Passive Circuit for Power Module Short Circuit Failure Mode Handling

Solution Overview

Problem

Existing power electronics modules face challenges in effectively managing short circuit failure mode transitions, particularly in handling arcing and thermal stress during semiconductor failures, which can lead to reduced performance and service life.

Innovation Solution

A power electronics module with a passive circuit arrangement comprising capacitors and resistors that utilizes arcing as an energy source to control and create new short circuit failure modes in parallel, improving current distribution and reducing thermal stress without requiring additional power sources or time-critical sensors and actuators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a semiconductor chip fails and enters short circuit failure mode, then the module can continue operating with reduced capability, but arcing occurs which generates extensive power dissipation and thermal stress

Engineering Contradiction:

Improvemodule operation continuityVSAvoidpower dissipation from arcing

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent converts the harmful arcing phenomenon into a useful energy source. The arcing that normally causes power dissipation and thermal stress is instead captured and used to charge a capacitor, which then provides the energy needed to trigger other semiconductor chips into short circuit failure mode. This transforms a harmful effect into a beneficial one, eliminating the need for external power sources during failure mode transitions.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system uses its own failure mode (arcing in the failed semiconductor chip) to serve the purpose of triggering additional chips into failure mode. The energy from the arcing is captured and reused within the system itself, creating a self-sustaining mechanism that doesn't require external power sources or complex control systems.

Inventive Principle:

Principle #25Self-service

2Productivity

If multiple semiconductor chips are operated in parallel to increase current capability, then the total current handling ability increases, but thermal stress on cooling means increases

Engineering Contradiction:

Improvecurrent capabilityVSAvoidthermal stress on cooling means

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent segments the current path by creating multiple independent short circuit failure modes in parallel semiconductor chips. Instead of having all chips share a single thermal path, the system divides the current distribution across multiple chips that are independently controlled, with each chip having its own thermal management path to the cooling means.

Inventive Principle:

Principle #1Segmentation

3Ease of operation

If traditional active control circuits are used to manage short circuit failure mode transitions, then precise control can be achieved, but device complexity and cost increase due to additional power sources and sensors

Engineering Contradiction:

Improvecontrol precisionVSAvoidcircuit arrangement complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The system uses its own failure mode (arcing in the failed semiconductor chip) to serve the purpose of triggering additional chips into failure mode. The energy from the arcing is captured and reused within the system itself, creating a self-sustaining mechanism that doesn't require external power sources or complex control systems.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent converts the harmful arcing phenomenon into a useful energy source. The arcing that normally causes power dissipation and thermal stress is instead captured and used to charge a capacitor, which then provides the energy needed to trigger other semiconductor chips into short circuit failure mode. This transforms a harmful effect into a beneficial one, eliminating the need for external power sources during failure mode transitions.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enhances the control of short circuit failure mode transitions, extends the service life of the module, and increases current capability by efficiently managing arcing and thermal stress, allowing for prolonged operation without additional power sources or complex sensing systems.

Implementation Method 1

the passive circuit arrangement comprises a parallel connection of at least one capacitor (106) and at least one resistor (107). The module is adapted to use arcing of at least one semiconductor chip as energy source to charge the at least one capacitor (106)

Methodology Applied

Scientific EffectArc: Electric Arc

Data Source

PatentUS9293909B2Passive circuit for improved failure mode handling in power electronics modules

Publication Date: 2016.03.22 HITACHI ENERGY LTD

AI summary

A power electronics module for enhancing short circuit failure mode (SCFM) transitions. The module is adapted to disconnect a gate unit from the module using a first switch, upon a failure of at least one of a plurality of semiconductor chips during which the failed chip enters an SCFM, and connect a passive circuit arrangement, including at least one capacitor and at least one resistor, to the module using a second switch. The passive circuit arrangement is adapted to switch on at least one of the remaining non-failed semiconductor chips.