Electronic Component Load Management for Thermal Mismatch
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Solution Overview
Problem
Electrified motor vehicles face premature failures of electronic components due to thermal mismatch and self-heating effects, leading to reduced service life and operational reliability.
Innovation Solution
A method to assess and adjust the load on electronic components by identifying types of damage through thermal step responses and changing variables such as current, current gradient, or voltage to extend service life, ensuring components operate within a setpoint service life and avoid premature failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electronic components operate at high current amplitudes during motor-driven boost and generator-driven recuperation processes, then power output and productivity are improved, but the service life and reliability of the components deteriorate due to self-heating and thermal mismatch
Solution Approach 1:
The patent implements dynamic load management by continuously monitoring accumulated load and adjusting operational parameters in real-time. The system dynamically adapts the operating conditions of electronic components based on their current thermal state and historical load patterns, allowing high power output when components are cool and reducing load when thermal limits are approached, thus resolving the contradiction between productivity and reliability
Solution Approach 2:
The system changes operational parameters (current amplitude, duty cycle, switching frequency) based on the ascertained accumulated load and service life predictions. By adjusting these parameters dynamically, the system optimizes the balance between power delivery and component stress, preventing premature failure while maintaining productivity when conditions permit
2Adaptability or versatility
If the number and amplitude of boost and recuperation processes are increased to meet varying driving conditions, then vehicle adaptability and productivity are improved, but the thermal cycling stress on electronic components increases, reducing their service life
Solution Approach 1:
The patent employs feedback mechanisms by continuously monitoring the accumulated load of electronic components and using this information to predict service life. The system feeds this information back into the control logic to adjust future operational decisions, creating a closed-loop system that adapts to both external driving conditions and internal component states, thereby protecting components while maintaining vehicle adaptability
3Reliability
If thermal models are used to estimate residual service life, then reliability prediction is improved, but system complexity and measurement requirements increase
Solution Approach 1:
The system uses the electronic components' own operational data (current, voltage, switching patterns) to generate the thermal load information needed for service life prediction. Rather than requiring external monitoring equipment, the control unit leverages existing sensor data and operational records to build the thermal model, reducing additional system complexity while maintaining prediction accuracy
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively extends the service life of electronic components by reducing or increasing load variables based on damage severity, thereby preventing premature failure and ensuring reliable operation of motor vehicle electrical systems.
Implementation Method 1
the residual service life is determined with the aid of a thermal model and by storing temperature lifts
Implementation Method 2
electronic components of the converter of the electric machine in such motor vehicles, which experience additional loads from active temperature lifts due to the self-heating at high current
Implementation Method 3
in assembly and connection technology materials having different expansion coefficients are used. These different expansion coefficients (so-called thermal mismatch) result in mechanical stresses during a thermal heating or cooling of the assembly and connection technology
Data Source
AI summary
A method for operating a motor vehicle having a vehicle electrical system, which includes at least one electrical or electronic component, which experiences a load during an operation of the motor vehicle, an accumulated load of the at least one component being ascertained, at least one type of damage contributing to the load being ascertained, a service life of the at least one component to be expected as a result of the ascertained accumulated load being ascertained, and at least one variable damaging the at least one component during operation, which is selected as a function of the at least one type of damage, being changed in a load-reducing direction if the service life to be expected of the at least one component deviates from a setpoint service life.