Power Converter Part-Life Estimation Using Temperature Exposure
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Solution Overview
Problem
Existing technologies cannot accurately estimate the remaining life of individual parts in a power converter, leading to erroneous determination of repair or replacement times.
Innovation Solution
A remaining life estimation device that calculates cumulative exposure time for each part temperature, converts it using a life conversion coefficient, and determines remaining life information based on a reference life time, allowing for accurate estimation of individual part lifespans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing life estimation techniques are used, then overall inverter life can be predicted, but individual part remaining life cannot be estimated accurately
Solution Approach 1:
The patent divides the inverter into multiple life parts (capacitor, MOSFET, diode, IGBT) and calculates remaining life for each individual component separately. This segmentation allows precise estimation of individual part remaining life while maintaining overall system life prediction capability, resolving the contradiction between overall prediction and individual accuracy.
2Measurement precision
If detailed individual part monitoring is implemented, then accurate remaining life estimation is achieved, but system complexity and cost increase
Solution Approach 1:
The patent utilizes operational data (current, voltage, temperature) that is already collected for power converter control and protection purposes. By repurposing this existing data for life estimation calculations, the system achieves accurate individual part remaining life prediction without adding dedicated sensors or monitoring hardware, thus avoiding increased system complexity.
3Reliability
If conservative life estimation is used, then safety is improved, but repair/replacement timing becomes erroneous
Solution Approach 1:
The patent incorporates temperature as a critical parameter in the life estimation calculation, using cumulative exposure time at different temperatures to predict remaining life. This parameter-based approach provides scientifically grounded predictions that balance reliability and timing accuracy, avoiding both overly conservative and overly optimistic estimates.
Data Source
AI summary
The remaining life estimation device is a remaining life estimation device of a power converter including a life part accommodated in a case. The remaining life estimation device includes a processor for calculating remaining life information of the life part. The processor calculates a cumulative exposure time for each life part temperature of the life part, converts each cumulative exposure time into a converted cumulative exposure time by reflecting a life conversion coefficient to each cumulative exposure time calculated for each life part temperature, and calculates the remaining life information based on a life reduction time that is a sum of the converted cumulative exposure time for each life part temperature and a reference life time that is a life time of the life part under the reference value.