IGBT Utilization and Life Cycle - ABB Group · New illustration is coming MINING USER CONFERENCE,...

New illustration is coming

MINING USER CONFERENCE, MAY 3-5, 2017

IGBT Utilization and Life CycleWith heavy duty load requirements on Electric Rope Shovels

Boris Rathmann, Product Manager Shovel & Dragline

Joy Global – ABB Success Story

Dynamic AC Drives for Electric Rope Shovels

Load cycle and live time requirements

IGBT physics and mining environment

IGBT analysis and continuous improvements

Product quality process

Summary

Mining User Conference 2017, StockholmSlide 2

Outline of presentation

May 3-5, 2017

Bild Canada


IGBT AC Drives for Electric Rope Shovels

Mining User Conference 2017, StockholmSlide 3May 3-5, 2017




Started 2005

– Demanding requirements for ABB AC Drives

• ACS800 Mining Drives for heavy duty environment

• Switchgear enforcement for high shock and vibration

• One inverter module size R8i for all drives and supply

• Special Firmware for dynamic load requirements

• 20 years life cycle requirement

• In operation 75 AC Drives for new Shovels and 8 for retrofit

• 2 x Premium Supplier Award from Joy Global

Cooperation with P&H / Joy Global / Komatsu

May 3-5, 2017

Proven Mining Drive solution for extreme conditions

Load cycle and live time requirements



Hoist Power, Torque, Speed / Load Cycle Hoist (40s)

May 3-5, 2017

-25000

-20000

-15000

-10000

-5000

0

5000

10000

15000

20000

25000

-4000

-3500

-3000

-2500

-2000

-1500

-1000

-500

0

500

1000

1500

2000

2500

3000

3500

4000

158.0

0549

159.7

5456

161.6

5179

163.5

4356

165.4

1656

167.2

8468

169.1

5477

171.0

4047

172.7

8848

174.6

3992

176.5

05

178.3

4305

180.1

8873

182.0

3048

183.7

785

185.6

4566

187.5

214

189.3

985

191.2

7347

193.1

543

195.0

1837

196.7

8312

198.6

1219

Hoist rpm

Hoist kW

Hoist Nm

IGBT Power Plate Temperature / Load Cycle Hoist (50s)

IGBT-Modules EconoPack

FS450R12KE3

Current: 450A

Peak: 900A

Voltage: 690V

Operation temp.: 125°C

Peak temp.: 150°C

Physics and mining environment


Mining User Conference 2017, StockholmSlide 6May 3-5, 2017

Physics and mining environment



Delivered since 2005 in different revisions

– Challenges for heavy duty mining

• Shock and vibrations

• Extreme temperatures -40 to +50°C

• Dynamic load cycle with temperature differences

• Constant torque operation with current cycling

• Continuous operation 24h

• Compound material stressed by different nature

IGBT PowerPack for ABB Drives ACS800

May 3-5, 2017

Physics: mechan, thermal, electrical, chemical, radiation

Analysis and continuous improvements



Supplier: Infineon

EconoPackTM FS450R17KE3

Transitor +Diode

3 phase module

Principles of expanded bond

wires

New is changed bonding wire design and soldering

Result: Bonding wire is flexible to withstand temp cycles and

vibration requirements

May 3-5, 2017

Transistor and Diode chip elements are connected with

bond wires




Principles of Thermal Interface Material (TIM)

New TIM as phase shift material, with stencil and

specific pattern

Result: no dry out

May 3-5, 2017

Heatsink after dry-out of thermal interface material

EconoPackTM FS450R17KE3

96 power elements for 1 shovel

576 IGBTs per machine

Quality process



Steps to be successful

– Q1

• Various on-site measurements and site surveys

• Sample analysis by 3rd parties with expert knowledge

Q2

• Providing the root cause analysis (RCA)

• Evaluation the RCA with supplier of power components

Q3

• Identify measures to improve the drive system

• Implement features in production and existing fleet

Q4

• Review of failure rate, which became <2% for over 2100 R8i

• Analysis of improvements after operating over time

ABB 4Q Process Improvements

May 3-5, 2017

Define opportunity Investigate to understand the current state in detail.

- Goal is to identify and use those processOutputs, metrics that can help to understand when, how and what problem occurred. - Or what additional measures do you need to help identify the problem root cause?

Maintain the improvements by standardizing the work methods or processes.

- Goal is to change the process to the new solution piloted in Q3. - Gains will be sustained by people working to the new process. New metrics may need to be monitored back in Q1 to- Close the continuous improvement loop.

4Q Process

Q1 - Measure

Q4 - Sustain Q3 - Improve

Q2 - Analyze

Identify and confirm root causes

of the problem.- Goal is to find the real root causes for the problem. Eliminating the root causes prevents the problem from occurring again.- Good root cause analysis is the key to success in any 4Q project.

Develop, pilot, and implement

solutions that eliminate root

causes. - Goal: create and execute pilot actions that

will eliminate the root causes.

- Test the results and decide if the results

are good enough to move forward to next

quadrant,

- Make the changes permanent




New drying furnace to dry out thermal grease according specification

Precisely laid and dried

Improved heat flow achieved

Internally tested for 100000+ cycles without any leakage signs

May 3-5, 2017

New device for thermal grease application

Precisely given amount in specified pattern

Test stand to check each IGBT before release to installation

Visual inspection

Electrical test

Output waveform scope check




Change system control program

– Analysis of load cycle and high torque requirements

– Changing switching frequency at low speed

– Parameter setting to limit switching frequency below 30% of nominal speed

– Default value switching frequency changed from2kHz to 1,4kHz

– Low limit of switching frequency reduced from 1,4 kHz to 1kHz

Result: Reduction of peak temperature by 40%

ACS800 Drives Firmware DTC (Direct Torque Control)

May 3-5, 2017

0

200

400

600

800

1000

40

60

80

100

120

140

CROWD Temp&Current OLD SOFT

ACS800 Temp [C] Current [A]

0

20

40

60

80

100

0

200

400

600

800

1000TEMPCROWD Temp&Current NEW SOFT

Current [A] ACS800 Temp [C]

ACS800 Live time improvement 10+ years

Quality process



Setup for 8 R8i inverter module testing

Ongoing Reliability Test (ORT) since 2013 with samples from the serial production

Accelerated Life Testing (ALT) simulation of 10 years life time within 16 weeks by higher temp. range and increased number of load cycles

New equipment on ABB Drives test lab with 2D & 3D x-ray system, Electron Microscope, ultrasonic analyzer

Result: MTBF R8i module = 93 Y (ACS800), 210 Y (ACS880)

ABB Process Improvements

May 3-5, 2017

Picture: R8i Ongoing Reliability Test container

ABB is providing an extensive product test process

Summary



Global fleet of Electric Shovels AC

Number of IGBTs 7000+

Failure rate below 2%

Product life cycle 12 years

Improved lifetime by reduced thermal cycling

Ongoing reliability testing for Drives modules

Established AC Drives Technology in extreme environment

May 3-5, 2017

NA 33

SA 34

MEA 7

EU 1

APA 8

IGBT Utilization and Life Cycle - ABB Group · New illustration is coming MINING USER CONFERENCE,...

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Transcript of IGBT Utilization and Life Cycle - ABB Group · New illustration is coming MINING USER CONFERENCE,...