Thermal fatigue reliability analysis of charging module based on Coffin-Manson model and Monte Carlo

In recent years, the charging equipment of new energy vehicles has developed rapidly. The failure of charging equipment can not only affect the customer experience, but also consume money and power. The data show that temperature is the influence of electronic products accounted for more than half of the factors. To solve this problem, based on FMMEA method, this paper analyzes the system principle of charging equipment, the thermal fatigue failure mechanism of charging module and the corresponding Coffin-Manson(C-M) failure physical model. According to the actual working condition of the charging equipment, the thermal stress simulation is carried out based on ANSYS Icepak. Combined with the simulation results and the CM failure physical model, the thermal fatigue failure analysis of the charging equipment was carried out. Finally, the failure analysis results are fitted to a function based on Weibull distribution and maximum likelihood estimation. The thermal reliability of the charging module was analyzed and evaluated based on the fitted function. The proposed method supports reduction of the operation and maintenance cost of the charging equipment and improving the reliability of the charging equipment.