Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with

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Specifications	Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Sam Parler Cornell Dubilier Electronics Inc.
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1 Presented at PCIM / Powersystems World, November 1999 Abstract ! Large-can aluminum electrolytic capaci- tors are widely us

Specifications	Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Sam Parler Cornell Dubilier Electronics Inc.
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Content	1 Presented at PCIM / Powersystems World, November 1999 Abstract ! Large-can aluminum electrolytic capaci- tors are widely used as bus capacitors in variable-speed drives, UPS systems and inverter power systems. Accu- rate thermal modeling of the capacitor’s internal tem- perature is needed to predict life, and this is a challenge because of the anisotropic nature of the capacitor wind- ing and the complexity of the thermal coupling between the winding and the capacitor case. This paper trans- lates analytical models for heat flow in bus capacitors into an equivalent three-loop, seven-resistor, lumped-pa- rameter thermal circuit model. This paper presents the results of a Finite-Element Analysis (FEA)-based par- tial differential equation solution and the results of the three-loop thermal circuit model. The latter model is the basis for an operating temperature and expected life- time Java applet which enables power-system designers to accurately predict capacitor operating temperature and expected life from operating conditions. Operating conditions permitted as inputs include applied voltage, ambient air temperature, air speed, thermal resistance of any heatsink attached, and capacitor characteristics like capacitance, ESR and case size. I. INTRODUCTION The useful life of an aluminum electrolytic capacitor is related to temperature exponentially, approximately doubling for each 10 ºC the capacitor’s core tempera- ture is reduced [1]. The temperature rise of the core is directly proportional to the core-to-ambient thermal re- sistance, and this paper models this thermal resistance for various capacitor construction techniques. Results are adapted for use in a new, lumped-parameter model suitable for use in a spreadsheet or a Java applet. This paper focuses on modeling computergrade, or screw terminal, capacitors. However, the concepts can be applied to other aluminum electrolytic capacitor con- structions, such as snapmount, radial, and axial capaci- tors. An aluminum electrolytic capacitor is generally com- prised of a cylindrical winding of aluminum anode and cathode foils separated by papers impregnated with a liquid electrolyte, usually based on ethylene glycol. See Fig. 1. The anode and cathode foils are made of alumi- num, and the foils are usually highly etched. There is a thin coating of aluminum oxide on the surface of the anode. The anode and cathode foils are contacted by aluminum tabs that are extended from the winding. These tabs are attached to aluminum terminals in a poly- meric top. The wet winding is sealed into an aluminum can. Analytical and FEA models have been developed and recently published by one of the authors of the present paper, and the reader is referred to [2]. The present pa- per focuses on the embodiment of these models into a lumped-parameter circuit model and a corresponding Java applet. Fig. 1. Typical screw terminal capacitor constructions: pitch (left) and pitchless (right). Predicting Operating Temperature and Expected Lifetime of Aluminum-Electrolytic Bus Capacitors with Thermal Modeling Sam G. Parler, Jr. and Laird L. Macomber Cornell Dubilier 140 Technology Place Liberty, SC 29657
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Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Sam Parler Cornell Dubilier Electronics Inc.

Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Predicting Operating Temperature and Expected Lifetime of Aluminum Electrolytic Bus Capacitors with T\ hermal Modeling Sam Parler Cornell Dubilier Electronics Inc.