Design Tools and Modelling (DTM) in Power Electronics. Prof Chris Bailey University of Greenwich

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1 Design Tools and Modelling (DTM) in Power Electronics Prof Chris Bailey University of Greenwich

2 Contents University of Greenwich DTM in Power Electronics Cross Theme Project Training & Outreach

3 University of Greenwich Royal Observatory

technologies to predict the physical behaviour, performance,

4 CMRG Established in 2004 Staff: 2 Profs, 2 Readers, 5 Post Doc s, 7 PhD s Research Mission To develop and apply CAE technologies to predict the physical behaviour, performance, reliability, and maintainability of complex engineering components/systems.

5 Engagement with Professional Societies IEEE-CPMT & Reliability Societies Chapter Chair UK & Ireland Member of Board of Governors National Agency for Finite Elements Members of NMI Contributed to INEMI Roadmap

6 UoG within Centre

7 Contents University of Greenwich DTM in Power Electronics Cross Theme Project Training & Outreach

8 Design Objectives Next generation PE Systems Reduced Volume Reduced Weight Higher power density Higher efficiency Higher Reliability Minimum EMI/EMC Lower costs DTM Cross-theme 12 Feb

9 Multi-Disciplinary Electrical Engineering Computer Science & Mathematical Sciences Mechanical Engineering Physics Material Sciences Power Electronics Design Engineers Design for Excellence (DfX) Design for Manufacture Design for Test Design for Reliability etc Goals/Constraints Options + Design Rules Optimisation, Parametric Analysis, Sensitivity Analysis EDA & Circuit Analysis Tools Thermal Analysis Tools EM Analysis Tools Stress/Reliability Analysis Tools Devices Components Convertors Drives

10 Traditional Design Flow Step 1: Analyse Topology and switching scheme Derive equations for I, V and switching waveform Check with circuit simulator Step 2: Analyse other design aspects Derive equations for losses Derive equations/model for temperature Assess EMI & Reliability Redesign Topology Geometry Step 3: Design Assessment Have objectives been meet? Efficiency, volume, weight, etc Have constraints been meet? Temperature, EMI, Reliability NO YES Manufacture DTM Cross-theme 12 Feb

Thermo-Mechanical ANSYS, ABAQUS (Finite Elements)

11 Modelling Tools - Examples Thermal and Electromagnetic ANSOFF, Opera (electromagnetics) Flotherm (CFD, Compact models, etc) Portunas/MotorCAD (LPM, etc) PSPICE, SABER Circuit/System level models Thermo-Mechanical ANSYS, ABAQUS (Finite Elements) Multi-Physics COMSOL, ANSYS Optimisation Optimus, Visual-Doc Excel, MATLAB, etc

Model Driven - DfX Modify Design Formulate Design Intention EDA MCAD Build Prototypes Testing of Prototypes Manufacturing In-Field Operation and Maintenance Traditional DESIGN BUILD TEST Product

12 Model Driven - DfX Modify Design Formulate Design Intention EDA MCAD Build Prototypes Testing of Prototypes Manufacturing In-Field Operation and Maintenance Traditional DESIGN BUILD TEST Product Development Cycle Modify Design Formulate Design Intention DESIGN EDA MCAD MODEL and SIMULATE Process Modelling Circuit Analysis Thermal Analysis EMI Analysis Reliability/Performance Prototype Validation Manufacturing In-Field Operation and Maintenance Numerical Design Optimisation Data Flow Simulation Driven Product Development Cycle

13 Design for Reliability Damage Models Wirebond; Solder (SnAg) Creep, Fatigue, Fracture D 1 e 0.05 p N f 178L p No dimple With Dimples N f p

14 Wirebond Parametric Analysis Minimise Damage Stress, Plastic Strains Design Changes Impact of wire diameter

15 Why Use Virtual Prototyping Incentive for virtual prototyping tools: MONEY!!! The cost of repairing mistakes increases roughly an order of magnitude at each critical phase. $1,000,000 > 91.4 $100,000 $1,000 $10,000 Design Prototype Production Field

16 Contents University of Greenwich DTM in Power Electronics Cross Theme Project Training & Outreach

DTM in Centre Devices Components Convertors Drives Thermal Compact Models Physics of failure

Thermal & Electrical Compact Thermal and Loss Models Physics of failure Interconnect reliability,

.) EMI, EMC, Thermal Loss Models Trade-off analysis Optimisation Tools Saber, PLECS, SPICE, COMSOL, Opera,

drives Tools SABER, Flux 3D DTM Vision: Development of new design methodologies, models and tools that

17 DTM in Centre Devices Components Convertors Drives Thermal Compact Models Physics of failure Electromigration Dielectric Breakdown Tools Silvaco, Matlab, ANSYS. Thermal & Electrical Compact Thermal and Loss Models Physics of failure Interconnect reliability, optimisation and robustness Tools ANSYS, Flotherm, Powerlife, Visual-Doc.. Passives (Magnets..) EMI, EMC, Thermal Loss Models Trade-off analysis Optimisation Tools Saber, PLECS, SPICE, COMSOL, Opera, MATLAB, Simulink PE & Drive Interactions Thermal, EMC, reliability Multi-physics models for High Speed drives Tools SABER, Flux 3D DTM Vision: Development of new design methodologies, models and tools that provide the ability to undertake co-design (device to system) and hence optimise a power electronics system in terms of its efficiency, power density, reliability, robustness, EMI, integration and cost.

18 DTM X-Theme project 2-Year Project (Started Feb 2015) Bristol, Nottingham, Manchester, Greenwich Methodologies for fast coupled physicalbehavioural models for design optimisation DTM Cross-theme 12 Feb

19 Work Package Overview WP0: Power Electronics Design Flow Review (Greenwich Lead)

20 Workpackage Overview WP1: Component Representation (Manchester Lead) How to represent components with a combined Physical and Behavioural description

models from geometry that are equivalent to high fidelity

21 Workpackage Overview WP2: Automated Reduced Order Physical Modelling (ROM) (Greenwhich Lead) How to automatically develop models from geometry that are equivalent to high fidelity models but run much quicker Optimization 40,932 Equations 2,621 Equations

and Validation (Bristol Lead) To demonstrate that the methodology and techniques identified can be applied

22 Work Package Overview WP3: System Level Modelling and Design Framework (Nottingham Lead) How to effectively integrate component models and ROM physical models for analysis and design optimization WP4: Demonstration and Validation (Bristol Lead) To demonstrate that the methodology and techniques identified can be applied to a representative power electronics example and the results verified. T 1 D 1 E Load or machine coil T 2 D 2

23 Deliverables Report on Design Flow, Tools and Software Specification (WP0) Report on Coupled Physical Behavioural Model format definition (WP1) Report on Model order reduction methods (WP2) Report detailing implementation of above methods in system level tool (WP3) Report & Software validation (WP4) Proposals for follow-on funding (TSB, EU, etc)

24 Contents University of Greenwich DTM in Power Electronics DTM across the Centre Cross Theme Project Training & Outreach

25 Conferences/Training IEEE Therminic Conference Held at UoG (Sep 2014) 120+ attendees Session from Centre This year Paris

26 Conferences/Training 2-Day Workshop on Thermal Modelling Held at Univ Bristol (June 2015) 30 attendees from centre Contributions from industry partners

27 Outreach How is DTM undertaken in UK industry Workshop, questionnaire, survey Working with MTC Training & Workshops Circuit Analysis Electromagnetics Reliability Etc

28 Conclusions DTM underpinning technology Challenges Co-Design & Co-Simulation Model abstraction.vs. speed/accuracy Modelling new materials/failures Multi-disciplinary skills

29 Contact Professor Chris Bailey University of Greenwich

2D Finite Element Analysis ofigbt Solder Joint

2D Finite Element Analysis ofigbt Solder Joint Hua Lui", Chris Bailey Department of Mathematical Sciences, University of Greenwich 30 Park Row, London, SElO 9L S, UK. Email: H.Lu@gre.ac.uk Abstract-2D