This paper describes the design, fabrication, and testing of a 1.2 kV, 6.5 mΩ, half-bridge, SiC MOSFET power module to evaluate the impact of parametric device tolerances on electrical and thermal performance. Paralleling power devices increases current handling capability for the same bus voltage. However, inherent parametric differences among dies leads to unbalanced current sharing causing overstress and overheating. In this design, a symmetrical DBC layout is utilized to balance parasitic inductances in the current pathways of paralleled dies to isolate the impact of parametric tolerances. In addition, the paper investigates the benefits of flexible PCB in place of wire bonds for the gate loop interconnection to reduce and minimize the gate loop inductance. The balanced modules have dies with similar threshold voltages while the unbalanced modules have dies with unbalanced threshold voltages to force unbalanced current sharing. The modules were placed into a clamped inductive DPT and a continuous, boost converter. Rogowski coils looped under the wire bonds of the bottom switch dies to observe current behavior. Four modules performed continuously for least 10 minutes at 200 V, 37.6 A input, at 30 kHz with 50% duty cycle. The modules could not perform for multiple minutes at 250 V with 47.7 A (23 A/die). The energy loss differential for a ~17% difference in threshold voltage ranged from 4.52% (~10 µJ) to -30.9% (~30 µJ). The energy loss differential for a ~0.5% difference in V_th ranged from -2.26% (~8 µJ) to 5.66% (~10 µJ). The loss differential was dependent on whether current unbalance due to on-state resistance compensated current unbalance due to threshold voltage. While device parametric tolerances are inherent, if the higher threshold voltage devices can be paired with devices that have higher on-state resistance, the overall loss differential may perform similarly to well-matched dies. Lastly, the most consistently performing unbalanced module with 17.7% difference in V_th had 119.9 µJ more energy loss and was 22.2°C hotter during continuous testing than the most consistently performing balanced module with 0.6% difference inV_th. / Master of Science / This paper describes the design, construction, and testing of advanced power devices for use in electric vehicles. Power devices are necessary to supply electricity to different parts of the vehicle; for example, energy is stored in a battery as direct current (DC) power, but the motor requires alternating current (AC) power. Therefore, power electronics can alter the energy to be delivered as DC or AC. In order to carry more power, multiple devices can be used together just as 10 people can carry more weight than 1 person. However, because the devices are not perfect, there can be slight differences in the performance of one device to another. One device may have to carry more current than another device which could cause failure earlier than intended. In this research project, multiple power devices were placed into a package, or "module." In a control module, the devices were selected with similar properties to one another. In an experimental module, the devices were selected with properties very different from one another. It was determined that the when the devices were 17.7% difference, there was 119.9 µJ more energy loss and it was 22.2°C hotter than when the difference was only 0.6%. However, the severity of the difference was dependent on how multiple device characteristics interacted with one another. It may be possible to compensate some of the impact of device differences in one characteristic with opposing differences in another device characteristic.

Ces travaux s’intègrent dans la recherche de solutions alternatives aux alliages de brasure pour les assemblages de puissance. De par les propriétés intrinsèques de l’argent et les premiers travaux publiés, le frittage de pâte d’argent a été sélectionné comme technique d’assemblage pour être étudiée et évaluée. Après avoir effectué un état de l’art sur la structure d’un module de puissance, sur les différentes techniques d’assemblage, la fiabilité des assemblages et le frittage, différents essais ont été menés en partenariat avec les projets FIDEA et ASPEEC. Ils nous ont permis de définir des procédés d’assemblages, de caractériser thermiquement et mécaniquement les assemblages frittés et d’évaluer la fiabilité de ces assemblages par des essais expérimentaux et des simulations numériques. Ces travaux nous ont permis au final de réaliser un prototype d’assemblage double face fonctionnel aux propriétés thermomécaniques supérieures à celles d’un assemblage brasé. / This work is part of the research for lead-free die-attach solutions for power modules to offer a solution to the European directive RoHS, which banishes lead in electrical and electronic equipments. The intrinsic silver properties and the previous work published helped us choose silver sintering as the die-attach technology to be tested and evaluated in our work. After a state of the art on power module structure, on different die-attach technologies and on power module reliability, various works have been carried out in collaboration with the FIDEA and ASPEEC projects. Through experimental tests and finite element modeling analysis (FEM), die-attach processes have been defined, thermal and mechanical characterizations and reliability assessment of silver sintered power modules have been done. Finally, a silver sintered rectifier bridge double side assembly with higher thermomechanical properties than a lead-solder die-attach assembly was developed as final prototype.

The knowledge about the reliability of power electronics is necessary for the design of converters. Especially for offshore applications it is essential to know, which fatigue processes happen and how the lifetime can be estimated. Numerical simulation is an important tool for the development of power electronic systems. This thesis analyse the thermal and thermal-mechanical behaviour of packages for power semiconductor devices with the help of simulations. One topic is the evaluation of different thermal models. The main focus is on the description of the thermal cross-coupling between the devices and the influence to the lifetime estimation. The power module is a well established package for power semiconductor devices. It will be explained how the heating period of power cycles influences the failure mode of this package type. Additionally, it will evaluated how SiC devices and DAB substrates influence the power cycling capability. The press-pack is in focus for high power applications as the package short-circuits during an electrical failure without external auxiliary systems. However, the knowledge about the power cycling behaviour is currently limited. With the help of simulations this behaviour will be analysed and possible weak points will be also derived. In the end of the work it will be discussed, how the lifetime can be estimated with help of FEM simulations. / Für die Entwicklung von Umrichtern ist die Kenntnis über die Zuverlässigkeit der Leistungselektronik ein wichtiges Kernthema. Insbesondere für Offshore-Anwendungen ist das Wissen über die stattfindenden Ermüdungsprozesse und die Abschätzung der zu erwartenden Lebensdauer der Bauteile essentiell. Hierfür hat sich die Simulation als ein wichtiges Werkzeug für die Entwicklung und Lebensdauerbewertung von leistungselektronischen Anlagen etabliert. In der folgenden Arbeit wird das thermische und das thermisch-mechanische Verhalten der Leistungselektronik mittels Simulationen untersucht. Hierzu wird ein Vergleich zwischen verschiedenen thermischen Modellen für Leistungsbauelemente durchgeführt. Schwerpunkt ist die Beschreibung der thermischen Kopplung zwischen den Chips und deren Einfluss auf die Lebensdauerabschätzung. Ein weiterer Schwerpunkt ist das Leistungsmodul, welches sich als ein Standardgehäuse etabliert hat. Dazu wird erklärt, wie die Variation der Einschaltzeit im aktiven Lastwechseltest den Fehlermodus dieses Gehäusetyps beeinflusst. Weiterhin wird untersucht, wie SiC als Leistungshalbleiter und DAB als Substrat die Zuverlässigkeit beein- flusst. Der Press-Pack ist für Hochleistungsapplikationen von hohem Interesse, da dieses Gehäuse im elektrischen Fehlerfall ohne äußere Unterstützung kurzschliesst. Jedoch ist das Wissen über diese Gehäusetechnologie unter aktiven Lastwechselbedingungen sehr limitiert. Mit Hilfe von Simulationen wird dieses Verhalten untersucht und mögliche Schwachpunkte abgeleitet. Am Ende der Arbeit werden Möglichkeiten untersucht, wie Mithilfe von FEM Simulationen die Lebensdauer von Leistungsmodulen evaluiert werden kann.

Ces travaux s’inscrivent dans le cadre du projet GENOME (GEstioN OptiMisée de l’Energie). Ce projet s’intéresse aux solutions de packaging haute-température pour des modules de puissance 40 kW embarqués en aéronautique. Ils s’intègrent dans l’étude de fiabilité des modules de puissance, notamment, les solutions alternatives aux alliages de brasure. De par leurs propriétés physiques, l’argent et l’or-étain ont été sélectionnés comme techniques d’assemblage afin d’étudier et d’évaluer leur fiabilité. Pour ce faire, une méthodologie d’étude de fiabilité des modules de puissance a été définie dans le but de garantir l’exploitabilité des résultats. Ensuite, des analyses destructives et non-destructives ont été réalisées sur des véhicules de tests. Ceux-ci ont été vieillis en cyclages thermiques suivant différents profils afin de comparer leurs influences sur la fiabilité des VTs. L’étude du comportement thermomécanique des assemblages de puissance a été réalisée à l’aide de modélisations par éléments finis. Une méthodologie d’évaluation de la fiabilité des assemblages, basée sur l’étude de la contrainte thermomécanique accumulée dans les couches de joints métalliques, au cours de vieillissements accélérés, est développée. Un deuxième axe devrait permettre de comprendre les modes de défaillance, afin de mettre en lumière les limitations des vieillissements accélérés sévères. / This work is part of “GENOME” project which focuses on high-temperature packaging solutions for electronic power modules. Its mission is to study the reliability of power modules, in particular, the die attach layer. Due to the physical properties of silver and gold-tin, they were selected as die bonds to assess the evolution of their reliability during ageing. In order to achieve this, an appropriate methodology of the power modules reliability has been defined in order to guarantee the results exploitability. Destructive and non-destructive analyzes were carried out on samples aged by different profiles of thermal cycling. These analyzes allowed us to compare the influence of each cycling profile on the reliability of samples. A study of the thermomechanical behavior of power assemblies was carried out using finite element modeling (FEM). A methodology for evaluating the reliability of assemblies during accelerated ageing is developed. A second axis allows us a better understanding of the failure modes and their effects. It also highlights the limitations of severe accelerated ageing. Consequently, the choice of temperature profile is questioned and a limitation of the temperature profile severity must be considered, in order to avoid producing degradations that are not actually found in mission profile.

In this thesis is described a laboratory process of example of traction control with frequency converter SINAMICS S120. The focus of this thesis is divided into three parts. Modification of the traction to translational motion for transport of the open vessel with liquid. Proposal of the autonomous operation of the traction without connection to other devices such as a personal computer or PLC, including wiring diagram. The simulation of a dynamic movement for transport of the vessel with liquid in the simulation environment MATLAB and implementation using the proposed laboratory traction. Commissioning and activation of each control functions is described step by step.

The knowledge about the reliability of power electronics is necessary for the design of converters. Especially for offshore applications it is essential to know, which fatigue processes happen and how the lifetime can be estimated. Numerical simulation is an important tool for the development of power electronic systems. This thesis analyse the thermal and thermal-mechanical behaviour of packages for power semiconductor devices with the help of simulations. One topic is the evaluation of different thermal models. The main focus is on the description of the thermal cross-coupling between the devices and the influence to the lifetime estimation. The power module is a well established package for power semiconductor devices. It will be explained how the heating period of power cycles influences the failure mode of this package type. Additionally, it will evaluated how SiC devices and DAB substrates influence the power cycling capability. The press-pack is in focus for high power applications as the package short-circuits during an electrical failure without external auxiliary systems. However, the knowledge about the power cycling behaviour is currently limited. With the help of simulations this behaviour will be analysed and possible weak points will be also derived. In the end of the work it will be discussed, how the lifetime can be estimated with help of FEM simulations. / Für die Entwicklung von Umrichtern ist die Kenntnis über die Zuverlässigkeit der Leistungselektronik ein wichtiges Kernthema. Insbesondere für Offshore-Anwendungen ist das Wissen über die stattfindenden Ermüdungsprozesse und die Abschätzung der zu erwartenden Lebensdauer der Bauteile essentiell. Hierfür hat sich die Simulation als ein wichtiges Werkzeug für die Entwicklung und Lebensdauerbewertung von leistungselektronischen Anlagen etabliert. In der folgenden Arbeit wird das thermische und das thermisch-mechanische Verhalten der Leistungselektronik mittels Simulationen untersucht. Hierzu wird ein Vergleich zwischen verschiedenen thermischen Modellen für Leistungsbauelemente durchgeführt. Schwerpunkt ist die Beschreibung der thermischen Kopplung zwischen den Chips und deren Einfluss auf die Lebensdauerabschätzung. Ein weiterer Schwerpunkt ist das Leistungsmodul, welches sich als ein Standardgehäuse etabliert hat. Dazu wird erklärt, wie die Variation der Einschaltzeit im aktiven Lastwechseltest den Fehlermodus dieses Gehäusetyps beeinflusst. Weiterhin wird untersucht, wie SiC als Leistungshalbleiter und DAB als Substrat die Zuverlässigkeit beein- flusst. Der Press-Pack ist für Hochleistungsapplikationen von hohem Interesse, da dieses Gehäuse im elektrischen Fehlerfall ohne äußere Unterstützung kurzschliesst. Jedoch ist das Wissen über diese Gehäusetechnologie unter aktiven Lastwechselbedingungen sehr limitiert. Mit Hilfe von Simulationen wird dieses Verhalten untersucht und mögliche Schwachpunkte abgeleitet. Am Ende der Arbeit werden Möglichkeiten untersucht, wie Mithilfe von FEM Simulationen die Lebensdauer von Leistungsmodulen evaluiert werden kann.

Advances in wide-bandgap semiconductor devices have increased the allowable operating temperature of power electronic systems. High-temperature devices can benefit applications such as renewable energy, electric vehicles, and space-based power electronics that currently require bulky cooling systems for silicon power devices. Cooling systems can typically be reduced in size or removed by adopting wide-bandgap semiconductor devices, such as silicon carbide. However, to do this, semiconductor device packaging with high reliability at high temperatures is necessary. Transient liquid phase (TLP) die-attach has shown in literature to be a promising bonding technique for this packaging need. In this work TLP has been comprehensively investigated and characterized to assess its viability for high-temperature power electronics applications. The reliability and durability of TLP die-attach was extensively investigated utilizing electrical resistivity measurement as an indicator of material diffusion in gold-indium TLP samples. Criteria of ensuring diffusive stability were also developed. Samples were fabricated by material deposition on glass substrates with variant Au–In compositions but identical barrier layers. They were stressed with thermal cycling to simulate their operating conditions then characterized and compared. Excess indium content in the die-attach was shown to have poor reliability due to material diffusion through barrier layers while samples containing suitable indium content proved reliable throughout the thermal cycling process. This was confirmed by electrical resistivity measurement, EDS, FIB, and SEM characterization. Thermal and mechanical characterization of TLP die-attached samples was also performed to gain a newfound understanding of the relationship between TLP design parameters and die-attach properties. Samples with a SiC diode chip TLP bonded to a copper metalized silicon nitride iv substrate were made using several different values of fabrication parameters such as gold and indium thickness, Au–In ratio, and bonding pressure. The TLP bonds were then characterized for die-attach voiding, shear strength, and thermal impedance. It was found that TLP die-attach offers high average shear force strength of 22.0 kgf and a low average thermal impedance of 0.35 K/W from the device junction to the substrate. The influence of various fabrication parameters on the bond characteristics were also compared, providing information necessary for implementing TLP die-attach into power electronic modules for high-temperature applications. The outcome of the investigation on TLP bonding techniques was incorporated into a new power module design utilizing TLP bonding. A full half-bridge inverter power module for low-power space applications has been designed and analyzed with extensive finite element thermomechanical modeling. In summary, TLP die-attach has investigated to confirm its reliability and to understand how to design effective TLP bonds, this information has been used to design a new high-temperature power electronic module.

As the renewable energy sources are finding more place in the energy generation technologies,the Swedish energy market is also undergoing transformations. Renewable energy sources inthe energy generation system brings more volatility and price fluctuations which can mean challenges and opportunities. Svenska Kraftnät, as the authority responsible for safety and stability of Swedish transmission system, addresses the challenges with higher shares of renewable energy sources to some extent with more frequency stabilizing solutions but the electricity prices are controlled by free market which is led by NordPool. Växjö Energi is a state-owned company with energy generation facility of combined heat and power, operating in SE4 area of electricity market. As SE4 is the region affected the most with the price fluctuations, Växjö Energi is interested in analyzing the possibility of increasing their profit by utilizing the available energy storage technologies in the market in long term energy storage applications. The available energy storage solutions and the ones under development have each, their own pros and cons that this project attempts to go through from economical, technical, and sustainability perspective. Technologies such as compressed air energy storage and pumped hydro are more mature and there are more data available about them with less uncertainty. However, technologies such as gravity power module are new and there is not much information so the uncertainty of data is higher. A model has been developed in this project from earlier work of other researchers, to measure the highest possible profit for each energy storage technology in a specific price time series through electricity storage. The result suggests the compressed air energy storage, gravity power module, and pumped thermal electricity storage are the interesting technologies for further study. We show through this work that their costs and possible revenues are comparable. The future work on this subject is to include the suggested technologies with more details and adaptation to Växjö Energi conditions for more detailed and reliable results. / Förnybara energikällor får en större andel av energiproduktionsteknikerna samtidigt som den svenska energimarknaden genomgår förändringar. Förnybara energikällor i energiproduktionssystemet ger mer volatilitet och prisfluktuationer som kan innebära både utmaningar och möjligheter. Svenska Kraftnät, den ansvariga myndigheten för säkerhet och stabilitet i det svenska överföringssystemet, hanterar utmaningarna relaterade till högre andel förnybara energikällor med mer frekvensstabiliserande lösningar men samtidigt styrs elpriserna av den fria marknaden som leds av NordPool. Växjö Energi är ett statligt företag med energiproduktionsanläggning för kraftvärme som verkar inom SE4-området på elmarknaden. Eftersom SE4 är den region som drabbas mest av prisfluktuationerna, är Växjö Energi intresserad av att analysera möjligheten att öka deras vinst genom att använda tillgängliga energilagringsteknologier på marknaden för energibitrageapplikationer. De tillgängliga energilagringslösningarna och de som är under utveckling har alla sina egna fördelar och nackdelar som detta projekt analyserar ur ett ekonomiskt-, tekniskt- och hållbarhetsperspektiv. Teknik som tryckluft, energilagring och vattenkraft är mer mogna och det finns mer information om dem samt mindre osäkerhet. Däremot, energilagringsystem såsom gravitationskraftmodul är ny vilket gör att den tillgängliga informationen är begränsad och följaktligen mer osäker. Detta projekt har utvecklat en modell utifrån tidigare forskning i området, för att mäta högsta möjliga vinst för varje energilagringsteknik under en specifik tid genom ellagring. Resultatet antyder att lagring av tryckluft, tyngdkraftsmodul och pumpad termisk ellagring är de intressanta teknikerna för vidare studier. Genom detta arbete visar vi att deras kostnader och eventuella intäkter är jämförbara. Vidare studier utifrån detta projekt är att studera de föreslagna teknikerna djupare med hänsyn till Växjö Energis förhållanden för mer detaljerade och tillförlitliga resultat.

Satisfaire les besoins en énergie de manière responsable est possible grâce aux énergies renouvelables, notamment éoliennes et solaires. Cependant ces centres de captation d’énergie sont éloignés dans zones de consommation. Le transport de l’énergie via des réseaux HVDC (haute tension courant continu) permet un rendement et une flexibilité avantageuse face au transport HVAC (haute tension courant alternatif). Ceci est rendu possible grâce aux convertisseurs utilisant l’électronique de puissance. Les récents développements sur les semi-conducteurs à large bande interdite, plus particulièrement le carbure de silicium (SiC) offrent la possibilité de concevoir ces convertisseurs plus simples, utilisant des briques technologiques de plus fort calibre (≤ 10 kV). Cependant le packaging, essentiel à leur bon fonctionnement, ne suit pas ces évolutions. Dans cette thèse, nous explorons les technologies actuelles ainsi que les limites physique et normatives liées au packaging haute tension. Des solutions innovantes sont proposées pour concevoir un module de puissance haute tension, impactant que faiblement les paramètres connexes (résistance thermique, isolation électrique et paramètres environnementaux). Les éléments identifiés comme problématiques sont traités individuellement. La problématique des décharges partielles sur les substrats céramiques métallisés est développée et une solution se basant sur les paramètres géométriques a été testée. Le boitier standard type XHP-3 a été étudié et une solution permettant de le faire fonctionner à 10 kV à fort degré de pollution a été développée. / The supply of carbon-free energy is possible with renewable energy. However, windfarms and solar power plants are geographically away from the distribution points. Transporting the energy using the HVDC (High Voltage Direct Current) technology allow for a better yield along the distance and result in a cost effective approach compared to HVAC (High Voltage Alternative Current) lines. Thus, there is a need of high voltage power converters using power electronics. Recent development on wide bandgap semiconductors, especially silicon carbide (SiC) allow a higher blocking voltage (around 10 kV) that would simplify the design of such power electronic converters. On the other hand, the development on packaging technologies needs to follow this trend. In this thesis, an exploration of technological and normative limitation has been done for a high voltage power module design. The main hot spot are clearly identified and innovative solutions are studied to provide a proper response with a low impact on parasitic parameters. Partial Discharges (PD) on ceramic substrates is analyzed and a solution of a high Partial Discharge Inception Voltage (PDIV) is given based on geometrical parameters. The XHP-3 like power modules are studied and a solution allowing a use under 10 kV at a high pollution degree (PD3) is given.

Cette thèse concerne la récupération d'énergie vibratoire dans le but de proposer une alternative aux batteries conventionnelles pour l’alimentation de systèmes autonomes sans fil. Ceci permettrait d’améliorer leur compacité (moins d’énergie stockée), leur tenue dans des environnements sévères (forte température) et de réduire leur besoin d'entretien. Cette étude se concentre plus particulièrement sur les générateurs oscillants bistables, intéressants pour leur grande plage de fréquences utile comparée à celle offerte par les générateurs linéaires (limitée à la zone de résonance). Cette thèse se divise en quatre grandes parties. La première présente la construction du modèle mathématique permettant de prédire les différents comportements du générateur bistable (ces derniers pouvant coexister sur certaines plages de fréquences) incluant l'étude de la stabilité aux petites perturbations. Ce modèle met en évidence des comportements du générateur encore peu exploités pour la récupération d'énergie : les comportements sous-harmoniques dont la plage de fréquences permet d'agrandir la bande passante globale du générateur. Afin d’améliorer la précision du modèle, celui-ci est ensuite complété dans la deuxième partie par un critère semi-analytique : le critère de robustesse de stabilité qui caractérise la sensibilité du générateur aux perturbations extérieures (plus un comportement est robuste plus il sera facile à maintenir dans le temps). Le modèle ainsi obtenu ainsi que le système expérimentale montrent une grande plage de fréquences sur laquelle coexistent des comportements intéressants pour la récupération d’énergie (les orbites hautes) et des comportements non désirables (les orbites basses). La troisième partie de cette thèse présente donc différentes stratégies permettant de sauter des orbites basses vers les orbites hautes en jouant directement sur les paramètres du générateur. Enfin, la quatrième et dernière partie s’attarde sur l’influence du circuit d'interface AC-DC entre le générateur bistable et la charge en vue de son intégration future. / This thesis concerns vibratory energy harvesting in order to propose an alternative to conventional batteries for the power supply of autonomous wireless systems. This would improve their compactness (less stored energy), their resistance to harsh environments (high temperature) and reduce their need for maintenance. This study focuses in particular on bistable oscillating generators, which are interesting for their large useful frequency range compared to that offered by linear generators (limited to the resonance zone). This thesis is divided into four main parts. The first presents the construction of the mathematical model to predict the different behaviors of the bistable generator (these behaviors can coexist over certain frequency ranges) including the study of stability to small disturbances. This model highlights original behaviors for energy recovery: subharmonic behaviors whose frequency range allows increasing the overall generator bandwidth. In order to improve the accuracy of the model, a semi-analytical criterion is then added: the stability robustness criterion which characterizes the sensitivity of the different behaviors to external disturbances (the more robust a behavior, the easier to maintain over time). The model obtained and the experimental prototype show a wide frequency range on which the interesting behaviors (high orbits) and the undesirable behaviors (low orbits) coexist. The third part of this thesis therefore presents different strategies for jumping from low to high orbits by playing directly on the generator parameters. Finally, the fourth and last part focuses on the influence of the AC-DC interface circuit between the bistable generator and the load for future integration.