A novel matrix topology-based analysis method of thermal circuits for reliability optimization of HSER

Hermetically Sealed Electromagnetic Relay (HSER), used in aviation and aerospace, demands high reliability due to its critical applications. Given its complex operating conditions, efficient thermal analysis is essential for optimizing reliability. The commonly used Finite Element Method (FEM) is often time-consuming and may not be efficient or adaptable for complex multi-dimensional system calculations and design processes. This paper introduces an analysis method for thermal networks based on matrix perspective technology, encompassing matrix transformation, backpropagation of the heat path model, temperature rise calculation, solution comparison, and product implementation. Using the similarity theory of heat circuits, a basic thermal unit is established. Based on the fundamental connection between key components, a thermal network for a typical HSER is designed. An experimental system is set up, and the thermal network model's accuracy is confirmed using test data. Employing the topology analysis method, the topology of the thermal network is analyzed under both coil-energized and de-energized states. Potential thermal paths are identified, leading to optimized solutions for the HSER. Utilizing these solutions, the thermal path matrix topology model is backpropagated to the thermal path for temperature rise calculations. When compared to prototype HSER test data, the efficiency and accuracy of this matrix topology-based analysis method are confirmed.