Heavy-Duty Vehicle Load Status Detection for Current Overload
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Solution Overview
Problem
Heavy-duty vehicles face reliability issues in their electrical networks due to additional external equipment, which can lead to premature fuse ageing, overheating, and network collapse, necessitating a method to estimate current consumption and detect anomalous conditions.
Innovation Solution
A method that measures global current consumption, detects activation/deactivation of electrical loads, calculates reference current consumption, and compares it with actual consumption to determine operational status, setting thresholds for nominal, anomalous, or overload conditions, with optional alarm signals and corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional external equipment is installed to adapt the vehicle to particular uses, then the vehicle's functionality and adaptability are improved, but the reliability of the electrical network deteriorates due to increased current consumption
Solution Approach 1:
The system performs preliminary measurements of current consumption during a learning phase to establish reference values before normal operation begins. This allows the system to detect anomalies in real-time by comparing actual consumption against pre-established baselines, enabling early detection of problematic external equipment installations.
Solution Approach 2:
The system continuously monitors current consumption and provides feedback by comparing measured values against reference values. When deviations exceed thresholds, the system generates warnings or alarms, creating a closed-loop monitoring system that allows operators to take corrective action before reliability issues manifest.
2Reliability
If the electrical network is designed to handle original equipment only, then the network operates within safe parameters, but the vehicle cannot accommodate additional external equipment
Solution Approach 1:
The system dynamically evaluates electrical parameters (current consumption, power demand) of external equipment and compares them against the network's safe operating parameters. By monitoring these parameters in real-time and comparing them to established reference values, the system determines whether the network can safely accommodate additional equipment without compromising reliability.
3Productivity
If fuse ratings are modified to accommodate higher current consumption, then the network can handle external loads, but premature fuse ageing and overheating occur
Solution Approach 1:
The system establishes reference current consumption values during a learning phase before normal operation, creating a baseline for safe operating parameters. This preliminary characterization allows the system to detect when external equipment causes current consumption to exceed safe thresholds, preventing thermal stress and fuse degradation before they occur.
Solution Approach 2:
The system continuously monitors current consumption and provides feedback when values deviate from reference ranges. By comparing real-time measurements against established baselines and generating warnings when thresholds are exceeded, the system enables preventive action to avoid harmful thermal effects and fuse degradation.
4Measurement precision
If multiple measurement iterations are performed to establish reference values, then measurement precision is improved, but the time required for system initialization increases
Solution Approach 1:
The system performs multiple measurement iterations during a dedicated learning phase to establish accurate reference values for current consumption. By concentrating these measurements during initialization rather than during normal operation, the system achieves high measurement precision without continuously delaying operational responses.
Data Source
AI summary
A control method for determining an operational status of an electrical load of a heavy-duty vehicle includes measuring a global current consumption of the electrical network when the electrical load is not activated, detecting an activation of the electrical load, measuring the global current consumption of the electrical network after the electrical load has been activated, determining an electrical current consumption of the electrical load, determining a reference current consumption of the electrical load, if the difference between the determined electrical current consumption of the electrical load and the determined reference current consumption is higher than a first predetermined threshold and lower than a second predetermined threshold, the second predetermined threshold being higher than the first predetermined threshold, set the operational status of the electrical load to a first status called “nominal operation”.