PhD Courses in Denmark

Organizer: Professor, Huai Wang hwa@energy.aau.dk

Lecturers: Philip C. Kjær, Chief Specialist, Vestas Wind Systems A/S

Rui Wu, Power Electronics Engineer, Vestas Wind Systems A/S

Huai Wang, Professor, Aalborg University

ECTS: 4

Date/Time: September 9-13, 2024

Deadline: 19 August 2024

Place: AAU Energy, Pontoppidanstraede, Aalborg, Denmark

Max no. of participants: 30

Description: The aim of the course is to meet both scientific challenges and industry needs for electrical engineers and scientists with reliability expertise and systems engineering concept, especially the D-FMEA for system design. The lecturers would like to extend for the workshop as a regular PhD course so that it can benefit a wider range of participants. Design Failure Mode and Effect Analysis (D-FMEA) helps to foresee design issues and to mitigate them at early stages of product development. Best practice of D-FMEA for power electronics design is believed to be of general benefits to the power electronic converter designer across industries and academic research. Based on engineering case studies, this course will introduce a systematical way to perform D-FMEA and its important aspects. Participants will bring their own designs to the course, and will leave with hands-on experiences in building up D-FMEA of their specific applications. The course will mainly cover the following aspects:

1)      Introduction to D-FMEA and systems engineering

2)      How to formulate functions and failures, link causes and effects, and score risk

3)      Examples applicable of mega-watt power converter

4)      Training in software tool for D-FMEA (IQ-FMEA) and free-of-charge use of tool for duration of course

5)      Hands on exercises of selected projects from course participants (teams or individuals)

Day 1 – Introduction of D-FMEA, Systems Engineering (Lecturers: Philip C. Kjær, Rui Wu, and Huai Wang, 08:30 – 16:30)

08:30 – 09:00 Welcome, introduction to the course

09:00 – 10:30 Introduction to D-FMEA

10:30 – 12:00 Introduction to systems engineering

12:00 – 13:00 Lunch

13:00 – 15:30 Exercise on functions & failures

15:30 – 16:30 Participant team project support

Day 2 – Failure Cause & Effect and Risk Scoring (Lecturers: Philip C. Kjær, Rui Wu, and Huai Wang,

08:30 – 16:30)

08:30 – 09:00 Recap from Day 1

09:00 – 10:30 Converter – a worked example

10:30 – 12:00 Cause & effect analysis

12:00 – 13:00 Lunch

13:00 – 14:00 Converter – a worked example

14:30 – 15:30 D-FMEA risk scoring

15:30 – 16:30 Software training of IQ-FMEA (I)

Day 3 – Failure Cause & Effect and Risk Scoring (Lecturers: Philip C. Kjær, Rui Wu, and Huai Wang,

08:30 – 16:30)

08:30 – 09:00 Recap from Day 2

09:00 – 11:30 Software training of IQ-FMEA (II)

11:30 – 12:00 Participant team project discussions

12:00 – 13:00 Lunch

13:00 – 15:00 Participant team project presentation

15:00 – 16:30 Participant team project discussions

Day 4 – Participant Team Project Implementation and Exercises (it is mainly performed intensively by the course participants in teams, lecturers can provide support upon the request, otherwise, no formal lecturers on this day)

Day 5 – Participant Team Project Presentations and Discussions (Lecturers: Philip C. Kjær, Rui Wu, and Huai Wang, 08:30 – 16:30)

Prerequisites:

1.      Pre-reading the shared materials

2.      Participants should choose their own products for studying in the course, which should be:

                      1) a product at an adequate complexity level within power electronics area, for instance, a EMI filter, a Print circuit board (PCB), a magnetic component, discrete semiconductors, a heat sink or a liquid cooling system;

                      2) a product with new designs, or a product with modifications to the exist design, or a exist product needs FMEA analysis

3.      Participants should form a DFMEA team inside their institutes/companies for their design, including: a core team - designers of the product, a support team - assembly, manufacturing, design, analysis/test, reliability, materials, quality, service, and suppliers, as well as designers responsible for the next higher system.

4.      Participants should be aware of the customers’ requirements/ expectations on their products.

Form of evaluation: A DFMEA report on the participants’ own project (teams or individuals)

Course literature:

1.    Handouts prepared by the lecturers (20 pages)
2.    INCOSE Systems Engineering Handbook (about 50 pages for key contents to this course)
3.     Effective FMEA (about 50 pages for key contents relevant to this course)