Transcript AC Power Switch

Phantom Works - HSV
Arc Fault Programmable Solid State Circuit
Breaker with Damaged Wire
Detector/Locator
John H. Blumer
Boeing Huntsville
[email protected]
System Vision
It is the vision of the Power Management and Distribution System Team
to develop a suite of power system building block products (Programmable
Solid State Circuit Breakers, Arc Fault Protection Devices, Damage Wire
Detectors/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 and
Distribution System Teams System Vision.
30 May 2002
2
Legacy
• The legacy for this technology is the Solid State Power Controller
Module operational on the International Space Station
- 50 Line Replaceable Units (LRU) in Production
- 12 Completed
- 6 On Orbit
30 May 2002
3
Legacy (continued)
• 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, generated
arcs for study and standardized arc test methodologies.
•Application Specific Integrated Circuits (ASIC) design capabilities.
30 May 2002
4
Digitally Programmable Solid State Power Controller - Demonstrator
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.
DPSSPC Functional Prototype
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.
30 May 2002
CHANNEL COMMAND
SET AND STORE CURRENT MAXIMUM LIMIT
SET AND STORE VOLTAGE MIN/MAX LIMIT
SET AND STORE TEMPERATURE MIN/MAX LIMIT
CHANNEL ON/OFF
DATA
INTERFACE
OUTPUT
CHANNEL
1
POWER
OUTPUT 1
OUTPUT
CHANNEL
2
POWER
OUTPUT 2
OUTPUT
CHANNEL
3
POWER
OUTPUT 3
OUTPUT
CHANNEL
4
POWER
OUTPUT 4
MICROCONTROLLER
HEALTH STATUS PER CHANNEL
CURRENT READINGS
VOLTAGE READINGS
TEMPERATURE READINGS
TRIP EVENT (I, V, T)
VERIFY CHANNEL ON/OFF
OUTPUT CHANNEL OPERATING PARAMETERS
SAFE
MODE
CIRCUIT
Digitally Programmable SSPC
5
Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc
Detection And Damaged Wire Detector/Locator Module
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
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
30 May 2002
6
AC Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With
Arc Detection And Damaged Wire Detector/Locator Module
Power Input
Power Common
Solid State Switch Devices
and Temperature Sensors
Power Output
DWDL Module Power
Output Interface
Secondary Power
Interface
Switch/Monitor Module
Controller Module
CANbus Interface
Arc Fault Detector and
Damaged Wire
Detector/Locator Module
RS232 Interface
Secondary Power Module (optional)
30 May 2002
7
Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc
Detection And Damaged Wire Detector/Locator Module
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)
HEALTH STATUS PER CHANNEL
CHANNEL COMMAND
CURRENT READINGS
Modular component design
SET AND STORE CURRENT MAXIMUM LIMIT
VOLTAGE READINGS
– Interface Module
– Controller Module
– Switch Monitor Module
– Arc Detection/DWDL Module
– Secondary Power Module (Optional)
 Safety issues:
– Output pulldown when switch is OFF
SET AND STORE VOLTAGE MIN/MAX LIMIT
SET AND STORE TEMPERATURE MIN/MAX LIMIT
CHANNEL ON/OFF
INTERFACE
MODULE
ON/OFF
TRIP INDICATOR
SYNC SIGNAL
– 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.




TEMPERATURE READINGS
TRIP EVENT (I, V, T)
VERIFY CHANNEL ON/OFF
OUTPUT CHANNEL OPERATING PARAMETERS
DISCRETE
INTERFACE
uCNTLR
VIN
SWITCH
CONTROL/MONITOR
CIRCUITRY
OUTPUT
CHANNEL
POWER
OUTPUT
SWITCH/MONITOR MODULE
GFCI CIRCUIT
ARC DETECT CIRCUIT
CONTROLLER
MODULE
DAMAGED WIRE CIRCUIT
ARC FAULT AND
DAMAGED WIRE DETECTOR/LOCATOR
MODULE
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.
30 May 2002
8
Arc Fault Detection And Damaged Wire Detector/Locator Module
Module Functional Makeup
The AFD and DWDL Module consist of
DWDL MODULE
GFCI CIRCUIT
 Arc Fault Detector Module
– Boeing Invention Disclosure No. 02-0528
 Damaged Wire Detector/Locator Module
– Boeing Invention Disclosure No. 02-0527
 GFCI Circuitry
ARC FAULT
DETECTOR MODULE
DWDL 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.
ARC FAULT
DETECTOR MODULE
30 May 2002
9
PSSCB/S Trip Curve
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
35
30
25
Vdiff
20
15
10
5
0
0
2
4
6
8
10
12
14
Time (in Sec)
30 May 2002
10
PSSCB/S Trip Curve
Established Trip Curve Modeling
 Standard circuit breaker curve.
BACC18AD Circuit Breaker
800
700
600
% Load
500
400
300
200
100
0
0
10
20
30
40
50
60
Time (in Sec.)
30 May 2002
11
Phantom Works - HSV
PSSCB/S, AFD and DWDL Module
In-System Maintenance Interface
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.
30 May 2002
13
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
30 May 2002
14