history drives the future - enea film –life vs hot-spot temperature ppm film development 3 ducati...
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History drives the future
3
Power Capacitor Designs for New Generation Power ConvertersDucati PPMhd – High Crystallinity Metallised Polypropylene
Capacitors
Roberto DefantSales Area Manager
Capacitors & [email protected]
INTRODUCTION
3
Applications of MKP Power Capacitors
IndustrialTransportRenewables
UPS Systems•AC Input Filter
Motor Drives•AC In/Out Filters
•DC Link
Welders•AC Tuning•DC Storage
EV / HEV•DC Link
Rail•Traction•AUX Power
Solar / Wind•DC Link
•AC Output Filter
INTRODUCTION
3
Why Metallised Film - Power Capacitors?
•Less Components – Simple Construction
•Low Power Losses
•Long Operating Life
•High Reliability – Low FIT Rate
INTRODUCTION
3
Metallised Film Comparison
PP PET PEN PPS
Dielectric Strength 650V/μm 550V/μm 500V/μm 450V/μm
Temperature Stability + − − ++
Dielectric Losses ++ − − − − +
Maximum Temperature 105°C 125°C 150°C 150°C
Self Healing Behaviour ++ O − −
Cost ++ + − − − −
Despite their relatively limited operating temperature range, MetallisedPolypropylene (MKP) Capacitors have become the preferred solution for HighPower Capacitors, due to the wide voltage range available, very low losses andexcellent cost
DIMENSIONING
3
Selection / Dimensioning of MKP Capacitors
Electrical Stress Determination
UAPP UN-CAP
UN-CAP V/μm
Assigned by each manufacturer basing on its Metallisationand Winding Technology as well as its chosenSafety/Reliability Level
Capacitor Dimension – Form Factor
Thermal Resistance RTH
DIMENSIONING
3
Selection / Dimensioning of MKP Capacitors
Thermal Stress Determination – HotSpot Calculation
θHS = θC + RTH x (PD + PJ)
θC = Temperature of the Case
PD = Dielectric Losses; practically negligible for MKP Capacitors
PJ = Resistive Losses = Rs x IRMS2
DIMENSIONING
3
Ducati PPMd - Lifetime Graphs @ FIT 50
1000
10000
100000
1000000
0,8 0,9 1 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8
Lif
eti
me
hrs
Working Voltage / Rated Voltage U/Un
DIMENSIONING
3
Lifetime Calculation for Variable Operating States
For Variable Operating States, the Lifetime can be compounded according to IEC61709 (Electric Components – Reliability – Reference conditions for failurerates and stress models for conversion)
OUTLOOK
3
New Generation Converters’ demand to DC-Link Caps
•Higher Power Density = Higher Capacitor RMS Currents
•Higher Ambient/Case Temperatures in Operation
θHS = θC + RTH x (PD + PJ)
•Longer Lifetime / Lower FIT Rates
θHS
θMAX
PPM FILM DEVELOPMENT
3
PP PPMDH PET PEN PPS
Dielectric Strength 650V/μm 650V/μm 550V/μm 500V/μm 450V/μm
Temperature Stability + + − − ++
Dielectric Losses ++ ++ − − − − +
Maximum Temperature 105°C 125°C 125°C 150°C 150°C
Self Healing Behaviour ++ ++ O − −
Cost ++ ++ + − − − −
Ducati developed a new high-crystallinity metallised PP Film
Ducati’s new PPMDH Metallised, High-Crystallinity Film increases the MaximumTemperature of the film to 125°C.
PPMD: 100.000hrs at U/Un=1 and θHS=70°CPPMDH: 100.000hrs at u/Un=1 and θHS=90°C
PPM FILM DEVELOPMENT
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Ducati Energia - New High-Crystallinity metallised PP Film
• Developed in cooperation with Raw Material Manufacturer and Research Institutions;
• Increased Max. Operating Temperature to 125°C;• Increased Operating Electric Stress V/μm (20-25% enhancement);• Competitive Cost;• No constructive limitation; 1-to-1 compatible with existing
applications.
3
Progressive Voltage Stress Test
-60
-50
-40
-30
-20
-10
0
10
500h 1,4xUn 500h 1,6xUn 500h 1,7xUn 500h 1,8xUn 500h 1,9xUn
ΔC
/C%ΔC/C% @70°C forced ventilation
Film StdFilm PPMDH
Capacitance Variation
PPM FILM DEVELOPMENT
3
Progressive Voltage Stress Test
Film StdFilm PPMDH
Tand Variation
PPM FILM DEVELOPMENT
3
Progressive Temperature Stress Test
-20,00
-15,00
-10,00
-5,00
,00
5,00
500h 85°C 500h 90°C 500h 95°C 500h 105°C
ΔC
/C%
ΔC/C% @1,4xUn
Film StdFilm PPMDH
Capacitance Variation
PPM FILM DEVELOPMENT
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Progressive Temperature Stress Test
,00
100,00
200,00
300,00
400,00
500,00
600,00
700,00
500h 85°C 500h 90°C 500h 95°C 500h 105°C
ΔT
an
/tan
%Δtan/tan% @1,4xUn
Tand Variation
PPM FILM DEVELOPMENT
3
Ducati PPMDH Film – Life vs Hot-Spot Temperature
PPM FILM DEVELOPMENT
3
Ducati PPMDH Film – Lifetime vs Working Voltage
Expected Lifetime @ 70°C HOT-SPOT vs working voltage
DC series vs DCH series
DCH
DC
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
1,3
1,4
1,5
1,6
1,7
10 100 1.000 10.000 100.000 1.000.000
Expected Lifetime [h]
Wo
rkin
g / R
ate
d v
olt
ag
e [U
w/U
n]
PPM FILM DEVELOPMENT
3
Advantages of Ducati PPMDH Film
For the same 100.000hrs Lifetime @ 300FIT
•+30°C θHS – respective to other manufacturers’ film
•+20°C θHS – respective to Ducati PPMD film
θHS = θC + RTH x (PD + PJ)
Higher RMS CurrentHigher Case/Amb. Temp.Longer Life / Lower FIT
No Reduction of typical PP Film Advantages
•Low Losses High Capacities / Powers
•Excellent Self-Healing Safety / Reliability
•Excellent Cost
CONCLUSIONS
3
Un
C
20μF
200μF
2.000μF
20.000μF
1000V 2000V 3000V 4000V 5000V 6000V
DC89HC
DC86PS
DC86PS
DC86PS
DC86PS
DC86PS
CONCLUSIONS
QUALITY SYSTEM APPROVED BY CSQ ACCORDING TO
ISO 9001:2008
ISO 14001
ISO 18001
Ducati Quality Assurance
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Grazie per l'attenzione
Thank you for your attention