Challenges and Strategies for a Real-Time Implementation of a Rainflow-Counting Algorithm for Fatigue Assessment of Power Modules

Abstract

The aim of this work is to obtain a reliable estimation of the remaining lifetime of power-electronic modules. Lifetime models provide information on the fatigue durability of power modules under repetitive loading circumstances. However, the thermo-mechanical stresses that a device is exposed to during operation are different than the ones evaluated to create the lifetime models. Rainflow counting provides a tool to analyze and evaluate the stress content of a randomly varying stress waveform, but counting stress cycles while the device is operating is challenging. In this paper, implementation challenges for an online rainflow-counting method are presented, and solutions to overcome them are discussed. An algorithm for online rainflow counting is implemented, and numerical results from tests on experimental device-temperature data are presented.

Limitations and Guidelines for Damage Estimation Based on Lifetime Models for High-Power IGBTs in Realistic Application Conditions

“…individual stress components [16], [17]. The analysis considered in this paper utilizes a real-time implementation of the rainflow-counting algorithm [21], and the damage contribution of each variation is evaluated using the lifetime model in (2). The contributions of all damage components are summed together using Miner's rule to get the accumulated damage on the device material, which also reflects the remaining lifetime of the device.…”

Enhancement of Stress Cycle-counting Algorithms for Li-ion Batteries by means of Fuzzy Logic

“…The rainflow counting algorithm has been employed as a method for fatigue analysis of materials for several decades, and various implementations have been proposed throughout the years [1], [2]. Favoured by the great research interest on RESs and electric vehicles (EVs), this technique has recently been applied to power electronics devices [3], [4] and batteries [5]- [7].…”

“…In both EV and stationary ESS applications, the main metric used to assess a battery's degradation (or damage) level is the state of health, which quantifies the energy storage capacity at a given instant compared to a reference value. It is computed as in (3).…”

A Review on IGBT Module Failure Modes and Lifetime Testing

“…17b. Commonly, this is achieved by Rainflow counting algorithm [94,126,127]. The second step is to estimate lifetime using cumulative degradation (damage) model [21,23,128,129].…”