Power module loop test method

Abstract

The invention relates to the technical field of power electronics, and discloses a power module cycle test method. According to the power module cycle test method, electrical parameters and working state information of the power module under various load and temperature conditions can be comprehensively collected and analyzed through systematized steps and multi-round dynamic tests, and compared with a traditional static test method, the method not only improves the authenticity and reliability of the test, but also improves the reliability of the test. The performance and the fault rate of the power module in practical application can be accurately evaluated, fault reasons can be found and analyzed in time through real-time monitoring and data recording, a scientific basis is provided for design optimization and improvement, the reliability of the power module is effectively improved, the service life of the power module is effectively prolonged, and the economic benefit is increased. The comprehensive test mode provides important support for research and development, production and quality control of the power module, and meets the requirements of modern electronic equipment for high performance and high reliability.

Description

Technical Field

[0001] The present invention relates to the technical field of power electronics, and in particular to a power module cycle testing method. Background Art

[0002] In modern electronic devices, power modules, as key power control and conversion components, are widely used in power management, electric vehicles, renewable energy systems, industrial automation, consumer electronics and other fields. With the advancement of science and technology and the continuous improvement of market demand, the performance requirements of power modules are becoming increasingly stringent, especially in terms of efficiency, thermal management, reliability and lifespan. Therefore, it is particularly important to conduct systematic testing and evaluation of power modules.

[0003] Traditional power module testing methods mostly focus on static testing and performance evaluation under single load conditions, which often cannot fully reflect the performance of power modules in actual working environments. With the diversification of power module application scenarios, this single testing method is obviously unable to meet the needs of design verification and quality control. Summary of the Invention

[0004] In response to the shortcomings of the existing technology, the present invention provides a power module cyclic testing method. Through systematic steps and multiple rounds of dynamic testing, it can comprehensively collect and analyze the electrical parameters and working status information of the power module under various load and temperature conditions. Compared with traditional static testing methods, this method not only improves the authenticity and reliability of the test, but also can accurately evaluate the performance and failure rate of the power module in actual applications. Through real-time monitoring and data recording, it can timely discover and analyze the cause of the failure, provide a scientific basis for design optimization and improvement, thereby effectively improving the reliability and service life of the power module. This comprehensive testing method provides important support for the research and development, production and quality control of power modules, and meets the requirements of modern electronic equipment for high performance and high reliability.

[0005] To achieve the above object, the present invention provides the following technical solution: a power module cycle test method, comprising the following steps: S1. Collect electrical parameters, including input voltage, input current, output voltage, and output current. Calculate and record instantaneous input power, instantaneous output power, and temperature rise. Simultaneously monitor and record the number of cycles, cycle time, and operating status information of the power module to provide basic data for subsequent analysis. S2. According to the test plan, gradually adjust the load conditions and input parameters, perform multiple rounds of cyclic testing, and in each cycle, monitor and record the electrical parameters and temperature change data in real time, monitor the working status data of the power module, and record faults and abnormal conditions; S3. Calculate the efficiency of each cycle based on the electrical parameters and temperature change data collected in S1 and S2. Also, count the frequency and type of failures in each cycle and calculate the failure rate to evaluate the reliability of the power module. S4. Based on the results of steps S1, S2, and S3, evaluate the performance of the power module under different load and temperature conditions. Combined with the monitored operating status data, conduct a comprehensive assessment of the reliability of the power module, calculate the energy loss and performance degradation rate, and write a test report summarizing the performance and reliability analysis results. S5. Conduct detailed analysis of faults that occur during the test, identify the causes of the faults, analyze the average fault duration, and propose design improvement plans based on the test results.

[0006] Preferably, the formula for calculating the instantaneous input power is as follows: ; In the formula, represents the instantaneous input power provided by the input terminal, Indicates the voltage at the input of the power module. Indicates the current at the input terminal.

[0007] Preferably, the formula for calculating the instantaneous output power is as follows: ; In the formula, Indicates the instantaneous output power at the module output end, Indicates the voltage at the output of the power module. Indicates the current at the output.

[0008] Preferably, the formula for calculating the temperature rise is as follows: ; In the formula, Indicates the module temperature rise relative to the ambient temperature. Indicates the temperature of the power module, Indicates the air temperature of the test environment.

[0009] Preferably, the calculation formula for the efficiency of each cycle is as follows: ; In the formula, represents the efficiency of each cycle, Indicates the instantaneous output power at the module output end, Indicates the instantaneous input power provided by the input terminal.

[0010] Preferably, the calculation formula of the failure rate is as follows: ; In the formula, represents the average number of failures per cycle, Indicates the number of failures that occurred during the test cycle, Indicates the total number of test cycles.

[0011] Preferably, the calculation formula for the energy loss is as follows: ; In the formula, represents the energy loss during the entire test, Indicates the instantaneous output power at the module output end, represents the instantaneous input power provided by the input terminal, Indicates the time interval of each sampling segment.

[0012] Preferably, the calculation formula for the performance degradation rate is as follows: ; In the formula, represents the performance degradation rate, Indicates the efficiency value at the beginning of the test, Indicates the final efficiency value of the test, Indicates the total number of test cycles.

[0013] Preferably, the root cause analysis is used to analyze the failures that occur during the test in detail. The method combines the time series data of fault occurrence to analyze the relationship between fault modes and fault influencing factors.

[0014] Preferably, the calculation formula for the mean fault duration is as follows: ; In the formula, The average duration of each failure, Indicates the duration of each fault. Indicates the total number of failures.

[0015] Compared with the prior art, the present invention provides a power module cycle test method with the following advantages: Through systematic steps and multiple rounds of dynamic testing, the present invention can comprehensively collect and analyze the electrical parameters and operating status information of the power module under various load and temperature conditions. Compared with traditional static testing methods, this method not only improves the authenticity and reliability of the test, but also can accurately evaluate the performance and failure rate of the power module in actual applications. Through real-time monitoring and data recording, it can promptly discover and analyze the cause of the failure, providing a scientific basis for design optimization and improvement, thereby effectively improving the reliability and service life of the power module. This comprehensive testing method provides important support for the research and development, production and quality control of power modules, and meets the requirements of modern electronic equipment for high performance and high reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the steps of the method of the present invention. DETAILED DESCRIPTION

[0017] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0018] Traditional power module testing methods focus on static testing and performance evaluation under single load conditions, which often cannot fully reflect the performance of power modules in actual working environments. To this end, a power module cycle test method is proposed. Figure 1 , the method comprises the following steps: S1. Collect electrical parameters, including input voltage, input current, output voltage, and output current. Calculate and record instantaneous input power, instantaneous output power, and temperature rise. Simultaneously monitor and record the number of cycles, cycle time, and operating status information of the power module to provide basic data for subsequent analysis. During the power module cycle performance test, high-precision electrical parameter measurement equipment is first used to collect key electrical parameters of the power module's input and output terminals in real time. Specifically, a high-sampling-rate data acquisition system is used to connect professional voltage and current sensors to monitor the input voltage and input current, as well as the output voltage and output current. These sensors are usually based on the Hall effect or shunt resistor principle and can achieve high-precision and fast-response measurements. The collected analog signals are converted into digital signals through an interface, and continuous and stable data acquisition is achieved using a high-speed data acquisition card (DAQ) or embedded data acquisition module. Subsequently, the collected instantaneous electrical parameters are processed in real time by a built-in or external high-performance computing unit (such as a microcontroller, FPGA, or industrial-grade embedded system) to calculate the instantaneous input power and instantaneous output power. The specific calculation method is to multiply the instantaneous voltage value by the corresponding instantaneous current value to obtain instantaneous power data, thereby reflecting the energy input and output status of the module at any moment. In addition, a temperature sensor (such as a thermocouple or integrated temperature sensor) is also equipped to monitor the temperature changes of key positions of the power module in real time, including chip temperature and heat sink surface temperature. The acquisition module synchronously collects the temperature signal through a high-precision analog / digital conversion interface to ensure that accurate thermal parameters can be obtained when the dynamic load changes. At the same time, to fully understand the test status, the system also automatically records various key working status information, including the number of test cycles, the duration of each cycle, and the module's working status (normal, abnormal, faulty, etc.). The number of cycles is accumulated in real time by a hardware counter or software statistical function, and the cycle time is controlled by a high-precision clock or timer. In terms of data storage, high-speed storage media or real-time databases are used to synchronously store all collected electrical parameters, temperature data, and working status information at each time point, forming continuous time series data, providing detailed basic data for subsequent analysis, evaluation, and fault diagnosis. The entire data acquisition solution utilizes a multi-channel, multi-precision, and multi-rate hardware platform combined with advanced signal processing and data storage technologies to ensure high accuracy and reliability of the collected parameters under complex cyclic test conditions. Through the combination of comprehensive hardware design and software algorithms, precise instantaneous power calculation and temperature rise analysis are achieved, providing extensive dynamic monitoring capabilities and laying a solid technical foundation for subsequent performance evaluation, reliability analysis, and fault diagnosis. S2. According to the test plan, gradually adjust the load conditions and input parameters, perform multiple rounds of cyclic testing, and in each cycle, monitor and record the electrical parameters and temperature change data in real time, monitor the working status data of the power module, and record faults and abnormal conditions; In the process of performance verification strictly in accordance with the preset test plan, the test system first configures a multi-channel automatic control unit to gradually adjust the load conditions and input parameters of the power module according to the pre-set parameter range. These adjustment behaviors are realized by the high-precision power supply and the intelligent load module. They can accurately control basic parameters such as voltage, current, and power to ensure that different working conditions are met in each round of cyclic testing. After each adjustment is completed, the system synchronously starts the continuous monitoring module to collect electrical parameters (including input voltage, input current, output voltage, output current) and thermal parameter changes collected by temperature sensors (such as thermocouples and infrared sensors) in real time through high-speed, multi-channel sampling equipment to ensure data continuity and high accuracy. At the same time, high-performance measurement and control hardware and embedded real-time operating system are used to monitor the working status of the power module (such as Real-time monitoring of all operating modes (normal, standby, fault, and abnormal warning) is performed. Embedded diagnostic algorithms and fault detection software uniformly record monitored electrical parameters, temperature changes, and operating status information in high-speed storage devices or real-time databases. Combined with fault detection and early warning mechanisms, abnormalities and fault signals are promptly captured. Once abnormal parameters or fault signs are detected, the system automatically triggers an alarm or records detailed fault information, including the time of occurrence, duration, and changes in related parameters, providing detailed fault traces for subsequent analysis. The entire adjustment and monitoring process is coordinated and automatically executed by advanced control software algorithms, ensuring that each round of cyclic testing can systematically, comprehensively, and efficiently collect multi-dimensional performance and status data under different load and input parameter conditions, providing a scientific and detailed basis for subsequent performance evaluation, reliability analysis, and fault diagnosis. S3. Calculate the efficiency of each cycle based on the electrical parameters and temperature change data collected in S1 and S2. Also, count the frequency and type of failures in each cycle and calculate the failure rate to evaluate the reliability of the power module. After completing the real-time acquisition of key indicators such as electrical parameters in steps S1 and S2, the system first calculates the efficiency value of each cycle using the collected instantaneous data to evaluate the performance of power conversion. Specifically, the formula is used: ; Among them, the instantaneous input power , instantaneous output power By continuously recording the input and output data of each cycle and calculating the corresponding efficiency, we can provide a quantitative basis for analyzing the energy efficiency level of the module under different working conditions. This calculation is of great significance for identifying performance degradation trends, optimizing designs, and formulating operating strategies. In addition, the system also collects statistics on the occurrence of faults during the monitoring period, including the frequency of faults (i.e., the proportion of faults occurring in all cycles) and the type of faults (such as overheating, overcurrent, abnormal oscillation, communication failure, etc.), using the formula: ; in, is the total number of failures, The total number of cycles is used to count the occurrence frequencies of multiple fault types, thereby identifying potential design defects or prone failure modes, and providing a scientific basis for subsequent reliability analysis and preventive maintenance. Based on these analyses, the system also summarizes the fault types and occurrence times in each cycle and constructs a failure rate index to reflect the performance stability of the power module under specific operating conditions. The failure rate calculation not only intuitively displays the reliability level of the equipment, but also guides engineers to implement targeted improvement and optimization measures. These multi-dimensional performance indicators and failure statistics, calculated through detailed formulas, provide a scientific basis for determining the performance bottlenecks and reliability defects of the equipment, further improving the professionalism of the entire testing process, the objectivity of the data, and the accuracy of the analysis, laying a solid foundation for the design improvement and application optimization of the power module. S4. Based on the results of steps S1, S2, and S3, evaluate the performance of the power module under different load and temperature conditions. Combined with the monitored operating status data, conduct a comprehensive assessment of the reliability of the power module, calculate the energy loss and performance degradation rate, and write a test report summarizing the performance and reliability analysis results. Based on the system's comprehensive collection and organization of multi-dimensional data, including electrical parameters, temperature changes, performance indicators, and fault statistics during steps S1, S2, and S3, and combined with the operating status information monitored during each cycle, engineers can conduct a detailed evaluation of the power module's performance under different load conditions (such as low load, medium load, and high load) and temperature environments (such as room temperature, improved cooling conditions, and harsh environments). Furthermore, by comparing electrical parameter changes and temperature rise under different operating conditions, the impact of thermal stress on performance can be intuitively reflected. The system also uses statistical data on fault frequency and type, combined with operating status monitoring information, to conduct a quantitative reliability assessment of the power module, predicting its stability and durability under various environmental conditions. Using the formula Calculating energy loss can quantify the energy waste during the entire test cycle, revealing the efficiency bottleneck and the severity of heat loss, while the performance degradation rate is calculated by the formula Calculations reflect the gradual performance degradation over multiple cycles, providing a basis for lifespan prediction and maintenance strategies. Ultimately, all data and analysis results are systematically organized into a detailed test report covering performance indicators, reliability assessments, energy loss, and degradation trends. Such a report is not only scientifically comprehensive but also helps engineers understand the performance and potential risks of power modules in actual applications, providing solid data support for future design improvements and optimizations, achieving both performance and reliability improvements. S5. Analyze the faults that occur during the test in detail, find the causes of the faults, analyze the average fault duration, and propose design improvement plans based on the test results; Throughout the testing process, a systematic and scientific Root Cause Analysis (RCA) approach was used to analyze and diagnose various faults, combining time series data of the faults. First, the precise time and duration of each fault were collected, along with relevant electrical parameters, temperature changes, and operating status information. The specific time and duration of the fault were identified, and statistical analysis of the duration of all faults was performed to calculate the average fault duration: ; in, represents the sum of all fault durations, The total number of failures helps assess the severity and repair difficulty of failures and is an important basis for developing reliability improvement measures. Time series data can also be used to analyze the frequency and time intervals of failures, as well as their relationship with electrical parameters or environmental conditions, to reveal potential influencing factors, such as thermal failures caused by excessive temperature rise, short circuits caused by power supply voltage fluctuations, or steady-state deviations caused by hardware aging. These analyses can be performed using Failure Mode and Effect Analysis (FMEA) tools to identify the potential root causes and impact paths of different failure types, providing a scientific basis for developing preventive measures. By combining the analysis results of failure modes and influencing factors, engineers can propose targeted design improvement plans, such as enhancing the heat dissipation system, optimizing electrical protection circuits, adopting more heat-resistant or interference-resistant hardware components, and improving load control strategies, thereby fundamentally reducing the probability and duration of failures. The entire fault analysis process not only improves the accuracy and systematicness of fault diagnosis, but also helps establish predictive warning models to enhance system reliability and stability.

[0019] This systematic testing process not only systematically and comprehensively evaluates the performance and reliability of the power module, but also provides solid data and technical support for future design optimization and quality improvement, thereby achieving efficient, safe and long-life operation of the equipment.

[0020] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A power module cycle test method, characterized in that: The following steps are involved: S1. Collect electrical parameters, including input voltage, input current, output voltage, and output current. Calculate and record instantaneous input power, instantaneous output power, and temperature rise. Simultaneously monitor and record the number of cycles, cycle time, and operating status information of the power module to provide basic data for subsequent analysis. S2. According to the test plan, gradually adjust the load conditions and input parameters, perform multiple rounds of cyclic testing, and in each cycle, monitor and record the electrical parameters and temperature change data in real time, monitor the working status data of the power module, and record faults and abnormal conditions; S3. Calculate the efficiency of each cycle based on the electrical parameters and temperature change data collected in S1 and S2. Also, count the frequency and type of failures in each cycle and calculate the failure rate to evaluate the reliability of the power module. S4. Based on the results of steps S1, S2, and S3, evaluate the performance of the power module under different load and temperature conditions. Combined with the monitored operating status data, conduct a comprehensive assessment of the reliability of the power module, calculate the energy loss and performance degradation rate, and write a test report summarizing the performance and reliability analysis results. S5. Conduct detailed analysis of faults that occur during the test, identify the causes of the faults, analyze the average fault duration, and propose design improvement plans based on the test results.

2. A power module cycle test method according to claim 1, characterized in that: The formula for calculating instantaneous input power is as follows: ； In the formula, represents the instantaneous input power provided by the input terminal, Indicates the voltage at the input of the power module. Indicates the current at the input terminal.

3. A power module cycle test method according to claim 2, characterized in that: The formula for calculating the instantaneous output power is as follows: ； In the formula, Indicates the instantaneous output power at the module output end, Indicates the voltage at the output of the power module. Indicates the current at the output.

4. A power module cycle test method according to claim 3, characterized in that: The formula for calculating temperature rise is as follows: ； In the formula, Indicates the module temperature rise relative to the ambient temperature. Indicates the temperature of the power module, Indicates the air temperature of the test environment.

5. A power module cycle test method according to claim 4, characterized in that: The calculation formula for the efficiency of each cycle is as follows: ； In the formula, represents the efficiency of each cycle, Indicates the instantaneous output power at the module output end, Indicates the instantaneous input power provided by the input terminal.

6. A power module cycle test method according to claim 5, characterized in that: The calculation formula of the failure rate is as follows: ； In the formula, represents the average number of failures per cycle, Indicates the number of failures that occurred during the test cycle, Indicates the total number of test cycles.

7. A power module cycle test method according to claim 6, characterized in that: The energy loss calculation formula is as follows: ； In the formula, represents the energy loss during the entire test, Indicates the instantaneous output power at the module output end, represents the instantaneous input power provided by the input terminal, Indicates the time interval of each sampling segment.

8. A power module cycle test method according to claim 7, characterized in that: The calculation formula of the performance degradation rate is as follows: ； In the formula, represents the performance degradation rate, Indicates the efficiency value at the beginning of the test, Indicates the final efficiency value of the test, Indicates the total number of test cycles.

9. A power module cycle test method according to claim 8, characterized in that: The root cause analysis is used to analyze the failures that occur during the test in detail. The method combines the time series data of fault occurrence to analyze the relationship between fault modes and fault influencing factors.

10. A power module cycle test method according to claim 9, characterized in that: The calculation formula of the mean duration of failure is as follows: ； In the formula, The average duration of each failure, Indicates the duration of each fault. Indicates the total number of failures.

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