Effective Monitoring and Early Warning of Electric Vehicle Fuse Status
To achieve effective status monitoring and early warning for electric vehicle fuses, the following methods can be employed:
1. Current Monitoring
Install High-Precision Current Sensors:
Install high-precision current sensors in the circuit to monitor the current passing through the fuse in real time. When the current exceeds a certain percentage of the fuse's rated current (e.g., 80%), the system should issue an early warning, indicating a potential overload risk. This prompts further inspection of the circuit and load conditions.
Analyze Current Change Trends:
Use an intelligent monitoring system to analyze trends in current changes. If the current rises sharply over a short period, it may indicate an impending short circuit or other faults. In such cases, an alarm should be triggered immediately to prompt the user to stop the vehicle and conduct a thorough inspection.
2. Temperature Monitoring
Use Temperature Sensors:
Install temperature sensors near the fuse. Since fuses heat up during overloads or poor contact, the system should issue a high-temperature warning when the temperature exceeds a set threshold (e.g., 30°C above ambient temperature). This indicates potential failure risks and necessitates checking the fuse and related circuits.
Thermal Imaging Monitoring:
Regularly scan the fuse box and surrounding circuits using a thermal imager. This allows visual observation of fuse heating through thermal images, enabling early detection of potential overheating areas for timely maintenance and repair.
3. Voltage Monitoring
Detect Voltage Drop:
Determine the fuse's status by measuring the voltage drop across it. When the fuse ages or experiences poor contact, its resistance increases, leading to an elevated voltage drop. If the voltage drop exceeds the normal range, the system should issue a fault warning, prompting replacement of the fuse or inspection of the connection point.
Monitor Power Supply Voltage:
Continuously monitor the output voltage of the electric vehicle's power supply. Abnormal voltage fluctuations or sudden drops may indicate a blown fuse or other circuit faults. In such scenarios, an alarm should be triggered immediately to alert the user to check the vehicle's electrical system.
4. Regular Inspection and Maintenance
Develop an Inspection Plan:
Create a reasonable fuse inspection plan based on the vehicle's usage frequency and operating environment. Generally, visual inspections of the fuse are recommended every 5,000–10,000 kilometers or every 3–6 months to check for abnormalities such as ablation, discoloration, or deformation.
Use Professional Testing Equipment:
Regularly employ professional electrical testing equipment, such as multimeters and insulation resistance testers, to assess the fuse's resistance and insulation performance. This helps identify potential fault hazards and ensures the fuse remains in optimal working condition.
5. Intelligent Early Warning System
Data Fusion and Analysis:
Integrate and analyze monitoring data from current, temperature, and voltage sensors. Use intelligent algorithms to assess the fuse's status by establishing fault models and setting thresholds. When monitoring data matches a specific fault pattern, the system should automatically issue accurate fault warnings, specifying the fault type and possible location.
Remote Monitoring and Reminders:
Leverage Internet of Vehicles (IoV) technology to remotely transmit fuse status data to the owner's mobile app or vehicle management platform. In case of abnormalities, push notifications or SMS alerts should be sent promptly to the owner, enabling timely action to ensure driving safety.
