A method and test system for evaluating power module reliability

Abstract

The application discloses a kind of for evaluating the method of power module reliability comprising the following steps: screening out weak components in power module and carrying out accelerated aging test, obtain the degradation state of weak components;Power module is divided into multiple functional modules and corresponding degradation state is bound to weak components, functional module and power module are simulated, and the performance degradation model of power module about overall performance is established;The accelerated aging test of the functional module of power module is carried out to correct the performance degradation model, and the final degradation model of power module is obtained;Measure the state data of power module to be evaluated, and obtain the reliability evaluation of power module by comparing the final degradation model.The application also discloses a kind of for evaluating the measuring system of power module reliability.The application evaluates the performance of power module by the running state of functional module and checks failure weak components, for predicting the remaining useful life of power module and the check replacement of failure weak components.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of reliability evaluation of power supply modules. BACKGROUND

[0002] The power supply module performs functions such as power conversion and automatic switching in the nuclear instrument control system, and the aging failure of components in the power supply module will cause abnormal operation of the unit, so it is necessary to regularly perform technical diagnosis on the power supply module to detect and replace the aging failure components in the power supply module. The current diagnosis technology mainly checks the input and output performance parameters of the power supply module during the shutdown of the equipment to determine whether the power supply module is failed. This method is relatively single and can only determine whether the power supply module is failed, and cannot take effective preventive measures for the components that will fail during this diagnosis process, which may cause safety hazards due to the failure of components in the power supply module during the subsequent operation of the equipment. Therefore, it is necessary to detect the components of the power supply module and predict the remaining service life of the power supply module to replace the components that will fail in the power supply module in time. The document CN112418590A evaluates whether a circuit branch is damaged by sequentially detecting all components in the circuit branch to achieve the purpose of circuit detection. However, for power supply modules with many components, the method of detecting the damage degree of components one by one to predict the remaining service life of the power supply module is very redundant and complex, which is not conducive to efficiently predicting the remaining service life. SUMMARY

[0003] The present application aims to provide a method for evaluating the reliability of a power supply module and a matching measurement system to realize in-service inspection and life evaluation of the power supply module.

[0004] To achieve the above-mentioned purpose, the technical solution adopted by the present application comprises:

[0005] A method for evaluating the reliability of a power supply, comprising the steps of:

[0006] S1, screening out fragile components in the power supply module and performing accelerated aging test on the fragile components to obtain the performance index matrix and the degradation state of the performance index of the fragile components during the aging process;

[0007] S2, establishing a power supply module model, dividing the power supply module model into multiple functional modules, binding the fragile components in the functional modules to the corresponding degradation states, and performing joint simulation on the functional modules of the power supply module model to obtain the simulation relationship between the degradation state of the fragile components and the operating state of the functional modules, as well as the operating state simulation relationship between the functional modules;

[0008] S3, simulate the overall performance of the power module model, obtain the simulation relationship between the running state of each functional module of the power module model and the overall performance, denoted as a performance degradation model;

[0009] S4, divide the functional modules of the power module according to the power module model, perform accelerated aging test on the functional modules, obtain the degradation model of the functional modules, correct the simulation relationship between the degradation state of the fragile components and the running state of the functional modules in the performance degradation model using the degradation model of the functional modules, and obtain the final degradation model of the overall performance of the power module;

[0010] S5, measure the state data of the power module to be evaluated, and obtain the reliability evaluation of the power module by comparing the final degradation model.

[0011] Preferably, in step 3, the performance degradation model of the power module further includes criterion indicators for failure of each functional module caused by the degradation state of the fragile components and corresponding fault diagnosis methods, and the failure of the functional module under the degradation state of the fragile components is obtained according to the criterion indicators and the corresponding fault diagnosis methods.

[0012] Preferably, in step S1, the fragile components of the power module include electrolytic capacitors, transistors, field effect tubes and optical couplers.

[0013] Preferably, in step 2, the functional modules of the power module include voltage stabilizing circuit modules, comparison circuit modules and thyristor phase control circuit modules, the input end of the thyristor phase control circuit module is connected with the power input end, the output end of the thyristor phase control circuit module is connected with the input end of the voltage stabilizing circuit module, the output end of the voltage stabilizing circuit module is connected with the power output end and the input end of the comparison circuit module respectively, and the output end of the comparison circuit module is connected with the input end of the thyristor phase control circuit module.

[0014] Preferably, in step S5, the state data measured by the power module to be evaluated includes the running state data of the functional modules and / or the degradation state data of the fragile components.

[0015] Preferably, the running state data includes output voltage and current rating, output voltage regulation range, voltage stability, and load stability.

[0016] A system for evaluating the reliability of a power module, comprising a hardware system and a software system.

[0017] The hardware system preferably comprises a display controller, an industrial computer, an Ethernet, a wide-range AC power supply, a wide-range DC power supply, an AC / DC load, a data collector, a control switch matrix and a test fixture; the industrial computer is connected with the display controller and the Ethernet respectively; the wide-range AC power supply, the wide-range DC power supply, the AC / DC load and the data collector are connected with the control switch matrix and the Ethernet respectively; the Ethernet is further connected with the control switch matrix and the test fixture respectively; and the control matrix is connected with the power supply module to be tested.

[0018] The software system preferably comprises an analysis and management module, a monitoring module, a design module, an execution module, a storage module, a communication module and a driving module; the communication module is connected with the design module, the driving module and the monitoring module respectively; the execution module is connected with the driving module, the monitoring module and the storage module respectively; the design module is connected with the analysis and management module and the storage module respectively; and the analysis and management module is connected with the storage module.

[0019] The power supply module reliability evaluation method has the advantages that an ultimate degradation model of the overall performance of the power supply module is established to predict the remaining service life and in-service state of the power supply module, and the subsequent maintenance and replacement of the aged components in the power supply module are facilitated; the detection efficiency is improved and the detection cost is reduced by collecting the running state data of the functional modules; on one hand, the running state data of the functional modules can be used to analyze the overall performance of the power supply module to predict the remaining service life, which replaces the cumbersome way of predicting the service life by detecting the damage degree of each fragile component; on the other hand, when the overall performance of the power supply module decreases, the running state data of each functional module can be used to narrow down the fault range, so that the fragile components that fail can be quickly located and replaced. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 Flowchart of the power supply reliability evaluation method in the application

[0021] Figure 2 Hardware diagram of the test system in the application

[0022] Figure 3 Software diagram of the test system in the application

[0023] Figure 4 Overall flowchart of the power supply module reliability evaluation method

[0024] Wherein: 1, display controller, 2, industrial computer, 3, Ethernet, 4, wide range AC power supply, 5, wide range DC power supply, 6, AC / DC electronic load, 7, data collector, 8, control matrix, 9, test fixture, 10, power module to be tested, 21, design module, 22, communication module, 23, drive module, 24, monitoring module, 25, execution module, 26, analysis and management module, 27, storage module. DETAILED DESCRIPTION

[0025] To achieve the above object, the present application is further described below in combination with the drawings.

[0026] Reference Figure 1 And Figure 4 A method for evaluating the reliability of a power module, comprising the steps of:

[0027] S1. First, according to the statistical experience of domestic and foreign power module general element failure, the fragile components of the power module are screened out, including electrolytic capacitor, transistor, field effect transistor and optocoupler, the fragile components are placed in an environment of 125℃ for accelerated aging test, the performance indicators of the fragile components are monitored and recorded during the aging process, and the performance indicator matrix and the degradation law of the performance indicators of the fragile components are obtained.

[0028] S2. Establishing a power module model, the power module model is divided into multiple functional modules, including a voltage stabilizing circuit module, a comparison circuit module and a thyristor phase control circuit module;

[0029] The input end of the thyristor phase control circuit module is connected with the power input end, the output end of the thyristor phase control circuit module is connected with the input end of the voltage stabilizing circuit module, the output end of the voltage stabilizing circuit module is connected with the power output end and the input end of the comparison circuit module respectively, and the output end of the comparison circuit module is connected with the input end of the thyristor phase control circuit module.

[0030] The fragile components in the functional modules are bound to the corresponding degradation states, the functional modules of the power module model are jointly simulated, the simulation relationship between the degradation states of the fragile components and the running states of the functional modules, and the running state simulation relationship between each functional module are obtained.

[0031] S3. The overall performance of the power module model is simulated to obtain the simulation relationship between the running states of each functional module of the power module model and the overall performance, which is recorded as a performance degradation model, wherein the performance degradation model also includes criterion indicators and fault mode diagnosis methods of the functional modules, which are used to obtain the faults of the functional modules under the degradation state of the fragile components.

[0032] S4. According to the power module model, the function module of the power module is divided, the function module is subjected to accelerated aging test, the test data of the function module are obtained by burning-in in the environment of 125 DEG C, the degradation model of the function module is obtained, the simulation relationship between the degradation state of the fragile component in the performance degradation model and the running state of the function module is corrected, and the final degradation model of the overall performance of the power module is obtained;

[0033] S5. The running state data of the function module and / or the degradation state data of the fragile component in the power module to be evaluated are measured, the running state data include output voltage and current rating, output voltage regulation range, voltage stability, load stability, and the reliability of the power module is evaluated according to the final degradation model.

[0034] The application also comprises a measuring system for evaluating the reliability of the power module. Figure 2 As shown in the figure, the measuring system hardware comprises a display controller 1, an industrial computer 2, an Ethernet 3, a wide-range AC power supply 4, a wide-range DC power supply 5, an AC / DC load 6, a data collector 7, a control switch matrix 8 and a test fixture 9; the industrial computer 2 is connected with the display controller 1 and the Ethernet 3 respectively, the wide-range AC power supply 4, the wide-range DC power supply 5, the AC / DC load 6 and the data collector 7 are connected with the control switch matrix 8 and the Ethernet 3 respectively, the Ethernet 3 is also connected with the control switch matrix 8 and the test fixture 3 respectively, and the control matrix 8 is connected with the power module 10 to be tested; the test fixture 9 is used for clamping different test power module output ports and intermediate test points; the input end of the power module 10 is connected with the control switch matrix 8, and the output end of the power module is connected with the data collector 7; the data collector 7 is used for collecting parameters such as output voltage and current rating, output voltage regulation range, voltage stability, load stability, ripple voltage, efficiency and power factor, overcurrent protection, overvoltage protection and harmonic component; the control switch matrix 8 is used for switching the corresponding input power circuit to adapt to different test requirements; the control switch matrix 8 is also connected with the wide-range AC power supply 4, the wide-range DC power supply 5 and the AC / DC load 6 respectively, and the three power supplies provide different power inputs to test the power module; the Ethernet 3 is used for transmitting the control signals of the industrial computer 2 and the test results collected by the data collector 7; the display controller 1 is used for test result display and active control in the test process; and the industrial computer 2 is used for executing the test program and analyzing and storing the test results.

[0035] The measuring system is also provided with a software system as shown in the figure, which comprises a test program 1, a data analysis program 2 and a data storage program 3. Figure 3As shown, it comprises: a design module 21 for the design of flow, algorithm, criterion, safety interlock, etc.; a communication module 22 for the transmission of equipment information; a driving module 23 for the control of instruments; a monitoring module 24 for the monitoring of test processes; an execution module 25 for the execution of programs; an analysis and management module 26 for the analysis of test results and the derivation of corresponding management measures according to the test results; a storage module 27 for the storage of test data and test processes; the communication module 22 is connected with the design module 21, the driving module 23 and the monitoring module 24 respectively, the execution module 25 is connected with the driving module 23, the monitoring module 24 and the storage module 27 respectively, the design module 21 is connected with the analysis and management module 26 and the storage module 27 respectively, and the analysis and management module 26 is connected with the storage module 27.

[0036] Those skilled in the art of the present technology should recognize that the above is only used to illustrate the present application, and is not used as a limitation on the present application, as long as the variations and modifications of the above examples are within the spirit and principles of the present application, they will fall within the scope of the claims of the present application.

Claims

1. A method for evaluating the reliability of a power module, characterized in that, Including the following steps: S1. Screen out the fragile and easily damaged components in the power module and conduct accelerated aging tests on the fragile components to obtain the performance index matrix and the degradation status of the performance index during the aging process. S2. Establish a power module model, divide the power module model into multiple functional modules, bind the vulnerable components in the functional modules to the corresponding degradation states, perform joint simulation on the functional modules of the power module model, and obtain the simulation relationship between the degradation state of the vulnerable components and the operating state of the functional modules, as well as the simulation relationship between the operating states of each functional module. S3. Simulate the overall performance of the power module model to obtain the simulation relationship between the operating status of each functional module of the power module model and the overall performance, which is denoted as the performance degradation model. S4. Divide the power module into functional modules according to the power module model, conduct accelerated aging tests on the functional modules to obtain the degradation model of the functional modules, and use the degradation model of the functional modules to correct the simulation relationship between the degradation state of fragile components and the operating state of the functional modules in the performance degradation model, so as to obtain the final degradation model of the overall performance of the power module. S5. Measure the status data of the power module to be evaluated and compare it with the final degradation model to obtain the reliability assessment of the power module.

2. The method for evaluating the reliability of a power module as described in claim 1, characterized in that, In step S3, the performance degradation model of the power module also includes criteria indicators for the failure of each functional module caused by the degradation state of the fragile components and corresponding fault diagnosis methods. Based on the criteria indicators and corresponding fault diagnosis methods, the faults of the functional modules under the degradation state of the fragile components are obtained.

3. The method for evaluating the reliability of a power module as described in claim 1, characterized in that, In step S1, the vulnerable components of the power module include electrolytic capacitors, transistors, field-effect transistors, and optocouplers.

4. The method for evaluating the reliability of a power module as described in claim 1, characterized in that, In step S2, the power supply module includes a voltage regulator circuit module, a comparator circuit module, and a thyristor phase control circuit module. The input terminal of the thyristor phase control circuit module is connected to the power input terminal, the output terminal of the thyristor phase control circuit module is connected to the input terminal of the voltage regulator circuit module, the output terminal of the voltage regulator circuit module is connected to both the power output terminal and the input terminal of the comparator circuit module, and the output terminal of the comparator circuit module is connected to the input terminal of the thyristor phase control circuit module.

5. The method for evaluating the reliability of a power module as described in claim 1, characterized in that, In step S5, the state data measured by the power module to be evaluated includes the operating state data of the functional modules and / or the degradation state data of the fragile components.

6. The method for evaluating the reliability of a power module as described in claim 5, characterized in that, The operating status data includes the rated values ​​of output voltage and current, the output voltage adjustment range, voltage stability, and load stability.

7. A system for evaluating the reliability of a power module, configured to perform a method for evaluating the reliability of a power module as described in any one of claims 1 to 6, characterized in that, The system includes a hardware system and a software system.

8. A system for evaluating the reliability of a power module according to claim 7, characterized in that, The hardware system includes: a display controller, an industrial computer, an Ethernet network, a wide-range AC power supply, a wide-range DC power supply, an AC / DC load, a data acquisition unit, a control switch matrix, and a test fixture. The industrial computer is connected to the display controller and the Ethernet network. The wide-range AC power supply, the wide-range DC power supply, the AC / DC load, and the data acquisition unit are all connected to the control switch matrix and the Ethernet network. The Ethernet network is also connected to the control switch matrix test fixture. The control switch matrix is ​​connected to the power supply module under test.

9. A system for evaluating the reliability of a power module according to claim 7, characterized in that, The software system includes: an analysis and management module, a monitoring module, a design module, an execution module, a storage module, a communication module, and a driver module. The communication module is connected to the design module, the driver module, and the monitoring module. The execution module is connected to the driver module, the monitoring module, and the storage module. The design module is connected to the analysis and management module and the storage module. The analysis and management module and the storage module are connected.

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