6. Oktober 2009 Ensuring product reliability in the wind power industry.

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2 MAKING MODERN LIVING POSSIBLE Ensuring product reliability in a cooperation between sub-suppliers and their customers Danfoss Silicon Power 6. Oktober Ensuring product reliability in the wind power industry

3 6. Oktober 2009 Ensuring product reliability in the wind power industry

4 Company Danfoss Silicon Power Area of the premises 40,000 m2 Building Complex Clean room area Offices/R&D facilities Infrastructure Area available for expansion 6. Oktober 2009 Ensuring product reliability in the wind power industry 4,500 1,500 1,400 1, m2 m2 m2 m2 m2

5 Products Custom Solutions in Standard Housings

6 Products Custom Solutions in Custom Housings

7 Industrial applications Special Industrial Drives Standard Industrial Drives Welding Renewables ransportation Medical

8 Various Stack Concepts Stacks are being build to requirements in co-operation with the customer

9 Applications, wind turbines Liquid cooled converter Source: Vestas V MW

10 Power modules Assemblies of large power semiconductors Power modules are placed in harsh environments

11 Power modules, failure mechanisms Major Failure Mechanisms Bondwire lift off due to rapid power cycling Large area soldering cracks between DBC and baseplates due to temperature changes caused by CE-mismatch Al Si DBC Alumina Cu 23.8 ppm/k 2.6 ppm/k 7-8 ppm/k 17.8 ppm/k

12 Power modules, failure mechanisms Lifetimes Assessment Short -cycles: Wire lift-off emperature / C Short/Medium -cycles: Die solder crack Long -cycles: Substrate solder crack symbolic graph 1 s ime 1 year

13 Wind profiles Class 10 m (33 ft) 30 m (98 ft) 50 m (164 ft) Wind power density (W/m 2 ) Speed m/s (mph) (0-9.8) ( ) ( ) ( ) ( ) ( ) ( ) Wind power density (W/m 2 ) Speed m/s (mph) (0-11.4) ( ) ( ) ( ) ( ) ( ) ( ) Wind power density (W/m 2 ) Speed m/s (mph) (0-12.5) ( ) ( ) ( ) ( ) ( ) ( ) Source:

14 Wind speed over time Distribution of wind speed (red) and energy (blue) for all of 2002 at the Lee Ranch facility in Colorado. he histogram shows measured data, while the curve is the Rayleigh model distribution for the same average wind speed. Energy is the Betz limit through a 100 m (328 ft) diameter circle facing directly into the wind. otal energy for the year through that circle was 15.4 GWh. Source:

15 Global wind resources Source:

16 Drive rain opologies Variable speed solutions: Doubly Fed Induction Generator Inverter controlled Rotor field Full Conversion Full Power flow through Inverter Applications with and without Gear and for both Induction Generator (IG) an Permanent Magnet Generator (PMG)

17 Learning Learning across context Customer requirements Sub-supplier requirements Common language/understanding Common specification Common design Source: Michael Sørensen, Danfoss Drives A/S

18 Mission profile analysis Losses vs. time, HEV application

19 Mission profile analysis he mission profile for one working condition

20 Mission profile analysis hermal step response analysis he step response curves are fitted to a sum of exponential functions from which the R-C values for the equivalent electric circuit will be extracted. Z () th t Ri 1 e i t = R i C i he thermal response in the component to a time dependant power dissipation, Pi(t), is found as: t () t + P( τ ) dz ( t τ ) dτ = 0 In incremental form: o th 1 t 1 = + ( ) τ i i 0 P Rth i i 0 1 e i t o

21 hermal response, cycle counting and analysis Mission profile analysis Δ = m ref B a ref ref f k E A N exp α 1. End-of-life power cycle tests lead to lifetime model for wire bond fatigue: 2. he damaging effect of all temperature swings of the mission profile are compared with a reference cycle: Δ Δ = Δ Δ = Δ Δ = m ref B a ref m B a fref f m ref B a ref m B a m ref B a ref m B a fref f k E k E N N k E k E k E A k E A N N exp exp exp exp exp exp α α α α α α c 3. he damaging effect of the mission profile is the sum of the damaging effect of all cycles. 4. If the mission profile is too damaging larger chips!! If the mission profile is too mild smaller chips!! - repeat step response, new RC s, new damaging effect emp Loss

22 Conclusion Product development for reliability requires Close collaboration between customer and sub-supplier Common language Common understanding Working together Specification often written jointly est specification and execution often done jointly Partnership