Scientific Development Research

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.

DC motor controller; Electrical damage mechanism; Multi-physics field coupling; Intelligent diagnosis; Protection technology