Digital Twin Enabled Smart E Fuse with Battery SOC and Harness Health Monitoring

This paper presented a four-channel smart e-fuse architecture that protects two LED loads and two DC motors with independent MOSFET switches. Current and MOSFET temperature are measured on every channel, battery measurements support SOC estimation and priority-based motor load shedding, and paired voltage measurements identify added harness resistance. The ESP32 performs deterministic protection and transfers structured data over UART, while the PC maintains synchronized branch, battery, and harness digital twins. The principal design decision is to keep the trip, low-SOC shedding, and critical-harness response independent of communication and AI prediction. This makes the platform suitable for controlled experiments in selective protection, motor-stall detection, thermal monitoring, battery-aware energy management, connector degradation detection, serial data integrity, and predictive warning. The dashboard makes all parameters and the GOOD-to-CRITICAL harness condition visible, while the proposed validation matrix defines the evidence required before numerical performance claims are made.

[1] Espressif Systems, ESP32 Series Datasheet, Version 5.3, 2026. [2] Texas Instruments, ADS111x Ultra-Small, Low-Power, I2C-Compatible, 860-SPS, 16-Bit ADCs with Internal Reference, Oscillator, and Programmable Comparator, Rev. E. [3] F. Tao, J. Cheng, Q. Qi, M. Zhang, H. Zhang, and F. Sui, “Digital twin-driven product design, manufacturing and service with big data,” International Journal of Advanced Manufacturing Technology, vol. 94, pp. 3563-3576, 2018, doi: 10.1007/s00170-017-0233-1. [4] F. T. Liu, K. M. Ting, and Z.-H. Zhou, “Isolation Forest,” Proceedings of the 2008 IEEE International Conference on Data Mining, pp. 413-422, 2008, doi: 10.1109/ICDM.2008.17. [5] L. Breiman, “Random Forests,” Machine Learning, vol. 45, pp. 5-32, 2001, doi: 10.1023/A:1010933404324. [6] G. L. Plett, “Extended Kalman filtering for battery management systems of LiPB-based HEV battery packs: Part 1. Background,” Journal of Power Sources, vol. 134, no. 2, pp. 252-261, 2004, doi: 10.1016/j.jpowsour.2004.02.031. [7] R. S. Timsit, “Electrical contact resistance: properties of stationary interfaces,” IEEE Transactions on Components and Packaging Technologies, vol. 22, no. 1, pp. 85-98, 1999, doi: 10.1109/6144.748837. [8] IEC 60747-8, Semiconductor devices - Discrete devices - Part 8: Field-effect transistors. [9] ISO 26262, Road vehicles - Functional safety, second edition, 2018. [10] Scikit-learn Developers, “Novelty and Outlier Detection,” Scikit-learn User Guide.