Predictive Thermal Management for Frequency Converter Power Semiconductors
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Solution Overview
Problem
Current frequency converters face operational interruptions due to excessive temperature of power semiconductors during periodic loading, leading to overheating and potential damage, as conventional dimensioning methods fail to account for recurring temperature increases and cooling system malfunctions.
Innovation Solution
A method that calculates the typical heating of power semiconductors during periodic use, determines a temperature limit by subtracting the mean heating from the maximum allowed temperature, and adjusts the operation mode by reducing torque or speed when the temperature approaches this limit to prevent overheating, while also monitoring the cooling system for malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the frequency converter operates continuously during periodic loading, then productivity is maintained, but the power semiconductor temperature exceeds the maximum limit causing operational interruptions
Solution Approach 1:
The system performs preliminary temperature calculation and prediction before the power semiconductor temperature exceeds the maximum limit. By calculating the typical heating during periodic use and determining when the temperature will reach critical levels, the system takes preventive action by interrupting operation in advance, thereby avoiding overheating damage while maintaining continuous productivity through predictable scheduling
Solution Approach 2:
The system implements a feedback mechanism by continuously monitoring the actual temperature of the power semiconductor and comparing it with the calculated typical heating. This feedback loop allows the system to adjust operation timing based on real-time temperature data, ensuring the temperature remains below the maximum limit while maximizing continuous operation time
2Reliability
If the frequency converter is dimensioned for the highest temporary temperature, then reliability is improved, but the apparatus becomes over-dimensioned when load density remains within planned limits
Solution Approach 1:
The system changes the parameter approach from static dimensioning (sizing for worst-case maximum temperature) to dynamic temperature management. By calculating typical heating based on actual periodic load patterns and monitoring real-time temperature, the system adapts operation to maintain reliability without requiring over-dimensioned cooling capacity or larger power semiconductors
Solution Approach 2:
The system transitions from static dimensioning to dynamic temperature management. The cooling system and operation timing are dynamically adjusted based on calculated typical heating and actual temperature measurements, allowing the system to maintain reliability under varying load conditions without being permanently over-dimensioned for peak scenarios
3Reliability
If the frequency converter interrupts operation when temperature exceeds the limit, then component damage is prevented, but the process controlled by the frequency converter stops undesirably
Solution Approach 1:
The system interrupts operation preliminarily, before the temperature reaches the maximum limit, based on calculated typical heating predictions. This preventive interruption prevents component damage while minimizing process stoppage by scheduling breaks before critical temperatures are reached, rather than reacting after overheating occurs
Solution Approach 2:
The system uses its own calculated typical heating data and temperature monitoring to automatically determine when interruptions are necessary. By serving its own temperature management needs through predictive calculations and adaptive timing, the system protects components while maintaining optimal process continuity without external intervention
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 approach prevents overheating-induced interruptions, ensures faultless operation by anticipating and mitigating temperature increases, and provides an estimate for the operating life of the frequency converter, allowing for proactive maintenance and reducing the risk of component damage.
Implementation Method 1
the power components of the frequency converter are considerably stressed during acceleration and braking
Implementation Method 2
the temperature of the power semiconductor is determined by determining a temperature of a cooling element, which is in thermal connection with a semiconductor component
Data Source
AI summary
A method in connection with a frequency converter and a frequency converter, the frequency converter being arranged for periodic recurrent use. The method comprises steps for generating and storing in a memory an average heating of a power semiconductor of the frequency converter, caused by one loading period, determining a temperature limit from the generated heating and the highest allowed temperature of the power semiconductor, determining the temperature of the power semiconductor in the frequency converter, and changing the operation mode of the frequency converter when the temperature of the power semiconductor exceeds the temperature limit when transferring to a loading period.