Thesis (MScEng (Electrical and Electronic Engineering))--University of Stellenbosch, 2010. / ENGLISH ABSTRACT: Voltage regulation on distribution networks has so far been done by means of mechanical tap changers. However, these tap changers are plagued by high maintenance costs due to the arcing caused while switching, which degrades both the contacts and transformer oil. The major advances made during the last decade with regard to semiconductor technology have led to the development of high power IGBTs. These high power IGBTs are capable of conducting currents up to 1 000 A, while the voltage over the IGBT reaches well over 3 000 V. Using these high power IGBTs to design and build a solid-state tap changer allows the tap changer to regulate the output voltage with higher accuracy and speed. The supporting hardware is also discussed, while the design is verified by the use of simulations and practical measurements conducted on a scale-model of the IGBT-based solid-state tap changer. / AFRIKAANSE OPSOMMING: Spannings regulasie op distribusie netwerke word hedendaags verrig deur meganiese tap geskalde spanning reguleerders. Maar hierdie tap skakelaars word konstant beïnvloed deur oorvonking wat plaasvind tussen die kontakte wat hierdie kontakte beskadig en die transformator olie degradeer. Die laaste dekade het groot vordering getoon in halfgeleier navorsing wat gelei het tot die ontwikkeling van hoë drywing halfgeleiers. Die halfgeleiers of IGBTs kan strome so groot soos 1 000 A gelei terwyl die spanning oor die halfgeleier 3 000 V kan oorskry. Die gebruik van die hoë drywing halfgeleiers maak die pad oop vir die ontwerp en bou van ’n tap geskakelde reguleerder wat die uitree spanning akurater en vinniger kan reguleer. Die aanvullende hardeware is ook bespreek en die ontwerp is geverifieër deur middel van simulasies en deur praktiese metings wat geneem is op ’n skaal model van die hoogspanning spannings reguleerder.

Insulated Gate Bipolar Transistors (IGBTs) are popular power electronic switching devices with several advantages. However, they have been known to fail in the field when subjected to significant variations in power dissipation – known as power cycling. In the work presented here, a novel alternating-current (AC) power cycling test method for IGBTs together with their free-wheeling diodes is proposed and verified. A review of previous work revealed that the parameter that most affects IGBT lifetime under power cycling conditions is the variation in its junction-case temperature difference. Through simulation, the behaviour of a conventional single phase inverter (H-bridge) using simple pulse width modulation (PWM) control was quantified, and the effect of switching frequency and load power factor was studied. Results of the simulations and literature review were used to develop design criteria for a new AC test circuit. The new AC test circuit (a modified version of the conventional H-bridge) was then designed and its performance compared to the criteria and to the simulation results of the conventional circuit. The circuit was then built and its performance was validated. The circuit complied with the performance criteria, in particular the desired variation in 7jc, to an adequate degree of accuracy. The proposed test circuit is novel for several reasons. The stresses on devices used in a conventional H-bridge using a high power factor inductive load are reproduced using a low power factor inductive load, considerably reducing the energy cost of running such a test. IGBT switching losses are not actively reduced, as is normal practice, but instead are actively increased to generate the required losses. Free-wheeling diodes are also tested, but do not have significant switching losses, as the nature of the test circuit dictates that these be transferred to the IGBTs. The main drawback of the proposed test circuit is that a larger number of devices are needed; however, this tradeoff is necessary to obtain the energy cost savings provided by this circuit.

Subestações blindadas são utilizadas por empresas de energia há mais de 50 anos. Muitas destas subestações estão em operação até os dias de hoje, sem qualquer modificação em seu projeto original, e ainda assim continuam operando sem apresentar problemas ou indícios de fadiga. Isto pode ser atribuído a sua qualidade construtiva em conjunto com o material isolante utilizado por este tipo de equipamento, o Hexafluoreto de Enxofre (SF6). Este gás possui todas as características desejáveis para manter adequadas as propriedades dielétricas da subestação, além de ser inerte e extremamente estável. O tempo de vida nominal de uma subestação blindada pode ser de 30 a 50 anos, dependendo de suas características ou recomendação do fabricante. A proximidade, ou até a ultrapassagem, do final do tempo de vida gera preocupação às empresas detentoras destes equipamentos antigos no que diz respeito a operação da subestação com segurança. Outro aspecto importante está relacionado a vazamentos de gás na atmosfera, pois o SF6 está entre os elementos mais danosos para o efeito estufa. Por estas razões este trabalho apresenta o desenvolvimento de um sistema para monitoramento de vazamentos e também de parâmetros indicativos do gás SF6 em uma subestação blindada antiga. O objetivo principal foi de desenvolver um sistema com dados históricos para se realizar estudos a respeito do comportamento do gás. A subestação utilizada neste trabalho não possuía nenhum sistema de monitoramento online. Assim, foi desenvolvido um sistema de tempo real para coletar dados de densidade do gás e de ponto de orvalho nos compartimentos da subestação. O sistema de coleta de dados foi instalado em três bays de uma subestação. Foram instalados sensores para medir estas duas grandezas, e também, módulos de aquisição de dados de baixo custo que se comunicam por meio de protocolos padrão e abertos. A partir do sistema instalado, no longo prazo, se espera a redução de vazamentos de gás com a possibilidade de inspeções online. Pode ser atribuído como resultado do trabalho a redução de custos, pois os dados históricos com indicativos favoráveis permitem estender o tempo entre manutenções preventivas. Como resultado complementar deste trabalho, o monitoramento de perdas de gás se torna mais eficiente e rápido, colaborando, assim com as expectativas ambientais atuais. / Gas Insulated Substations (GIS) are used by energy companies for over 50 years. Many early substations have been in operation until the present day, without any modification in its original design, and still are operating without problems or indications of fatigue. This can be attributed to its constructive quality along with the insulating material used for this type of equipment, the gas sulfur hexafluoride (SF6). This gas has all the desirable features for maintaining the dielectric of the substation as well as being inert and extremely stable. The nominal lifetime of a GIS substation can be 30 to 50 years, depending on their characteristics or manufacturer\'s recommendation. The proximity, or even exceeding, the lifetime generates concern to companies holding these old equipment as regards the operation of the substation safely. Another important aspect is related to gas leakages into the atmosphere because SF6 is among the most damaging elements to the greenhouse effect. Therefore, this work presents the development of a system for monitoring leakage and also indicative parameters of SF6 gas at an old GIS. The main objective was to develop a system with historical data to conduct studies about the behavior of the gas. The substation used for this work had no online monitoring system. Thus, it was developed a real-time system for collecting data of gas density and dew point in the compartments of the substation. The data collection system was installed in three bays of the substation. Sensors were installed to measure these two quantities, and also low cost data acquisition modules which communicate via standard and open protocols. In long term, with the system, there should be a reduction of gas leakages with the possibility of online inspections of the gas. May be assigned as a result the reduction of costs, since the historical data with good indicative allows extending the time for preventative maintenance. As additional result of this work, it is expected that the monitoring of leakage become more efficient and faster, thus contributing to the current environmental expectations.

Subestações blindadas são utilizadas por empresas de energia há mais de 50 anos. Muitas destas subestações estão em operação até os dias de hoje, sem qualquer modificação em seu projeto original, e ainda assim continuam operando sem apresentar problemas ou indícios de fadiga. Isto pode ser atribuído a sua qualidade construtiva em conjunto com o material isolante utilizado por este tipo de equipamento, o Hexafluoreto de Enxofre (SF6). Este gás possui todas as características desejáveis para manter adequadas as propriedades dielétricas da subestação, além de ser inerte e extremamente estável. O tempo de vida nominal de uma subestação blindada pode ser de 30 a 50 anos, dependendo de suas características ou recomendação do fabricante. A proximidade, ou até a ultrapassagem, do final do tempo de vida gera preocupação às empresas detentoras destes equipamentos antigos no que diz respeito a operação da subestação com segurança. Outro aspecto importante está relacionado a vazamentos de gás na atmosfera, pois o SF6 está entre os elementos mais danosos para o efeito estufa. Por estas razões este trabalho apresenta o desenvolvimento de um sistema para monitoramento de vazamentos e também de parâmetros indicativos do gás SF6 em uma subestação blindada antiga. O objetivo principal foi de desenvolver um sistema com dados históricos para se realizar estudos a respeito do comportamento do gás. A subestação utilizada neste trabalho não possuía nenhum sistema de monitoramento online. Assim, foi desenvolvido um sistema de tempo real para coletar dados de densidade do gás e de ponto de orvalho nos compartimentos da subestação. O sistema de coleta de dados foi instalado em três bays de uma subestação. Foram instalados sensores para medir estas duas grandezas, e também, módulos de aquisição de dados de baixo custo que se comunicam por meio de protocolos padrão e abertos. A partir do sistema instalado, no longo prazo, se espera a redução de vazamentos de gás com a possibilidade de inspeções online. Pode ser atribuído como resultado do trabalho a redução de custos, pois os dados históricos com indicativos favoráveis permitem estender o tempo entre manutenções preventivas. Como resultado complementar deste trabalho, o monitoramento de perdas de gás se torna mais eficiente e rápido, colaborando, assim com as expectativas ambientais atuais. / Gas Insulated Substations (GIS) are used by energy companies for over 50 years. Many early substations have been in operation until the present day, without any modification in its original design, and still are operating without problems or indications of fatigue. This can be attributed to its constructive quality along with the insulating material used for this type of equipment, the gas sulfur hexafluoride (SF6). This gas has all the desirable features for maintaining the dielectric of the substation as well as being inert and extremely stable. The nominal lifetime of a GIS substation can be 30 to 50 years, depending on their characteristics or manufacturer\'s recommendation. The proximity, or even exceeding, the lifetime generates concern to companies holding these old equipment as regards the operation of the substation safely. Another important aspect is related to gas leakages into the atmosphere because SF6 is among the most damaging elements to the greenhouse effect. Therefore, this work presents the development of a system for monitoring leakage and also indicative parameters of SF6 gas at an old GIS. The main objective was to develop a system with historical data to conduct studies about the behavior of the gas. The substation used for this work had no online monitoring system. Thus, it was developed a real-time system for collecting data of gas density and dew point in the compartments of the substation. The data collection system was installed in three bays of the substation. Sensors were installed to measure these two quantities, and also low cost data acquisition modules which communicate via standard and open protocols. In long term, with the system, there should be a reduction of gas leakages with the possibility of online inspections of the gas. May be assigned as a result the reduction of costs, since the historical data with good indicative allows extending the time for preventative maintenance. As additional result of this work, it is expected that the monitoring of leakage become more efficient and faster, thus contributing to the current environmental expectations.

Track stiffness is the one of the most critical parameters of the track structure. Its evaluation is important to assess track quality, component performance, localised faults and optimise maintenance periods and activities. Keeping the track stiffness within acceptable range of values is connected with keeping the railway network in a satisfactorily performing condition, allowing thereby upgrade of its capacity (speed, load, intensity). Current railway standards are changing to define loading and stiffness requirements for improved ballasted and ballastless performance under high speed train traffic. In recent years various techniques have been used to measure track deflection which have been also used to validate numerical models to assess various problems within the railway network. Based on recent introduction of the Video Gauge for its application in the civil engineering industry this project provides the proof of effective applicability of this DIC (Digital image correlation) tool for the accurate assessment of track deflection and the calculation of track stiffness through its effective applicability in various track conditions for assessing the stiffness of various track forms including track irregularities where abrupt change in track stiffness occur such as transition zones and rail joints. Attention is given in validation of numerical modelling of the response of insulated rail joints under the passage of wheel load within the goal to improve track performance adjacent to rail joints and contribute to the sponsoring company s product offering. This project shows a means of improving the rail joint behaviour by using external structural reinforcement, and this is presented through numerical modelling validated by laboratory and field measurements. The structural response of insulated rail joints (IRJs) under the wheel vertical load passage is presented to enhance industry understanding of the effect of critical factors of IRJ response for various IRJ types that was served as a parametric FE model template for commercial studies for product optimisation.

To investigate the wheel/rail contact impact forces at insulated rail joints (IRJs), a three-dimensional finite element model and strain gauged experiments are employed and reported in this thesis. The 3D wheel/rail contact-impact FE model adopts a two-stage analysis strategy in which the wheel-IRJ railhead contact is first established in the static analysis and the results transferred to dynamic analysis for impact simulations. The explicit FE method was employed in the dynamic analysis. The Lagrange Multiplier method and the Penalty method for contact constraint enforcement were adopted for the static and dynamic analyses respectively. The wheel/rail contact-impact in the vicinity of the end post is exhibited via numerical examples from the FE modelling. The wheel/rail contact impact mechanism is investigated. The strain gauged experiments which consist of a lab test and a field test are reported. The signature of the strain time series from the field test demonstrates a plausible record of the dynamic responses due to the wheel/rail contact impact. By using the experimental data, both the static and the dynamic FE models are validated. It is found that the stiffness discontinuity of the IRJ structure causes a running surface geometry discontinuity during the wheel passages which then causes the impact in the vicinity of the end post. Through a series of sensitivity studies of several IRJ design parameters, it is shown that the IRJ performance can be effectively improved with optimised design parameters.

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This thesis demonstrates the feasibility of methods developed to increase the quality of the crescent bond together with the tail bond quality. Low pull force of the crescent bond limits the usage of insulated Au wire in microelectronics assembly. Premature break of the tail which results in the stoppage of the bonding machine is one of obstacles to overcome for Cu wire. The primary focus of this thesis is to understand the tail and crescent bonding process and then to propose methodologies to improve thermosonic wire bonding processes when Cu and insulated Au wires are used. Several series of experiments to investigate the crescent and tail bonding processes are performed on auto bonders. Cu and insulated Au wires with diameters of 25mm are bonded on the diepads of Ag leadframes. For simplicity, wire loops are oriented perpendicular to the ultrasonic direction. It was found that the crescent bond breaking force by pulling the wire loop (pull force) with insulated Au wire is about 80 % of that of bare Au wire. A modification of the crescent bonding process is made to increase the pull force with insulated Au wire. In the modified process, an insulation layer removing stage (cleaning stage) is inserted before the bonding stage. The cleaning stage consists of a scratching motion (shift) toward to the ball bond in combination with ultrasound. Bonds are then made on the fresh diepad with the insulation removed from the contact surface of the insulated Au wire. This process increases the pull force of the crescent bond up to 26% which makes it comparable to the results obtained with bare Au wire. An online tail breaking force measurement method is developed with a proximity sensor between wire clamp and horn. Detailed understanding of tail bond formation is achieved by studying tail bond imprints with scanning electron microscopy and energy dispersive x-ray analysis. Descriptions are given of the dependence of the tail breaking force on the bonding parameters, metallization variation, and cleanliness of the bond pad. Simultaneous optimization with pull force and tail breaking force can optimize the Cu wire bonding process both with high quality and robustness. It is recommended to first carry out conventional pull force optimization followed by a minimization of the bonding force parameter to the lowest value still fulfilling the pull force cpk requirement. The tail bond forms not only under the capillary chamfer, but also under the capillary hole. The tail breaking force includes both the interfacial bond breaking strength and the breaking strength of the thinned portion of the wire that will remain at the substrate as residue. Close investigations of the tail bond imprint with scanning electron microscopy indicate the presence of fractures of the substrate indicating substrate material being picked up by Cu wire tail. Pick up is found on Au and Cu wires, but the amount of pick up is much larger on Cu wire. The effect on the hardness of the subsequently formed Cu free air ball (FAB) as investigated with scanning electron microscopy and micro - hardness test shows that Cu FABs containing Au and Ag pick ups are softer than those without pick up. However, the hardness varies significantly more with Au pick up. The amount of Au pick up is estimated higher than 0.03 % of the subsequently formed FAB volume, exceeding typical impurity and dopant concentrations (0.01 %) added during manufacturing of the wire.