By Trine Reinholt Andersen, AAU Technology Transfer Office

Power converters play a crucial role in modern power electronics, enabling the efficient conversion and control of electrical energy across various applications. These devices, which include DC-DC, DC-AC, and AC-DC converters, are fundamental in industries where system reliability, efficiency, and performance are critical. 

From high-speed trains and metro systems to electric mobility, renewable energy solutions, and industrial drives, power converters facilitate the seamless integration of different power sources and loads. Their ability to enhance energy efficiency, ensure power stability, and support the transition to cleaner energy sources makes them indispensable in today's technological landscape.

HEALTH MONITORING WITH UNMATCHED ACCURACY

Health monitoring of power semiconductors is essential for ensuring the reliability, efficiency, and safety of power converters as failures can lead to costly downtime, system malfunctions, or even catastrophic damage. 

PED Insight, a spin-out from Aalborg University, has developed the world’s first device for on-state voltage health monitoring of power semiconductors. Via the embedded AI-algorithm, the device enables users to perform predictive maintenance of any existing and future power converters in daily operation: non-invasively at converter-level and with high accuracy.

The monitoring method is based on converter-level signals instead of device-level signals, reducing the complexity and size compared to existing methods while providing noise-free data on the evolving health status of the individual components.

PLUG’N’PLAY MONITORING FOR MAXIMUM RELIABILITY

E-Sense Power is comparable to an Apple Watch – a wearable device able to detect irregular rhythms and overall health without accessing the system in need of monitoring.

Compared to existing solutions, the device is 3-10 times more cost-effective, up to 50% smaller in size, and directly connects to the power converter through the three accessible AC output terminals reducing the need of connecting terminals with up to 75%. 

By using the accessible AC output terminals of the converter, the E-Sense Power secures that both offline diagnosis and online condition monitoring of power converters can be achieved “plug’n’play”, thereby enabling system owners to achieve the highest system reliability and availability while minimizing system downtime, repair costs, loss of operational income, and avoid service penalties.

E-Sense Power have been tested in collaboration with companies in train, electric vehicle, and renewable energy sectors, however, the application area furthermore spans across:

• E-mobility: electric vehicle, train, metro, airplane.
• Renewable energy: offshore wind power, onshore wind power, lifetime extension for existing wind farms, photovoltaic systems.
• Other industry: motor drives, data centers 
• R&D: University labs and industry R&D centers use the developed sensor unit as a special voltage probe for instruments.

SUPPORTED BY ACADEMIA AND INDUSTRY

E-Sense Power is based on years of research from Professor Huai Wang and former PhD student Yingzhou Peng from AAU Energy at Aalborg University. In 2023, the technology formed the basis for the spin-out company PED Insight, established by Professor Huai Wang.

E-Sense Power has received funding support equivalent to more than 700,000 Euro through among other an AAU Proof of Concept grant, an InnoExplorer grant from Innovation Fund Denmark and two collaborative industry projects as background IP to explore industrial applications in train and electric vehicles. 

In 2024, the E-Sense Power technology was licensed to PED Insight.

AAU Technology Transfer Office has been a key part of the journey from the start; evaluating the invention, assisting on developing the business case, applying for funding, and negotiating contracts for the industrial partnerships, as well as negotiating the licensing agreement with PED Insight.