Electrical Fuse Fatigue Monitoring Using Temperature-Based Life Estimation
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Solution Overview
Problem
Existing high voltage electrical power systems for electric vehicles face challenges in monitoring fuse fatigue, leading to potential premature failure due to thermal-mechanical fatigue, which is not effectively addressed by current complex, costly, and large fuse monitoring systems.
Innovation Solution
A system and method for monitoring fuse fatigue by tracking temperature and mechanical strain of the fuse element, comparing these parameters to known fatigue data, and using regression models to estimate the remaining service life of the fuse, thereby enabling timely replacement before failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex fuse monitoring systems are used to detect thermal-mechanical strain fatigue, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential monitoring function to only what is needed: measuring fuse temperature and calculating fatigue parameters based on temperature cycles. This eliminates complex sensor arrays and sophisticated analysis systems, achieving reliable fatigue detection through simple temperature measurement and basic calculation algorithms.
Solution Approach 2:
The fuse element itself serves as the temperature sensor through its inherent electrical resistance properties. By measuring the resistance changes of the fuse element during operation, the system obtains temperature data without requiring separate temperature sensors, thereby simplifying the monitoring system while maintaining measurement accuracy.
2Reliability
If comprehensive fuse monitoring is implemented to estimate service life, then reliability is improved, but cost increases
Solution Approach 1:
The monitoring system is designed to serve multiple functions using the same components: the fuse element's resistance measurement simultaneously provides both operational status information and temperature data for fatigue analysis. This multi-functionality eliminates the need for separate dedicated fatigue sensors, reducing system cost while maintaining reliable service life estimation.
Solution Approach 2:
The system uses changes in electrical resistance parameters of the fuse element to infer temperature and fatigue state. By monitoring readily available electrical parameters rather than requiring specialized mechanical strain sensors, the system achieves reliable fatigue detection at lower cost.
3Difficulty of detecting and measuring
If existing fuse monitoring systems are used, then fatigue detection capability is improved, but ease of operation deteriorates due to system size
Solution Approach 1:
The patent merges the fatigue monitoring function with the existing fuse component and electrical measurement system. By integrating temperature measurement and fatigue analysis into a unified system that leverages the fuse's inherent electrical properties, the system becomes easier to install and maintain while maintaining sophisticated fatigue detection capability.
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 proposed solution allows for accurate and cost-effective estimation of fuse service life, reducing the risk of premature failure and enhancing the reliability and efficiency of high voltage electrical power systems for electric vehicles.
Implementation Method 1
when electrical current flow through the fuse and/or temperature of the fuse exceeds a predetermined limit
Implementation Method 2
fuse failure as a result of a thermal-mechanical fatigue process
Data Source
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AI summary
Systems and methods for estimating a thermal-mechanical fatigue in an electrical conductor in a thermal-mechanical fatigue assessment system include an electrical conductor having a cold resistance and a non-linear resistance when connected to an electrical power system, and a controller receiving temperatures of the conductor as inputs, wherein the controller is operable to estimate a service life of the conductor based on at least the input temperatures of the conductor and the cold resistance of the conductor.