Failure-Mechanism Transferability of Cumulative-Damage Features for Health State Estimation of SiC Power Modules

Silicon carbide (SiC) power modules are increasingly deployed in automotive traction inverters, where condition monitoring is essential to prevent in-service failures. Despite extensive qualification under AQG 324, no consolidated approach exists for in-field health state estimation: physics-of-failure lifetime models lack real-time applicability, purely data-driven architectures require large labeled datasets and generalize poorly, and physics-informed frameworks remain too demanding for embedded deployment. We address SiC MOSFET modules assembled with sintered packaging, which suppresses solder degradation and produces aging behavior distinct from previously studied devices. Instead of the smooth quasi-exponential drift of solder-based modules, the forward voltage drop $V_{DS}$ exhibits multi-regime profiles, with wirebond liftoff events introducing abrupt, non-monotonic perturbations. We propose a condition monitoring framework combining three elements. First, physics-informed features replace raw sensor signals with cumulative damage indicators derived from junction temperature swing, mean junction temperature and a Miner rule accumulator, encoding degradation history in an interpretable form. Second, a monotonicity constraint enforced by gradient penalty regularization embeds the expected degradation direction as a physics-guided prior. Third, a heavy-tailed output distribution replaces the point estimate, giving calibrated uncertainty robust to the out-of-distribution variance introduced by liftoff. On an industrial power cycling dataset from Infineon Technologies, several neural architectures are compared under a strict cross-validation protocol. The full configuration reduces mean absolute error by approximately 70% over purely data-driven baselines and stays stable across all folds, while remaining lightweight enough for embedded deployment.

Always-on converter health monitoring demands sub-mW edge inference, a regime inaccessible to GPU-based physics-informed neural networks. This work separates spiking temporal processing from physics enforcement: a three-layer leaky integrate-and-fire SNN estimates passive component parameters while a differentiable ODE solver provides physics-consistent training by decoupling the ODE physics loss from the unrolled spiking loop. On an EMI-corrupted synchronous buck converter benchmark, the SNN reduces lumped resistance error from $25.8\%$ to $10.2\%$ versus a feedforward baseline, within the $\pm 10\%$ manufacturing tolerance of passive components, at a projected ${\sim}270\times$ energy reduction on neuromorphic hardware. Persistent membrane states further enable degradation tracking and event-driven fault detection via a $+5.5$ percentage-point spike-rate jump at abrupt faults. With $93\%$ spike sparsity, the architecture is suited for always-on deployment on Intel Loihi 2 or BrainChip Akida.

Progress in Prognostics and Health Management (PHM) is hindered by the lack of standardized and reusable evaluation practices across tasks, datasets, and application domains. Reported results are often difficult to reproduce and compare, as key protocol choices, such as data splits, preprocessing, label alignment, temporal windowing, and metrics, are often implicit or implemented ad hoc. We introduce \picid, a modular evaluation infrastructure that formalizes the PHM evaluation pipeline as an explicit, executable, and reproducible protocol. Through well-defined abstractions, \picid enforces deterministic, leakage-safe dataset construction while remaining flexible across diverse PHM settings. The framework supports fault detection, diagnostics, and prognostics through a unified interface and can be extended to new datasets and model classes without violating protocol invariants. By standardizing data contracts and evaluation boundaries, \picid also enables fair cross-task comparisons across diagnostics (classification) and prognostics (regression), allowing identical model families to be evaluated consistently across heterogeneous settings. We demonstrate \picid through an empirical evaluation of thirteen models on twelve datasets spanning batteries, bearings, turbofan engines, hydraulics, filtration systems, and buildings. This work establishes a reusable foundation for standardized, fair and reproducible evaluation in PHM.