Smart Power Module Stress Sensor Integration for Thermal Fit Control
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Solution Overview
Problem
There is no effective method to detect a poor fit between a smart power component and an external heat sink, leading to overheating and potential burnout due to inadequate thermal management, and excessive stress from improper fitting.
Innovation Solution
A control method and apparatus that acquire and analyze fitting information around fixed and non-fixed points using stress measuring sensors, converting analog signals to digital signals to determine if the fit meets preset conditions, and output prompts to adjust the fitting as necessary to prevent overheating and stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the smart power component fits tightly with the external heat sink, then heat dissipation is improved, but stress is generated on the smart power component and internal chip causing failures
Solution Approach 1:
The patent segments the detection function by placing multiple stress sensors at different locations (fixed points and non-fixed points) on the smart power component. This segmentation allows independent measurement of stress at various positions, enabling precise identification of fitting issues without requiring a monolithic detection approach.
Solution Approach 2:
The patent implements a feedback mechanism where stress sensor data is continuously monitored, processed, and used to generate adjustment prompts. The control unit compares measured stress values against threshold conditions and provides real-time feedback to guide fitting adjustments, creating a closed-loop system that prevents both overheating and excessive stress.
2Strength
If the smart power component does not fit well with the external heat sink, then stress is reduced, but temperature rises too high causing burnout
Solution Approach 1:
The patent divides the heat sink interface into multiple monitoring zones with dedicated stress sensors at fixed and non-fixed points. This segmentation enables differentiated detection of fitting quality across the component surface, allowing optimization of both thermal contact and stress distribution simultaneously.
Solution Approach 2:
The system uses feedback from stress sensors to continuously monitor fitting conditions and provide adjustment guidance. By comparing real-time stress measurements with preset thresholds, the system generates actionable prompts to achieve optimal fitting that balances heat dissipation requirements with stress prevention.
3Measurement precision
If multiple stress sensors are integrated in the smart power component, then fitting detection precision is improved, but device complexity increases
Solution Approach 1:
The patent makes the smart power component multi-functional by integrating stress sensing capability directly into the component structure. The same component serves both power processing and stress monitoring functions, eliminating the need for separate external sensing systems and reducing overall system complexity despite multiple sensors.
Solution Approach 2:
The patent merges the stress sensing function with the smart power component structure. By integrating sensors during the manufacturing process and using the component's existing electrical infrastructure for signal processing, the system achieves high measurement precision without proportionally increasing device complexity.
4Difficulty of detecting and measuring
If stress measuring sensors are integrated in the smart power component, then fitting information detection is enabled, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by integrating stress sensors during the smart power component manufacturing process rather than as an afterthought. This allows sensor placement to be coordinated with existing manufacturing steps, and enables calibration and testing to be performed during assembly, thereby reducing overall manufacturing complexity despite the added sensing 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
Ensures a normal fit between the smart power component and the external heat sink, preventing overheating and stress-related failures by providing prompt adjustments to achieve stable and safe operation.
Implementation Method 1
a deformation quantity of a contact surface between the smart power component and the external heat sink is detected through a stress measuring sensor integrated in the smart power component
Data Source
Figure 1
Figure 2~3
AI summary
A control method and apparatus for a smart power component, a storage medium and a processor are provided. The method includes that: first fitting information and second fitting information, which is detected by the smart power component, between a smart power component and an external heat sink is acquired; it is determined whether the first fitting information satisfies a preset condition, and it is determined whether the second fitting information satisfies a preset condition; when the first fitting information does not satisfy the preset condition, first prompt information is output; and when the second fitting information does not satisfy the preset condition, second prompt information is output. Thus, the technical problem that a poor fit between a smart power component and an external heat sink is not detected is solved.