Analysis and solutions for electrical damage mechanisms in DC motor controllers
直流电机控制器电损伤机理分析及解决方案

摘要

针对直流电机控制器因电损伤导致的可靠性问题，本研究构建了涵盖瞬态电场、热场与机械场多物理场耦合作用的损伤分析模型，揭示了浪涌电压、热应力与机械振动协同作用下的失效机制。“主动防护-智能诊断-寿命预测”一体化解决方案的提出包括开发基于TVS管与压敏电阻复合防护电路（残留电压<120V）、相变材料智能散热系统（温升抑制<10℃）及堆叠双向LSTM故障预测算法（准确率92%）。实验验证表明该方案使IGBT损坏率从12.3%降至0.9%，MTBF提升至12,000小时，满足ISO 26262 ASIL-C标准。研究成果已获3项发明专利，在工业机器人、新能源汽车等领域完成工程验证，为高精度运动控制技术突破提供理论支撑。

Abstract

To address reliability issues caused by electrical damage in DC motor controllers, this study constructed a damage analysis model that incorporates the multi-physics coupling of transient electric, thermal, and mechanical fields, revealing the failure mechanism under the synergistic effects of surge voltage, thermal stress, and mechanical vibration. The proposed integrated "active protection - intelligent diagnosis - life prediction" solution includes the development of a TVS diode and varistor composite protection circuit (residual voltage <120V), a phase change material intelligent heat dissipation system (temperature rise suppression <10°C), and a stacked bidirectional LSTM fault prediction algorithm with 92% accuracy. Experimental verification shows that this solution reduces the IGBT damage rate from 12.3% to 0.9% and increases the mean time-to-market (MTBF) to 12,000 hours, meeting the ISO 26262 ASIL-C standard. The research results have been awarded three invention patents and have been successfully validated in industrial robots, new energy vehicles, and other fields, providing theoretical support for breakthroughs in high-precision motion control technology.