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How do you design a power electronic circuit for high temperatures?

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Power electronic circuits are essential for converting, controlling, and conditioning electrical energy in various applications, such as renewable energy systems, electric vehicles, and industrial drives. However, designing power electronic circuits for high temperatures can be challenging, as they have to withstand harsh environments, thermal stress, and reliability issues. In this article, you will learn some basic principles and tips for designing power electronic circuits for high temperatures.

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Julio Fassarela

Técnico de instrumenta??o

1 Power electronics fundamentals

Power electronic circuits typically consist of switches, diodes, capacitors, inductors, and transformers, which are used to manipulate the voltage, current, frequency, and phase of electrical signals. The switches can be either mechanical or solid-state devices, such as transistors, thyristors, or IGBTs. The switches are controlled by a pulse-width modulation (PWM) technique, which varies the duty cycle of the switch to achieve the desired output waveform. The diodes are used to rectify the alternating current (AC) into direct current (DC), or to provide freewheeling paths for the inductive currents. The capacitors and inductors are used to filter, smooth, and store the electrical energy, while the transformers are used to step up or step down the voltage levels.

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Julio Fassarela

Técnico de instrumenta??o
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Projetar um circuito eletr?nico de potência para Opera??o em altas temperaturas envolve considera??es específicas para garantir a confiabilidade e a eficiência do circuito em condi??es extremas.

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2 Temperature effects on power electronics

The performance and reliability of power electronic circuits are heavily dependent on the temperature of the components and the environment. High temperatures can cause several issues, such as increased conduction and switching losses, which reduce efficiency and generate more heat, increased leakage currents leading to reduced insulation and increased noise and interference, thermal expansion and contraction resulting in mechanical stress and fatigue on materials and joints, and degradation and aging of components, resulting in a reduced lifetime and increased failure rate. To ensure safe and reliable operation at high temperatures while minimizing losses and cooling requirements, it is essential to design power electronic circuits accordingly.

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Julio Fassarela

Técnico de instrumenta??o
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Escolha componentes de excelente qualidade e durabilidade, projetados para trabalhar em temperaturas elevadas. Certifique-se de que os componentes possuam classifica??es de temperatura adequadas para o ambiente de trabalho. Crie um sistema de resfriamento adequado para dissipar o calor gerado pelos componentes. Isso pode envolver o uso de dissipadores de calor, ventoinhas ou até mesmo técnicas avan?adas de resfriamento, como a refrigera??o líquida.

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Hassan Ibrahim Engr (COREN), NEMSA certified
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This can achieves using standard rated wire sizes and other components. Factor in the power rating of components and ensure that they are suitable for the intended high-temperature operation to prevent degradation or failure.

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3 Component selection and rating

When designing power electronic circuits for high temperatures, it is essential to select components that can handle the thermal conditions. This includes taking into account the maximum junction temperature (Tj), the thermal resistance (Rth), and the derating factor. For example, a switch with a maximum junction temperature of 150°C, a thermal resistance of 1°C/W, and a derating factor of 80% at 100°C can handle a maximum power dissipation of 40 W at 100°C, which is 80% of its rated power dissipation at 25°C. Therefore, it is important to carefully consider these factors when selecting components for high-temperature applications in order to ensure reliable and efficient operation.

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Julio Fassarela

Técnico de instrumenta??o
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é importante considerar a utiliza??o de materiais isolantes térmicos para proteger componentes sensíveis ao calor e reduzir a transferência de calor para áreas n?o desejadas. é importante considerar a adi??o de prote??o contra interferências eletromagnéticas que podem ser excessivas em ambientes de alta temperatura. é importante também realizar avalia??es minuciosas para assegurar a confiabilidade do circuito em condi??es extremas.

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4 Circuit topology and layout

Designing power electronic circuits for high temperatures requires an optimal circuit topology and layout that can reduce losses, improve performance, and enhance reliability. Factors to consider include the number and type of switches, diodes, capacitors, and inductors, which can affect complexity, cost, and efficiency; the switching frequency which influences switching losses, passive component size, and output ripple/harmonics; the parasitic elements of wires, traces, and connections which can cause voltage/current spikes, ringing/oscillations, and EMI; as well as the thermal coupling of components to the heat sink which affects temperature distribution and cooling. For instance, a buck converter with a synchronous rectifier topology, high switching frequency, low parasitic inductance, and good thermal coupling can be more efficient, smaller in size, have a lower output ripple, and reduced temperature rise compared to a conventional diode rectifier topology.

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5 Thermal management and protection

Designing power electronic circuits for high temperatures necessitates an effective thermal management and protection system that can monitor, control, and dissipate the heat generated by the circuit. This system should consider factors such as a heat sink, which transfers heat from the components to the ambient air or coolant, a fan that increases airflow or coolant flow over the heat sink, a thermistor that changes its resistance according to temperature, and a thermal switch that opens or closes a circuit according to its temperature. For instance, a system with a heat sink with fins, a fan with variable speed, an NTC thermistor, and a thermal switch with NC contacts can regulate the temperature of the circuit within a safe range by adjusting fan speed, measuring thermistor resistance, and cutting off power supply if it exceeds a limit.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you design a power electronic circuit for high temperatures?

1

2

3

4

5

6

1 Power electronics fundamentals

2 Temperature effects on power electronics

3 Component selection and rating

4 Circuit topology and layout

5 Thermal management and protection

6 Here’s what else to consider

Power Engineering

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How do you design a power electronic circuit for high temperatures?

1

2

3

4

5

6

1 Power electronics fundamentals

2 Temperature effects on power electronics

3 Component selection and rating

4 Circuit topology and layout

5 Thermal management and protection

6 Here’s what else to consider

Power Engineering

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