Fusible Link With Integrated PCB And Sensor Monitoring
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Solution Overview
Problem
Conventional fuses lack diagnostic capabilities, making it difficult to monitor and prevent malfunctions in safety-relevant automotive applications, where increasing complexity of electronic components increases the risk of faults that can lead to safety hazards.
Innovation Solution
A safety fuse with integrated connection pins and a printed circuit board that includes sensors and a microcontroller to monitor the fusible conductor, allowing for real-time data evaluation and error detection, enabling preventive maintenance by comparing measured values with reference data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug-in fuses are used, then the structure remains simple and easy to replace, but diagnostic capability and monitoring functions are lacking
Solution Approach 1:
The patent combines the fuse element with a printed circuit board and integrated circuits to create a hybrid device. The connection contacts are integrated with the PCB, and monitoring functions are built into the same structure, allowing the fuse to perform both protection and diagnostic functions simultaneously.
Solution Approach 2:
The fuse structure is designed to serve multiple functions: current protection through the fusible element, electrical connection through integrated contacts, signal transmission through connection pins, and monitoring through sensors and ADCs. This multi-functional design eliminates the need for separate diagnostic components.
2Loss of information
If monitoring functions are added to detect faults, then diagnostic capability is improved, but the fuse structure becomes more complex
Solution Approach 1:
Connection pins serve as intermediaries between the fusible conductor and the printed circuit board. These pins transmit electrical signals and measurement data from the fuse element to the monitoring circuits on the PCB, enabling fault detection without direct complex integration.
Solution Approach 2:
The patent replaces mechanical monitoring concepts with electronic sensing. Instead of mechanical indicators of fuse status, electronic sensors and ADCs measure electrical parameters (current, voltage, temperature) to detect faults, providing more precise and reliable monitoring.
3Reliability
If sensors and integrated circuits are integrated into the fuse, then real-time monitoring is enabled, but manufacturing complexity increases
Solution Approach 1:
The fuse is designed as a modular assembly with distinct functional segments: the fusible conductor, connection contacts with integrated pins, PCB with monitoring circuits, and housing. This segmentation allows each component to be manufactured separately using standard processes and then assembled, reducing overall manufacturing complexity.
Solution Approach 2:
The patent uses standard electronic component parameters and values (voltage ratings, current capacities, ADC resolutions) that align with industry norms. This allows manufacturers to use existing production lines and component inventories, minimizing the need for specialized manufacturing processes.
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 the detection of potential faults before they occur, allowing for timely intervention and reducing the risk of safety-critical malfunctions in automotive systems.
Implementation Method 1
The wire cross-section and conductivity of the fusible conductor is adjusted in such a way that it melts at a certain current intensity and thus separates an electrical path between the two connection contacts
Implementation Method 2
Analog output signals from such sensors can be digitized using the AD converter and then further processed on a microcontroller
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a fusible link comprising a fusible conductor which is arranged between a first and a second connection contact, characterized in that a connection pin is respectively arranged on the first and on the second connection contact, in that a printed circuit board is mounted on the connection pins, and in that at least one integrated circuit is arranged on the printed circuit board, on that side which is averted from the fusible conductor.