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Reliability Prediction and Assessment Models for Power Components: A Comparative Analysis

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Abstract

Reliability prediction and assessment play a significant role in determining the performance of power converter designs. Typically, the DC–DC power converters are one of the most required electronic components, and their reliability must be improved to increase the overall efficiency of the entire system. Usually, for power converters, the reliability is estimated using different standards such as MIL—HDBK, RIAC-217, Telcordia, IEC-TR-6238, and FIDES. This work aims to review the three main reliability assessment models (MIL—HDBK, RIAC-217, and FIDES) mainly used to validate the performance of DC-DC power converters. The advantages and disadvantages of each technique used in the DC-DC converter’s reliability design have been discussed and compared. We also presented an optimum assessment tool, which covers the fundamental factors for the reliability analysis of power converters. Furthermore, the reliability calculation tools like Markov, Monto Carlo and others are discussed with their significance in the reliability analysis of power converters. The inevitable part of the reliability study is the fault identification and diagnosis, which are elaborated with the methodologies reported in the literature for power converters. The importance of reliability study with respect to the application is briefly discussed. Finally, a comparative analysis of the various reliability statistical approaches would guide the researchers in choosing the appropriate methods for their reliability study. The principal objective behind this study is to propose a road map for power electronic engineers to perform the reliability study on DC–DC power converters.

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Abbreviations

MIL-HDBK-217:

Military handbook—2017

RIAC-217:

Reliability information analysis center—217

FIDES:

Latin:trust

MTTR:

Mean time to repair

MTTF:

Mean time for failure

MTBF:

Mean time between failure

RAMS:

Reliability availability maintainability safety

FIT:

Failure in time

IEC:

International electrotechnical commission

DC:

Direct current

SiC:

Silicon carbide

DMPPT:

Distributed maximum power point tracking

PV:

Photovoltaic

SEM:

Scanning electron microscopy

SAM:

Scanning acoustic microscope

OC:

Open-circuit

SC:

Short-circuit

PI:

Proportional-integral

SMPS:

Switched-mode power supply

PoF:

Physics of failure

WEC:

Wind energy conversion

LVRT:

Low voltage ride through

ALTs:

Accelerated lifetime tests

PHM:

Prognostics and health management

R(t):

Reliability of the converter

µ :

Average failure rate

\({\lambda }_{SW}\) :

Failure rate of the switch

\({\lambda }_{P}\) :

Predicted failure rate

\({\lambda }_{D}\) :

Failure rate of the diode

\({\lambda }_{Physical}\) :

Physical contribution

\({\lambda }_{TCB}\) :

Base failure rate, temperature cycling

\({\lambda }_{L}\) :

Failure rate of the inductor

\({\lambda }_{EOS}\) :

Failure rate, electrical overstress

\({\lambda }_{C}\) :

Failure rate of the capacitor

\({\pi }_{T}\) :

Temperature factor

\({\pi }_{G}\) :

Reliability growth failure rate multiplier

\({\pi }_{E}\) :

Environmental factor

\({\pi }_{TE}\) :

Failure rate multiplier, temperature—environment

\({\pi }_{DCO}\) :

Failure rate multiplier for duty cycle, operating

\({\pi }_{S}\) :

Stress factor/failure rate multiplier for stress

\({\pi }_{C}\) :

Contact construction factor

\({\pi }_{DCN}\) :

Failure rate multiplier for duty cycle, non-operating

\({\pi }_{TO}\) :

Failure rate multiplier for temperature

\({\pi }_{Q}\) :

Quality factor

\({\pi }_{A}\) :

Application factor

\({\pi }_{CR}\) :

Failure rate multiplier, cycling rate

θ JC :

Junction to case temperature

T board-amb :

Average board temperature during a phase (°C)

\({\pi }_{PM}\) :

Part manufacturing

\({\pi }_{Process}\) :

Quality control over the development, manufacturing and usage process

\({{\lambda }_{OB}/\lambda }_{b}\) :

Base failure rate

T AO :

Operating temperature

ΔT cycling :

Amplitude of variation associated with a cycling phase (°C)

T AE :

Ambient temperature, non-operating

T C :

Case temperature

T m :

Mean junction temperature

T J :

Worst case junction temperature

ΔT :

Change in temperature

Vs :

Stress ratio

E a :

Activation energy parameter

RH ambient :

Humidity associated with a phase (%)

K :

Boltzmann constant

T max-cyc :

Maximum board temperature during a cycling phase (°C)

\({\pi }_{Thermal}\) :

Thermal stress factor

\({\pi }_{Electrical}\) :

Electrical stress factor

\({\pi }_{Mechanical}\) :

Mechanical stress factor

\({\pi }_{Chemical}\) :

Chemical stress factor

tannual :

Time associated with each phase over a year (hours)

\({\pi }_{Humidity}\) :

Humidity stress factor

N annual-cy:

Number of cycles associated with each cycling phase over a year

Grms:

Vibration amplitude associated with each random vibration phase

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Authors and Affiliations

  1. Department of Electrical and Electronics Engineering, SRM Institute of Science and Technology, Kattankulathur, 603203, India

    Divya J. Navamani & A. Lavanya

  2. Renewable Energy Lab, College of Engineering, Prince Sultan University, Riyadh, 11586, Saudi Arabia

    Jagabar M. Sathik & Dhafer Almakhles

  3. Electrical Engineering Department, College of Engineering, Prince Sattam Bin Abdulaziz University, Wadi Addawaser, 11991, Saudi Arabia

    Ziad M. Ali

  4. Electrical Engineering Department, Aswan Faculty of Engineering, Aswan University, Aswan, 81542, Egypt

    Ziad M. Ali

  5. Department of Electrical Engineering, Valley High Institute of Engineering and Technology, Science Valley Academy, Qalyubia, 44971, Egypt

    Shady H. E. Abdel Aleem

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DJN had the idea for the article, JMS and AL performed the literature search and data analysis and drafted the work. DA, ZMA and SHEAA critically revised the work.

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Correspondence to Shady H. E. Abdel Aleem.

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Navamani, D.J., Sathik, J.M., Lavanya, A. et al. Reliability Prediction and Assessment Models for Power Components: A Comparative Analysis. Arch Computat Methods Eng 30, 497–520 (2023). https://doi.org/10.1007/s11831-022-09806-8

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