Monitoring systems and methods for detecting thermal-mechanical strain fatigue in an electrical fuse

1. An electrical fuse fatigue assessment system comprising:

a controller monitoring a fuse fatigue parameter of an electrical fuse over a period of time while the electrical fuse is connected to an energized electrical power system; and

a circuit connected in electrical parallel with the electrical fuse, the circuit including a current source injecting current across the electrical fuse;

wherein the controller measures a resistance of the electrical fuse based on the injected current across the electrical fuse;

wherein the controller assesses the monitored fuse fatigue parameter in reference to the measured resistance; and

wherein, based on the assessed monitored fuse fatigue parameter, the controller determines at least one of a consumed service life of the electrical fuse or a service life remaining of the electrical fuse.

2. The system of claim 1 , wherein the assessed monitored fuse fatigue parameter includes a change in measured resistance, a change in mechanical strain, or an accumulated damage component.

3. The system of claim 1 , wherein the current source injects an AC current at a preset frequency across the electrical fuse.

4. The system of claim 3 , wherein the controller compares the measured resistance to a predetermined fuse fatigue resistance plot for the electrical fuse.

5. The system of claim 1 , wherein the controller, using the measured resistance, calculates a current flowing through the electrical fuse; and

wherein the controller further calculates a strain associated with the current flowing through the electrical fuse.

6. The system of claim 5 , wherein the controller compares the calculated strain to a predetermined fuse fatigue strain plot for the electrical fuse.

7. The system of claim 1 , wherein the controller, using the measured resistance, calculates a current flowing through the electrical fuse; and

wherein the controller further calculates a fatigue damage component based on a detected number of current peaks in a predetermined range and a total number of cycles to failure at the calculated strain.

8. The system of claim 7 , wherein the controller further accumulates the calculated fatigue damage components over time; and

wherein the controller further compares the accumulated calculated fatigue damage components to 1 to determine the at least one of a consumed service life of the electrical fuse or a service life remaining of the electrical fuse.

9. The system of claim 1 , wherein the controller communicates information regarding the at least one of a consumed service life of the electrical fuse or the service life remaining of the electrical fuse.

10. The system of claim 9 , wherein the controller wirelessly communicates the information.

11. The system of claim 1 , wherein the controller identifies a type of fault current in the energized electrical power system.

12. The system of claim 11 , wherein the controller communicates the identified type of fault current.

13. The system of claim 12 wherein the controller wirelessly communicates the identified type of fault current.

14. The system of claim 11 , wherein the controller identifies the fault current based on an assessment window of a predetermined duration.

15. The system of claim 1 , wherein the controller is built-in to the electrical fuse.

16. The system of claim 1 , wherein the controller is built-in to a fuse holder.

17. The system of claim 1 , wherein the controller is built-in to a disconnect switch.

18. The system of claim 1 , further comprising at least one of a reader device or a remote device in communication with the controller.

19. The system of claim 1 , wherein the electrical fuse includes a metal fuse element stamped into a geometry including at least one weak spot.