phantom works - hsv arc fault programmable solid state circuit breaker with damaged wire...
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Phantom Works - HSV
Arc Fault Programmable Solid State Circuit Breaker with Damaged Wire
Detector/Locator
John H. BlumerBoeing Huntsville
30 May 2002 2
System Vision
It is the vision of the Power Management and Distribution System Teamto develop a suite of power system building block products (Programmable Solid State Circuit Breakers, Arc Fault Protection Devices, Damage WireDetectors/Locators and Wire Inspection Systems) that will provide the Safety, Quality, Reliability and Cost Effectiveness required by our customers for use on Aircraft, Ground, Sea and Industrial Platforms.
Thrust
To license or partner the building block products for production to a vendor and/or vendors that will support the Power Management andDistribution System Teams System Vision.
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• The legacy for this technology is the Solid State Power ControllerModule operational on the International Space Station
- 50 Line Replaceable Units (LRU) in Production- 12 Completed- 6 On Orbit
Legacy
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• The Arc Fault Programmable Solid State Circuit Breaker is a Boeing funded technology.
- One patent pending- Foreign Patent Application- Three invention disclosure, submitted in 2002
•Design and integration of electrical interconnect system on many aircraft, space and ground platforms.
•Developed methods to characterize airplane load inrushes, generatedarcs for study and standardized arc test methodologies.
•Application Specific Integrated Circuits (ASIC) design capabilities.
Legacy (continued)
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Digitally Programmable Solid State Power Controller - Demonstrator
Design Accomplishments Patent Pending (09/842,967). Foreign patent applied for. 28V 10A version assembled, tested and in
demonstration stage. Proved that multiple SSPC outputs could be controlled
and monitored using a single microcontroller.
Design Status Can be readily modified for 28V 20A, 120Vdc or 270Vdc
operation without relay out of PCB. Built using COTS materials. Studies to upgrade for space environment applications. Design is a test bed for Silicon Carbide (SiC)
technology.
DPSSPC Functional Prototype
The Digitally Programmable Solid State Power Controller was developed as a base for a power management and distribution system to meet the needs of future and existing platforms requirements for safe circuit protection devices on aircraft, space platforms, automobiles and the power industry. This generation of Solid State Power Control and Distribution Technology is currently patent pending. Functional demonstrations were given to show the diversity of the design. This demonstration is 28Vdc 1 to 10 Amps and is capable of controlling sixteen (16) output channels. The proven functions of this design is being integrated into the next generation smaller and cost efficient packages.
POWEROUTPUT 1
POWEROUTPUT 2
POWEROUTPUT 3
POWEROUTPUT 4
SAFEMODE
CIRCUIT
CHANNEL COMMANDSET AND STORE CURRENT MAXIMUM LIMITSET AND STORE VOLTAGE MIN/MAX LIMIT
SET AND STORE TEMPERATURE MIN/MAX LIMITCHANNEL ON/OFF
Digitally Programmable SSPC
HEALTH STATUS PER CHANNELCURRENT READINGSVOLTAGE READINGS
TEMPERATURE READINGSTRIP EVENT (I, V, T)
VERIFY CHANNEL ON/OFFOUTPUT CHANNEL OPERATING PARAMETERS
OUTPUTCHANNEL
1
OUTPUTCHANNEL
2
OUTPUTCHANNEL
3
OUTPUTCHANNEL
4
DATAINTERFACE
MICROCONTROLLER
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AC PSSCB/S Characteristics Output configurable:
– 120VAC, 25A 1phase
– 60HZ, 400Hz and variable frequency
– Gang together for multi-phase operation
– Drive Y or Delta configurations Zero crossing and Phase detection.
AC PSSCB/S WITH ARC DETECTION/DWDL MODULE
Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module
DC PSSCB/S Characteristics Output configurable:
– 28VDC, up to 25A
– Outputs can be paralleled for higher current operation
120VDC versions available 270VDC versions being evaluated
New Technology Applications for AC and DC IGBT alternative for higher voltage and current
switchgear SiC MOSFET devices will be integrated and evaluated
upon availability DC PSSCB/S WITH ARC DETECTION/DWDL MODULE
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Switch/Monitor Module
Controller Module
Arc Fault Detector and Damaged Wire Detector/Locator Module
Secondary Power Module (optional)
DWDL Module Power Output Interface
Solid State Switch Devices and Temperature Sensors
Power Input
Power Output
CANbus Interface
RS232 Interface
Secondary Power Interface
Power Common
AC Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module
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AC and DC PSSCB/S Common Features Boeing Invention Disclosure No. 02-0526 “A Remotely Programmable Solid State Circuit Breaker/Switch With
Integrated Arc Detector And Damaged Wire Detector/Locator for AC or DC Applications” Microcontroller controlled Solid State Power Controller (SSPC). Integrated overcurrent, over/under voltage and over/under temperature monitoring. User selectable current, voltage and temperature limits from Maintenance Testing Equipment. Integrated Arc Fault, GFCI and Damaged Wire detection. Serial data bus interface. (RS232 and CANbus) Modular component design
– Interface Module
– Controller Module
– Switch Monitor Module
– Arc Detection/DWDL Module
– Secondary Power Module (Optional) Safety issues:
– Output pulldown when switch is OFF
– Ground Fault Circuit (GFCI) Interrupt protection
– No startup if DWDL detects cable or connector changes
– No re-startup if arc event was previously detected
– Output placed in safe mode in case of microcontroller failure Can be integrated into rack systems. Reduces weight through cable reduction by being at load locatable. Provides health and operating status to system. Can be be controlled without a serial data interface via discrete ON/OFF and TRIP INDICATOR signals. Watchdog circuitry for placing switch in safe mode due to microcontroller failure. Soft-start up circuitry. Firmware upgradable via serial maintenance port.
Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module
POWEROUTPUT
VIN
OUTPUTCHANNEL
SWITCHCONTROL/MONITOR
CIRCUITRY
SWITCH/MONITOR MODULE
DISCRETEINTERFACE
INTERFACEMODULE
CONTROLLERMODULE
uCNTLR
CHANNEL COMMANDSET AND STORE CURRENT MAXIMUM LIMITSET AND STORE VOLTAGE MIN/MAX LIMIT
SET AND STORE TEMPERATURE MIN/MAX LIMITCHANNEL ON/OFF
ON/OFFTRIP INDICATOR
SYNC SIGNAL
ARC FAULT ANDDAMAGED WIRE DETECTOR/LOCATOR
MODULE
DAMAGED WIRE CIRCUIT
GFCI CIRCUIT
ARC DETECT CIRCUIT
HEALTH STATUS PER CHANNELCURRENT READINGSVOLTAGE READINGS
TEMPERATURE READINGSTRIP EVENT (I, V, T)
VERIFY CHANNEL ON/OFFOUTPUT CHANNEL OPERATING PARAMETERS
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Arc Fault Detection And Damaged Wire Detector/Locator Module
Module Functional MakeupThe AFD and DWDL Module consist of Arc Fault Detector Module
– Boeing Invention Disclosure No. 02-0528 Damaged Wire Detector/Locator Module
– Boeing Invention Disclosure No. 02-0527 GFCI Circuitry
ARC FAULTDETECTOR MODULE
DWDL MODULE GFCI CIRCUIT
DWDL MODULE
ARC FAULTDETECTOR MODULE
Design Concept Base The PSSCB/S provides arc fault protection via:
– Monitoring for an arc signature
– Ground Fault Circuit Interrupt (GFCI)
– Current Limiting capability of PSSCB/S
– Output shutdown via PSSCB/S upon arc event This approach is applicable to AC and DC devices. Detects parallel and series arcs. GFCI monitoring. Damaged wire detector utilizes Time Domain
Reflectometry (TDR) practices.
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Embedded Trip Curve Capabilities Firmware configurable trip curve. Maximum current limiting is component dependent. Trip time in current limit depends on voltage drop across MOSFET.
DC Current Limit
0
5
10
15
20
25
30
35
0 2 4 6 8 10 12 14
Time (in Sec)
Vd
iff
PSSCB/S Trip Curve
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Established Trip Curve Modeling Standard circuit breaker curve.
PSSCB/S Trip Curve
BACC18AD Circuit Breaker
0
100
200
300
400
500
600
700
800
0 10 20 30 40 50 60
Time (in Sec.)
% L
oa
d
Phantom Works - HSV
PSSCB/S, AFD and DWDL ModuleIn-System Maintenance Interface
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PSSCB/S Control and Analysis Display
PSSCB/S Maintenance Display Allows for control and testing of power devices in-system from the maintenance testing equipment without having to enter a
vehicle. Maintenance personnel can analyze fault data and set operating parameters from the maintenance testing equipment. Fault data can be time stamped by the master control system and stored for further analysis. The type of fault is indicated on this display.
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Damaged Wire Detector/Locator Maintenance and Analysis Display
DWDL Maintenance Display Left view shows data stored from initial training session on a fifty foot wire with load. Right view shows data from a short that is located approximately 12 1/2 feet down the same fifty foot wire with load. Maintenance personnel can train the DWDL Module and analyze fault data from the maintenance testing equipment. Additional testing can be initiated from the maintenance testing equipment without having to enter a vehicle or disconnect
cables to hookup wire testing equipment