Fuse Ageing Estimation Using Current Peak Monitoring

Solution Overview

Problem

Existing methods for monitoring the service life of electrical fuses in vehicles are overly complex due to the need for precise voltage and current measurements, making it difficult to predict when fuses need replacement for safety and reliability.

Innovation Solution

A method that involves measuring and monitoring current through each fuse, incrementing a counter for current peaks, determining a threshold from a pre-established model, and estimating the ageing state by calculating a quotient, along with a maintenance system using sensors to measure current, voltage, and temperature to predict remaining service life without complex diagnostics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If monitoring methods based on precise voltage and current measurements are used, then the reliability of fuse service life prediction is improved, but the device complexity and measurement precision requirements increase significantly

Engineering Contradiction:

Improvefuse service life prediction accuracyVSAvoidmeasurement system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts only the essential information needed for fuse ageing assessment - specifically current peaks and their duration - while discarding the need for precise voltage measurements and complex resistance calculations. This selective extraction of critical parameters simplifies the monitoring system while maintaining prediction reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of calculating fuse resistance from voltage and current measurements (the traditional approach), the patent inverts the logic by directly monitoring current peaks and using them to assess fuse ageing. This inversion eliminates the need for precise voltage measurements and complex resistance calculations.

Inventive Principle:

Principle #13The other way round (Inversion)

2Measurement precision

If precise voltage and current measurements are implemented, then the accuracy of fuse ageing assessment is improved, but the ease of operation and implementation becomes difficult

Engineering Contradiction:

Improveelectrical variable measurement accuracyVSAvoiddiagnostic method implementation ease

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The patent extracts only the essential information needed for fuse ageing assessment - specifically current peaks and their duration - while discarding the need for precise voltage measurements and complex resistance calculations. This selective extraction of critical parameters simplifies the monitoring system while maintaining prediction reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses a simple counter that increments with each current peak event, replacing complex continuous measurement and calculation systems. This discrete, simple tracking approach is easier to implement and operate while providing sufficient accuracy for fuse ageing assessment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If continuous monitoring of multiple electrical parameters is performed, then the reliability of service life prediction is improved, but the use of energy and computational resources increases

Engineering Contradiction:

Improveservice life prediction reliabilityVSAvoidenergy consumption for monitoring

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent extracts only the essential information needed for fuse ageing assessment - specifically current peaks and their duration - while discarding the need for continuous voltage measurements and complex resistance calculations. This selective extraction of critical parameters simplifies the monitoring system while maintaining prediction reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses a simple counter that increments with each current peak event, replacing complex continuous measurement and calculation systems. This discrete, simple tracking approach is easier to implement and operate while providing sufficient accuracy for fuse ageing assessment.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11899078B2Method for estimating the ageing state of fuse elements and an electrical fuse maintenance system

Publication Date: 2024.02.13 VOLVO TRUCK CORP

AI summary

An electrical fuse maintenance system includes sensor adapted to measure the current flowing through a fuse element, the voltage on the fuse element, the temperature of the fuse element, and/or the temperature of an environment surrounding the fuse element, a controller configured to monitor the current, the voltage, the temperatures over a period of time while the fuse element is connected to an energized electrical power unit. Based on the monitored current, voltage and temperatures, the controller is adapted to estimate a service life remaining of the fuse element.