Semiconductor Module Temperature Diagnosis via Current Delay Time

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Solution Overview

Problem

Existing power conversion apparatuses for railway and industrial electric motors face challenges in precisely detecting temperature abnormalities in semiconductor chips, leading to potential thermal runaway and system failures, with existing methods being costly and imprecise, and lacking the ability to differentiate between semiconductor and cooling system issues.

Innovation Solution

A diagnostic system that measures temperature by analyzing the delay time of main current waveforms at two preset values, allowing for the detection of overall and local chip temperatures without modifying the semiconductor module, and provides feedback for maintenance and life extension.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If temperature sensors are provided in each semiconductor chip to detect individual chip temperatures, then measurement precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:
Improvetemperature detection precisionVSAvoidmodule structure complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent uses delay time of main current as an intermediary parameter to indirectly measure semiconductor chip temperature. Instead of directly measuring temperature with sensors on each chip, the system measures the delay time between gate signal and collector current, which correlates with temperature through the transistor's thermal characteristics. This intermediary measurement approach achieves temperature detection without adding physical temperature sensors to each chip.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical/physical temperature sensor system with an electrical measurement system. Instead of using physical temperature sensors that require mounting on each semiconductor chip, the system uses electrical signal timing measurements (delay time of main current) to infer temperature. This substitution eliminates the need for physical temperature sensing hardware on each chip while still achieving temperature monitoring.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If packaging temperature sensors in individual chips is done, then temperature monitoring accuracy is improved, but manufacturing cost increases

Engineering Contradiction:
Improvechip temperature monitoring accuracyVSAvoidmanufacturing cost
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent uses delay time of main current as an intermediary parameter to indirectly measure semiconductor chip temperature. Instead of directly measuring temperature with sensors on each chip, the system measures the delay time between gate signal and collector current, which correlates with temperature through the transistor's thermal characteristics. This intermediary measurement approach achieves temperature detection without adding physical temperature sensors to each chip.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent uses the electrical characteristics (current delay time) of the semiconductor device itself as a copy or proxy for temperature measurement. Instead of adding separate temperature sensing hardware, the system exploits the inherent electrical response of the transistor to temperature changes. The delay time characteristic serves as an electrical copy of the thermal state, eliminating the need for separate temperature sensing components.

Inventive Principle:
Principle #26Copying

3Device complexity

If only average temperature of parallel chips is detected, then device complexity is reduced, but measurement precision for individual chips deteriorates

Engineering Contradiction:
Improvedetection system complexityVSAvoidindividual chip temperature precision
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The patent segments the temperature detection by measuring delay time for each individual semiconductor chip or switch device rather than measuring only the average temperature of all parallel chips. By measuring the delay time of main current for each switch device individually, the system can identify temperature abnormalities in specific chips, enabling targeted monitoring and maintenance decisions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent uses delay time of main current as an intermediary parameter to indirectly measure semiconductor chip temperature. Instead of directly measuring temperature with sensors on each chip, the system measures the delay time between gate signal and collector current, which correlates with temperature through the transistor's thermal characteristics. This intermediary measurement approach achieves temperature detection without adding physical temperature sensors to each chip.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Use of energy by moving object

If cooling capacity is reduced during operation, then energy consumption is reduced, but temperature increases leading to potential failure

Engineering Contradiction:
Improvecooling system energy consumptionVSAvoidsemiconductor module reliability
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The patent implements feedback control by continuously monitoring the delay time of main current, which reflects the temperature state of semiconductor chips. When the delay time indicates elevated temperature, the system can respond by adjusting cooling capacity or operating parameters. This feedback mechanism enables dynamic balancing between energy consumption and reliability, allowing reduced cooling only when temperatures are within safe ranges.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent performs preliminary detection of temperature abnormalities through delay time measurement before thermal runaway occurs. By detecting temperature increases early through the delay time characteristic, the system can take preventive actions such as adjusting operating conditions or activating cooling measures before the temperature reaches dangerous levels, thereby maintaining reliability without requiring continuous maximum cooling capacity.

Inventive Principle:
Principle #10Preliminary action

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

Enables precise detection of abnormalities and deterioration in power semiconductors, preventing failures and ensuring long-term operation by distinguishing between semiconductor and cooling system issues, thus extending the life of the power conversion apparatus.

Implementation Method 1

This example discloses a method of determining a junction temperature of an IGBT (insulated gate bipolar transistor) device by detecting a time delay between start and end of a Miller plateau phase of a gate-emitter voltage characteristic of the IGBT device during a switch-off phase of the IGBT device.

Methodology Applied
Scientific EffectJunction temperature detection through current waveform delay:

Data Source

PatentEP3457149B1Diagnosis system for power conversion device, diagnosis method for semiconductor module, and power conversion device
Publication Date: 2022.12.21 HITACHI LTD
  • EP3457149B1 patent drawingFigure 1
  • EP3457149B1 patent drawingFigure 2
  • EP3457149B1 patent drawingFigure 3

AI summary

A diagnostic system for a power conversion apparatus including a semiconductor device and performing a switching operation for carrying and interrupting a main current to a main current is disclosed. This system includes a trigger circuit that acquires reference time for the switching operation; and a delay time calculation circuit that acquires first time at which the main current takes a first main current set value and second time at which the main current takes a second main current set value, and that detects numerical data about a difference between the first time and the reference time and numerical data about a difference between the second time and the reference time.