The effect of different mission profiles and ambient temperature on the lifetime of boost converter IGBT with a robust controller in a hybrid electric vehicle

Abstract The reliability of power electronic converters is one of the essential issues in designing of electric vehicles. This paper estimates the lifetime of the boost converter switch by Semikron and Coffin‐Manson models for two common failure mechanisms of Bond wire and Base plate solder, respectively. Four mission profiles based on the Artemis standard are applied to hybrid electrical vehicle model to determine unidirectional output power. Kharitonov's theory is used to design a robust controller to handle the uncertainty raised by different power cycles of the electric vehicle and the parameters of the converter during simulation. Stability of converter is achieved during simulation by identifying simple proportional integral controller coefficients with Kharitonov's theorem. A prototype 230 W boost converter is designed and utilized to validate average model and switch loss calculation relationships. The lifetime results indicate that the number of cycles, and the average and the maximum junction temperature have a more impact than the duration of the drive cycle on the lifetime of the converter. A mixed mission profile is considered to investigate the effect of sudden change in driving modes and speed on total consumed life and lifetime to enhance the study's applicability. Lifetime of switch is decreased significantly in mixed mode in comparison with other mission profiles in the same driving time. Furthermore, the motorway mission profile has 53%, 39.6%, and 160% less total consumed life in comparison with the urban, rural and mixed mission profiles, respectively. In addition, the effect of ambient temperature changes on IGBT lifetime has been investigated for four mission profiles. While motorway had the least total consumed life in 25°C, the urban had better performance in comparison with other mission profiles from 25 to 55°C.