lengths and a decrease of the delay by 25%.
Applications in engineering frequently require the adjustment of certain parameters. While the mathematical laws that determine these parameters often are well understood, due to time limitations in every day industrial life, it is typically not feasible to derive an explicit computational procedure for adjusting the parameters based on some given measurement data. This paper aims at showing that in such situations, direct optimization offers a very simple approach that can be of great help. More precisely, we present a numerical implementation for the local minimization of a smooth function f:Rn→R subject to upper and lower bounds without relying on the knowledge of the derivative of f. In contrast to other direct optimization approaches the algorithm assumes that the function evaluations are fairly cheap and that the rounding errors associated with the function evaluations are small. As an illustration, this algorithm is applied to approximate the solution of a calibration problem arising from an engineering application. The algorithm uses a Quasi-Newton trust region approach adjusting the trust region radius with a line search. The line search is based on a spline function which minimizes a weighted least squares sum of the jumps in its third derivative. The approximate gradients used in the Quasi-Newton approach are computed by central finite differences. A new randomized basis approach is considered to generate finite difference approximations of the gradient which also allow for a curvature correction of the Hessian in addition to the Quasi-Newton update. These concepts are combined with an active set strategy. The implementation is public domain; numerical experiments indicate that the algorithm is well suitable for the calibration problem of measuring instruments that prompted this research. Further preliminary numerical results suggest that an approximate local minimizer of a smooth non-convex function f depending on n≤300 variables can be computed with a number of iterations that grows moderately with n.
A Novel Approach to Identify Wood Species Optically using Fluorescence Lifetime Imaging Microscopy
(2021)
This contribution presents the results obtained with fluorescence lifetime imaging microscopy (FLIM)within the optical identification and differentiation of the four wood species walnut, beech, spruce, and maple. The experimental setup as well as the evaluation algorithm, with which the experiments were carried out, is explained briefly.