Converters play a central role in the energy transition: they are vital technical components for connecting photovoltaic systems and modern wind turbines to the power grid in order to feed in energy from renewable sources at a grid-compliant voltage and frequency. The converters thus have to be extremely reliable. Yet, they are subject to particularly challenging operating and environmental conditions. They have been among the most frequently failing system components for years and often cause considerable costs. Long-lasting converters which are able to withstand environmental influences are in great demand. They represent an indispensable technological component of the energy transition and, as such, have a high economic potential.

The goal of this three-year project is therefore to develop solutions for substantially improving the reliability and robustness of converters for decentralized electrical energy conversion. The project focuses on investigating in greater detail the application-specific weaknesses determined on the basis of comprehensive field data and damage analyses and their failure mechanisms. Such mechanisms are often the result of the combination of climatic and electrical loads. In addition to hardware modifications and protection concepts, the project is also exploring suitable testing procedures in order to assess them under typical application conditions.

Another important aspect is the development of long-term alliances between Fraunhofer institutes. A total of five Fraunhofer institutes are involved in the power4re project: the Fraunhofer Institute for Integrated Systems and Device Technology IISB, the Fraunhofer Institute for Microstructure of Materials and Systems IMWS, the Fraunhofer Institute for Solar Energy Systems ISE, the Fraunhofer Institute for Wind Energy Systems IWES (consortium manager), and the Fraunhofer Institute for Reliability and Microintegration IZM. A team of consultants is also involved in this power4re project, representing the companies ConverterTec (formerly Woodward Kempen), SMA Solar Technology AG, and Mitsubishi Electric R&D Centre Europe.
Dr. Vera Gramich from the Department for Internal Research Programs is supporting and monitoring this project for the Fraunhofer-Gesellschaft.

»With power4re, we are driving forward a socially responsible energy transition together with our project partners. After all, it is important that wind turbines and PV systems become more reliable so as to cut the generation costs of renewable energy even further. Our comprehensive and long-term system understanding of converters is of great benefit here«, explains Prof. Jan Wenske, Deputy Director Fraunhofer IWES & Technical Director.

»We are opening up new methods for field-data based failure analysis and are working on a condition monitoring system which is focused on the relevant failure mechanisms. We expect that this cross-society cooperation will lead to new, important findings, for example from the comparison of PV and wind applications«, adds Dr. Katharina Fischer, Project Manager and Senior Scientist at Fraunhofer IWES.

The solutions pursued for increasing converter reliability are not solely restricted to wind energy and photovoltaic applications, they may also potentially be of use in other areas such as railway transport, avionics, and electromobility, where converters are also exposed to challenging environmental factors. 

Contacts

Dr. Katharina Fischer, Project Manager
Fraunhofer Institute for Wind Energy Systems IWES
Postkamp 12
30159 Hanover, Germany
Phone: +49 (0)471 14290-542
katharina.fischer@iwes.fraunhofer.de

Julia Walgern, Deputy Project Manager
Fraunhofer Institute for Wind Energy Systems IWES
Postkamp 12
30159 Hanover, Germany
Phone: +49 (0)471 14290-549
julia.walgern@iwes.fraunhofer.de

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The Fraunhofer Institute for Wind Energy Systems IWES secures investments in technological developments through validation, shortens innovation cycles, accelerates certification procedures, and increases planning accuracy by means of innovative measurement methods in the wind energy sector. At present, there are around 220 academics and employees as well as more than 80 students employed at the five sites: Bremerhaven, Hanover, Bremen, Hamburg, and Oldenburg.

The Fraunhofer Institute for Reliability and Microintegration IZM is one of the world’s leading institutes for applied research and the development and system integration of robust and reliable electronics. For over 26 years, more than 230 institute researchers have been finding technological solutions in cooperation with partners from industry and academia. Emerging challenges are addressed in branches such as automotive and industrial electronics, medical engineering, ICT, and semiconductor technology.

With its research areas of work, the Fraunhofer Institute for Integrated Systems and Device Technology IISB covers the entire value chain for power electronics; from the development and manufacture of semiconductor materials to system development and specialization in various application fields. Key topics include integrated circuit packaging and reliability and lifetime analyses. The institute currently employs around 250 members of staff as well as more than 100 students.

Ensuring sustainability in all areas of life and, in particular, the efficient use of limited resources, is the central challenge faced by humanity in the 21^st century. The Fraunhofer Institute for Microstructure of Materials and Systems IMWS is engaged in applied research in the field of material efficiency and acts as a driving force, innovator, and problem solver for industry and public clients in terms of the reliability, safety, lifetimes, and functionality of materials in components and systems. Its core strengths are concentrated on the characterization of materials down to atomic scale and material development.

With 1,200 employees, the Fraunhofer Institute for Solar Energy Systems ISE is the largest solar research institute in Europe. Within the scope of research focusing on energy efficiency, acquisition, distribution, and storage, this institute creates the technical prerequisites for efficient and environmentally friendly energy supplies around the world. To this end, the institute develops materials, components, systems, and processes in a total of five business areas. The Fraunhofer ISE is distinguished in particular by its outstanding technical infrastructure, which is currently divided into eight laboratory centers and four production-relevant technological evaluation centers. The institute also boasts several accredited test centers.