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Estimation of Peak Junction Hotspot Temperature in Three-Level TNPC-IGBT Modules for Traction Inverters Through Chip-Level Modeling and Experimental Validation

Research Authors
Ahmed H. Okilly, Peter Nkwocha Harmony, Cheolgyu Kim, Do-Wan Kim, Jeihoon Baek
Research Member
Research Department
Research Date
Research Year
2025
Research Journal
Energies
Research Publisher
MDPI
Research Vol
18
Research Rank
International Journal (SCIE), IF=3.2
Research_Pages
3390
Research Website
https://www.mdpi.com/1996-1073/18/14/3829
Research Abstract

Monitoring the peak junction hotspot temperature in IGBT modules is critical for ensuring the reliability of high-power industrial multilevel inverters, particularly when operating under extreme thermal conditions, such as in traction applications. This study presents a comprehensive chip-level analytical loss and thermal model for estimation of the peak junction hotspot temperature in a three-level T-type neutral-point-clamped (TNPC) IGBT module. The developed model includes a detailed analytical assessment of conduction and switching losses, along with transient thermal network modeling, based on the actual electrical and thermal characteristics of the IGBT module. Additionally, a hybrid thermal–electrical stress experimental setup, designed to replicate real operating conditions, was implemented for a balanced three-phase inverter circuit utilizing a Semikron three-level IGBT module, with testing currents reaching 100 A and a critical case temperature of 125 °C. The analytically estimated module losses and peak junction hotspot temperatures were validated through direct experimental measurements. Furthermore, thermal simulations were conducted with Semikron’s SemiSel benchmark tool to cross-validate the accuracy of the thermo-electrical model. The outcomes show a relative estimation error of less than 1% when compared to experimental data and approximately 1.15% for the analytical model. These findings confirm the model’s accuracy and enhance the reliability evaluation of TNPC-IGBT modules in extreme thermal environments.

Research Rank
International Journal