Electrical Fuse Fatigue Monitoring via Resistance-Based Temperature Estimation
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Solution Overview
Problem
High voltage electrical power systems in electric vehicles face challenges with complex, costly, and large fuses for temperature monitoring, leading to premature fuse element fatigue and unplanned downtime due to cyclic thermal and mechanical stress, which is not effectively addressed by existing technologies.
Innovation Solution
A computationally-efficient and cost-effective system for estimating the temperature of a fuse element with non-linear resistance by deducing current flow, applying a state-space model with ambient temperature, and using compensation circuitry to calculate and monitor temperature cycles, providing alerts and notifications for impending fuse failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex temperature monitoring systems are installed in high voltage fuses, then temperature monitoring capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical/physical temperature sensing systems with an electrical measurement system. By measuring the voltage across the fuse element and using its known resistance characteristics, the system calculates temperature through electrical parameters rather than requiring physical temperature sensors, thereby reducing device complexity while maintaining monitoring capability
Solution Approach 2:
The fuse element itself serves as the temperature sensor. Its electrical resistance, which naturally changes with temperature, is used to monitor thermal conditions. This eliminates the need for separate monitoring components, as the fuse element's inherent electrical properties provide the temperature information needed
2Reliability
If traditional fuse monitoring systems are used, then reliability is improved, but cost and size increase
Solution Approach 1:
The patent uses a pre-characterized resistance-temperature relationship curve (obtained during manufacturing) to determine actual temperature during operation. This allows the system to achieve accurate temperature monitoring without requiring complex real-time sensing hardware, thereby reducing manufacturing costs while maintaining reliability
Solution Approach 2:
The system monitors changes in electrical parameters (voltage and resistance) of the fuse element to infer temperature changes. By tracking parameter variations rather than directly measuring temperature, the system achieves reliable monitoring with simpler, less expensive components
3Measurement precision
If real-time temperature monitoring is implemented, then prediction accuracy is improved, but computational requirements and system complexity increase
Solution Approach 1:
The patent applies a simplified thermal model that considers only the most significant thermal factors (electrical heating and ambient temperature) rather than attempting to model all thermal pathways. This partial modeling approach achieves sufficient prediction accuracy for practical applications while keeping computational requirements manageable
Solution Approach 2:
The system pre-characterizes the fuse element's resistance-temperature relationship during manufacturing and stores this data for later use. This preliminary characterization eliminates the need for complex real-time calculations, as the system can directly reference pre-computed relationships to determine temperature from measured resistance values
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
This approach allows for accurate and timely prediction of fuse fatigue, enabling proactive replacement and reducing downtime, while being more affordable and compact than existing solutions, thus enhancing the reliability and efficiency of high voltage electrical systems.
Implementation Method 1
estimating a temperature of a fuse element (208) having a non-linear resistance
Implementation Method 2
based at least in part on the deduced current in the fuse element and an ambient temperature of the electrical power system, an first temperature differential between a temperature of the fuse element and a temperature of an arc quenching medium is estimated
Data Source
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AI summary
Thermal-mechanical fatigue assessment systems and methods include a controller operable to estimate a temperature of the conductor having a non-linear resistance based on an ambient temperature input and a current input for current flow through the conductor when connected to an energized electrical power system. A state of fatigue of the conductor may be assessed in view of an estimated first temperature differential between the conductor and an arc extinguishing medium surrounding the conductor, an estimated temperature differential between the temperature of the arc quenching medium and the ambient temperature, and the estimated temperature of the conductor.