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Technical Paper

Data-driven Modeling of Thermal Fuses

Both the integration of safety-critical electrical systems and the increasing power requirements in vehicles present a challenge for electrical distribution systems in terms of reliability, packaging, weight, and cost. In this regard, the wire protection device is a key element, as it determines the reliability of the short circuit detection, the immunity against false tripping, and the wire diameters. Currently, in most cases, thermal fuses are used, due to their low cost and robust design. However, the description of their tripping behavior based only on steady-state currents is insufficient for the increasingly complex current profiles in vehicles. Thus, to achieve an optimum dimensioning of a fuse-wire combination, a profound understanding of the thermal behavior of both components under dynamic load conditions is mandatory. However, the FEM tools used for the thermal design of fuses are relatively slow, require huge calculation resources, and must be well-parameterized.