Electrical Fuse Fatigue Monitoring for Service Life Prediction
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Solution Overview
Problem
Existing high voltage electrical power systems in electric vehicles face challenges in monitoring fuse fatigue and predicting service life due to complex, expensive, and large circuit protection fuses, which are not adequately addressing thermal-mechanical fatigue issues, leading to premature failure.
Innovation Solution
A system and method for estimating fuse service life by monitoring fatigue parameters such as temperature and mechanical strain, using compensation circuitry to calculate current and temperature, and applying regression models to predict remaining service life, thereby facilitating timely replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex monitoring systems are used to track fuse fatigue, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical/electrical monitoring systems with a computational approach. A processor executes algorithms that calculate fatigue parameters (thermal-mechanical fatigue, service life) by processing basic electrical measurements (current, voltage, temperature) from simple sensors. This substitutes complex hardware monitoring with software-based analysis, achieving high measurement precision while keeping the physical system simple.
Solution Approach 2:
The patent introduces computational algorithms as an intermediary between simple sensor measurements and fatigue assessment. The processor runs regression models and fatigue calculations that transform basic electrical measurements into meaningful fatigue predictions, avoiding the need for complex direct monitoring hardware while maintaining high accuracy.
2Reliability
If advanced temperature monitoring is implemented, then reliability improves, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive advanced temperature monitoring hardware with computational models. The system uses basic temperature sensors combined with processor-based fatigue calculations (thermal-mechanical fatigue models, regression analysis) to achieve high reliability in service life prediction. This software-based approach significantly reduces manufacturing costs compared to hardware-based advanced monitoring systems.
Solution Approach 2:
The monitoring system leverages existing electrical parameters (current, voltage, temperature) that are already present in the circuit, and uses the processor to self-calculate fatigue metrics. The system serves itself by using readily available data and computational power to generate reliability predictions, avoiding the need for additional expensive sensors or monitoring infrastructure.
3Loss of time
If real-time fatigue monitoring is added, then loss of time is reduced, but device complexity increases
Solution Approach 1:
The patent uses processor-based real-time calculations to rapidly assess fatigue conditions. The system continuously processes basic electrical measurements through fatigue algorithms, providing immediate service life predictions without complex monitoring hardware. This computational approach enables real-time detection while maintaining system simplicity.
Solution Approach 2:
The system continuously processes electrical measurements and updates fatigue predictions in real-time. The processor constantly calculates thermal-mechanical fatigue and service life metrics based on ongoing electrical operation data, ensuring continuous monitoring without interruption or complex batch processing mechanisms.
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
Enables accurate and cost-effective estimation of fuse service life, reducing nuisance failures and enhancing system reliability by predicting thermal-mechanical fatigue, thus optimizing vehicle performance and reducing maintenance costs.
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
Implementation Method 3
when electrical current flow through the fuse and/or temperature of the fuse exceeds a predetermined limit, the fusible elements melt and opens one or more circuits
Data Source
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.