Universal high-voltage direct-current distribution board

Abstract

A high voltage direct current distribution board is provided that enables two electromechanical power contactors to be mounted in a series direction or a parallel direction. Positions for mounting the fixed and movable contact terminal cavities of the two contactors are provided on a first main surface of the panel, and positions for mounting complementary assemblies of the two contactors are provided on a second main surface of the panel, each comprising a motor intended to drive the contact terminals of the respective contactor. On the first surface there is an installation location without any contact terminal cavities and fixed contacts, which is protected by a protection box with built-in diverters to ensure continuity of the electrical connection. According to the device, the insulation performance of a live part can be improved while the size is reduced.

Description

Technical Field

[0001] The present invention relates to the field of power distribution, in particular to power distribution in an aircraft, and more specifically to a universal high-voltage direct current power distribution board. Background Art

[0002] To distribute the power in the aircraft's power distribution network, power distribution units equipped with electromechanical power contactors (Kn and Kp) are usually used, designed to switch the high-voltage lines (HV+ and HV-) between the power supply and the load. The power contactors (Kn and Kp) are used on the one hand to switch on the power supply and on the other hand to isolate the lines.

[0003] Generally, in the power distribution process, contactors Kn and Kp are associated with other components such as pre-charging circuits. The pre-charging circuit is included in the HV+ line with contactor K1 and power resistor R1. In addition, current sensors are able to measure the current in the HV+ and HV- lines to control contactors Kp, Kn and K1 and provide current protection for the distribution lines. The control electronics start the motor used to drive the contactor. This assembly constitutes a BPMU (bus power management unit) that can be used, for example, between the high-voltage battery and the electric motor in the case of all-electric propulsion of small aircraft. This BPMU is an example of a high-voltage disconnect device with a pre-charging resistor.

[0004] Figure 1 An example general block diagram of such a BPMU is shown 10 .

[0005] like Figure 1 As shown, the BPMU 10 intended to be included in a power distribution unit includes a branch (pre-charge branch 12) connected in parallel with a Kp / Kn main switching element 14, which is located between the high voltage line HV+ and the low voltage line HV- of the power source and the load. The electromechanical contactors of this pair of Kp / Kn provide electrical isolation in the open state and provide very low impedance (one hundred millivolts at rated current) in the closed state. These electromechanical contactors are usually controlled by a control module 16 based on voltage and / or current information measured upstream and downstream of these contactors.

[0006] The components of the pre-charging parallel branch 12 (contactor K1 and current limiting resistor R1) have a defined impedance to generate a current I2 determined by the power supply voltage R1, which corresponds to the pre-charging current of the load (usually tens of amperes). The contactor K1 is also electromechanical to ensure electrical isolation in the disconnected state and is also controlled by the control module 16.

[0007] The physical implementation of the power distribution unit is based on boxes and / or panels. The specific arrangement of the different parts of the BPMU depends on the application, so each time the distribution unit must be "customized" to the application. Only the basic components (switches, motors, resistors, etc.) are universal products and constitute building blocks that can be reused in various applications. In short, the distribution unit is designed to adapt to various requirements based on mechanically combined discrete components.

[0008] In patent application FR22 01421, the applicant has proposed a universal electrical switchboard which combines a large number of components while allowing adaptation to the requirements of distribution and pre-charging operations in a high voltage direct current network.

[0009] Figure 2 shows a top view of an example 40 of a universal power distribution board in patent application FR22 01421, Figure 3 A bottom view is shown.

[0010] In this universal power distribution board, the contactors (e.g. contactors Kp, Kn) are integrated on a panel 40 which acts as a mechanical support for the assembly, making the solution compact and keeping electrical and mechanical interfaces to a minimum. The motor, auxiliary contacts and beams of the movable part are on one side of the panel, while the contact chambers (fixed and movable) are on the other side of the panel.

[0011] More specifically, the panel 40 has two opposing main surfaces 41 and 42. Four contact cavities 45a, 46a, 45b and 46b are mounted on the first surface 41, and these contact cavities accommodate the fixed and movable contact terminals of the contactors Kp and Kn. In order to prevent arcing, these contact cavities 45a, 46a, 45b and 46b can be, for example, vacuum cavities or oil-filled cavities.

[0012] On the first surface 41 of the panel, power connection terminal blocks 31a, 31b, 34a, 34b are also mounted to connect the panel to the distribution circuit and the power supply on the one hand and to the load or the grid on the other hand. Insulating screw protection caps 32a, 32b, 35a, 35b are provided to avoid the risk of short circuit between the two poles through external objects.

[0013] On the second surface 42 of the panel, complementary components 48a, 48b of the contactor and other components are mounted. Figure 2 In the example shown, other components include: a current probe 52, two resistors 54, 55, and a pre-charge contactor 56. Other components (such as fuses) may also be present, but are not shown.

[0014] The complementary assembly of contactors 48a, 48b comprises motors, auxiliary contacts of contactors Kp and Kn and the crossbar of the movable part. The motors are indicated in the figures by 51a and 51b. Motor 51a is used to drive Kp.

[0015] This universal panel 40 can be used to implement Figure 1 The circuit shown and other circuits. In particular, the universal panel enables the arrangement of complementary components of the contactor in two orthogonal directions, so that the motor can drive the contact terminals of different subassemblies of the contact chamber, thereby forming a parallel or series configuration of the contactor. The connection point 60 and the screw 61 enable the complementary components 48a, 48b of the contactor to be connected according to the desired configuration (series or parallel).

[0016] The arrangement of the components arranged on the second main surface 42 of the panel 40 leaves a free space, which constitutes a connection area of ​​two contactor complementary components. The size design of the connection area allows the complementary components of the contactor to be arranged along two orthogonal directions. In the first direction, each motor-driven contact terminal cavity of the contactor complementary component corresponds to a terminal of the first subassembly, and in the second direction, each motor-driven contact terminal cavity of the contactor complementary component corresponds to a terminal of the second subassembly, and the contact cavities of the first and second subassemblies are aligned along their respective orthogonal directions.

[0017] The center-to-center distance of the cavities of the plurality of contactors and the center-to-center distance of the plurality of contactor complementary assemblies are dimensioned so as to align the contacts of the two contactors with the corresponding motors of the contactor complementary assemblies along the first and second directions of the contactor complementary assemblies.

[0018] Thus, the modular universal panel with integrated contactors on the switchboard and allowing two arrangement configurations simplifies the adaptation process to the requirements of distribution and precharging operations in HVDC networks. The high integration of components on the switchboard makes it possible to optimize the mass and volume of the functions. The modularity of the solution also allows to meet different needs, thanks to the proposed configuration, making it universal.

[0019] However, the universal panel 40 can also be used to produce a circuit requiring only two contactors, ie, a circuit omitting Kp or Kn, in which case two contact cavities at corresponding positions on the panel surface 41 can be omitted for each omitted contactor. Figure 4 The area 47a on the universal panel is shown, where the fixed contacts 371, 372 are located when no contact cavity is installed at a certain position on the panel surface 41: Figure 4 In the example shown, the contact cavity 45a is omitted from the device.

[0020] like Figure 4As shown, when a contact cavity is not installed at a certain position on the panel surface 41, the fixed contact is no longer insulated and the power connection is interrupted. To date, in order to protect the fixed contact in this case, an insulating cover 50 is installed on the panel surface 41, and the insulating cover 50 covers the area 35a where the fixed contact is located. To provide power connection, a power bar 30 and related connecting elements 39 (terminals, etc.) are added to the assembly. Such a configuration is as shown in FIG. Figure 5 As shown (showing the case where the contact cavity 45b is omitted in the device).

[0021] Therefore, this prior art approach involves adding electrical connection components (terminals, power bars, nuts and bolts) and insulating covers to cover the fixed contacts, which increases the bulk of the device. Figure 5 shown.

[0022] also, Figure 5 The power strip shown includes mechanical components to make the electrical connections in the case of a configuration using two contactors. These connections are not fully insulated and therefore have bare, live metal parts exposed. This can be hazardous to maintenance operators or a source of electrical faults if foreign metal objects are present in the area.

[0023] The present invention aims to remedy the above-mentioned drawbacks. Summary of the invention

[0024] Therefore, the main object of the present invention is to provide a modular universal power distribution board with integrated contactors, which can be configured to adapt to the distribution and pre-charging working requirements in the high voltage DC network, including adapting to the lack of movable contacts in the installation positions provided on the panel.

[0025] These objects are achieved by a high voltage DC switchboard, characterized in that:

[0026] Positions for mounting fixed and movable contact terminal cavities of two electromechanical contactors are provided on the first main surface of the panel, and a pair of fixed contacts are provided at each contact cavity mounting position, and positions for mounting complementary components of the two contactors are provided on the second main surface of the panel, each of which includes a motor for driving the contact terminal of the corresponding contactor,

[0027] A protective component is installed at at least one contact cavity installation position to replace the movable contact. The protective component includes an insulating cover that defines a closed space with the panel surface. An electrical connection shunt is arranged in the closed space for connecting a pair of fixed contacts to each other.

[0028] The panel with the above configuration can achieve optimal integration and can connect fixed contacts with a smaller volume.

[0029] In a preferred embodiment, the protective component of the high voltage switchboard comprises a pressure spring, which is used to push the connecting shunt toward the fixed contact. In this way, the continuity of the current path can be more reliably ensured.

[0030] In a preferred embodiment, the high voltage DC switchboard includes a pre-charging function, which can significantly reduce the mass and volume compared to previous devices with a pre-charging function.

[0031] The present invention also relates to a high-voltage direct current distribution unit equipped with the above-mentioned high-voltage distribution board. In a preferred embodiment, the above-mentioned high-voltage distribution board is installed between the energy storage unit and the high-voltage direct current (HVDC) bus of the aircraft. Advantageously, the energy storage unit can be a battery or a supercapacitor.

[0032] The present invention also relates to an aircraft power distribution network comprising the above power distribution unit. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Other features and advantages of the invention will become apparent from the following description with reference to the accompanying drawings, which illustrate an exemplary embodiment of the invention but are not limited thereto, in which:

[0034] Figure 1 A general block diagram of an example of a power distribution unit equipped with an electromechanical power contactor in the prior art is shown.

[0035] Figure 2 A top view of a generic high voltage DC switchboard is shown, wherein complementary assemblies of power contactors are arranged along a first direction.

[0036] Figure 3 Shown Figure 2 Bottom view of the medium and high voltage switchboard.

[0037] Figure 4 Shown Figure 2 The uncovered fixed contact area on the lower surface of the medium and high voltage DC distribution board.

[0038] Figure 5 A prior art power strip for protecting the stationary contact area is shown.

[0039] Figure 6 is a schematic diagram showing a side equipped with Figure 5 The power strip shown has a panel on one side equipped with a protection component according to an embodiment of the present invention.

[0040] Figure 7 yes Figure 6 A cross-sectional view of an example of a protective component is shown in FIG. Specific implementation plan

[0041] The present invention is based on the configuration of a high voltage switchboard so as to integrate a large number of components while being able to accommodate the requirements of distribution and pre-charging operations in a high voltage DC network, including accommodating the absence of contact terminal cavities in the locations provided on the panel.

[0042] This panel is particularly useful for producing lightweight BPMUs. Its overall block diagram is similar to Figure 1 For example, in the case of all-electric propulsion of a small aircraft, such a lightweight BPMU can be used between a high-voltage energy storage device (such as a battery or supercapacitor) and an electric motor.

[0043] As described in patent application FR22 01421, the panel is designed so that contactors Kp and Kn can be mounted on the same panel in two directions, thanks to a carefully chosen geometry and center-to-center distance. To this end, positions are provided on one of the main surfaces of the panel for mounting four contact cavities intended to accommodate the fixed and movable contact terminals of contactors Kp and Kn. However, depending on the application, it may be necessary to use only one of the two contactors (Kn and Kp).

[0044] According to one example, the panel houses a high-voltage DC contactor K1 for a pre-charging line on the power line HV+, a power resistor R1 for current limitation in the pre-charging line on the HV+ line, current sensors on the HV+ and HV- lines, a high-voltage DC contactor Kp on the HV+ line or a high-voltage DC contactor Kn on the HV- line, and control electronics for contactors Kp / Kn and K1 and current measurement management.

[0045] According to this example, since the device only accommodates one of the two contactors (Kn and Kp), it is not necessary to install all four fixed and movable contact terminal cavities. More specifically, one movable contact can be omitted. Therefore, there is no contact cavity at the location on the panel for mounting the contact terminal cavity. Since a pair of fixed contacts are set at this location, according to one embodiment of the present invention, a new component is provided to protect the fixed contacts and provide power connection. This is a component equivalent to a subassembly for protecting the fixed contacts, which includes an integrated electrical shunt (conductive connection, such as a metal connection), which replaces and is located at the position of the movable contact that was originally to be arranged on the fixed contact.

[0046] This solution provides panel configurability while ensuring the safety of the electrical connections, as the connections made through the shunts are covered and fully insulated.

[0047] Figure 6 A panel 100 is shown having an integrated protective component 200 according to one embodiment of the present invention, and Figure 5 A power strip 30 of the method shown. Figure 6 The rectangle R in indicates an area corresponding to the configuration of the embodiment of the present invention.

[0048] To simplify the description, Figure 6 Zhongyu Figures 2 to 5 Like elements shown in FIG. 1 are indicated by equivalent reference numerals preceded by the numeral 1 (e.g., Figure 6 The contact cavity 146a in is equivalent to Figure 3 Therefore, the description of the related elements will be omitted or simplified below.

[0049] exist Figure 6 In the figure, the two configurations are shown side by side so that these configurations can be compared intuitively, thereby better understanding the advantages brought by the invention, especially in terms of the reduced volume occupied by the solution of the invention. However, those skilled in the art will understand that in practical applications, it is best to use only the solution provided by the invention, that is, to use the protective component 200 in all contact terminal cavity installation positions without any contact / movable contact cavity.

[0050] The protection component 200 includes a conductive connection (eg, according to Figure 7 The conductive connection is configured to be used as a power connection shunt, that is, to provide power connection by connecting a fixed contact located at a contact cavity mounting position of the mounting protection component 200. The protection component 200 further includes an insulating cover 201.

[0051] Figure 6 The difference in integration and volume between the prior art solution and the embodiment of the invention is shown in the rectangular area R. The installation of the components on the left corresponds to the prior art, with the power bar being bare and exposed. The installation depicted on the right shows an embodiment aimed at optimizing the volume and eliminating the live bus bar.

[0052] The embodiment adopted can omit the terminal 139, the power bar 130 and the insulating cover 150 that are not covered with insulating material.

[0053] The panel 100 comprises a board 110 which serves as a "mechanical" structure supporting the assembly. According to one embodiment of the invention, the board 110 is made of epoxy resin, for example of the FR4 or FR5 type.

[0054] Panel 100 houses the following components:

[0055] - power terminal blocks 31a, 31b, 34a, 134b, connecting the panel to the distribution circuit, to the power supply, on the one hand, and to the load or the grid, on the other hand;

[0056] - insulating screw protection caps 32a, 32b, 35a, 35b, for avoiding the risk of short circuits between the two poles through external objects;

[0057] - contactor contact chambers 46a, 46b, 46A, 46b; and

[0058] A protection component 200 , which corresponds to a subassembly with an integrated shunt.

[0059] like Figure 6 As shown, using the protection component 200 can reduce the number of components and achieve better integration, which can save mass and make modularization as simple as possible. Then, different configurations of the power contact shunt subassembly 200 of a universal high voltage direct current (HVDC) power distribution device can be standardized.

[0060] Figure 7 Shown Figure 6 FIG. 2 is a cross-sectional view of an exemplary embodiment of a protective component 200. According to this example, the protective component 200 is composed of the following elements:

[0061] - Movable connecting strip 212: used for power transmission between two contact pads;

[0062] Retaining screw 213: used to connect the movable bar and the translation axis;

[0063] Contact pad 214: used to transfer power between the high voltage power bar and the movable contact;

[0064] Axis 215, which allows contact to be made by translation and maintains the contact pressure between the contact pad and the power bar in the activated state. In the idle state, it ensures that the contacts are separated.

[0065] As long as the protective component 200 includes a power connection shunt for connecting the fixed contacts and insulation provided by a cover or other means, it can be relatively Figure 7 The examples shown can be modified, for example, according to the application requirements or the designer's wishes. For example, a spring can be added to strengthen the connection.

[0066] According to other embodiments of the present invention, the above-mentioned panel is integrated into a power distribution unit, such as a power distribution unit installed between an energy storage unit and a high voltage direct current (HVDC) bus of an aircraft.

[0067] According to other embodiments of the present invention, an aircraft power distribution network includes a high voltage DC power distribution unit with the above-mentioned integrated panel.

[0068] The present invention has specific applications in the aviation industry and the automotive industry, for example, applications related to power generation channels, high voltage DC batteries, fuel cells, primary power distribution, secondary power distribution, electric propulsion, hybrid propulsion, etc.

[0069] The device provided by the present invention can reduce the number of components and achieve better integration to save mass and make modularization as simple as possible. Different configurations of power contact shunt subassemblies of universal high voltage direct current (HVDC) power distribution panels can then be adapted and standardized.

Claims

1. A high voltage DC switchboard (100) having two opposite main surfaces, characterized in that: Positions for mounting fixed and movable contact terminal cavities of two electromechanical contactors are provided on a first main surface (41) of the panel, a pair of fixed contacts (371, 372) are provided at each contact cavity mounting position, and positions for mounting complementary components of the two contactors are provided on a second main surface (42) of the panel, each of the components comprising a motor for driving the contact terminals of the corresponding contactor, A protective component (200) is installed at at least one contact cavity installation position (47a) to replace the movable contact, and the protective component (200) includes: an insulating cover (201), the insulating cover and the panel surface define a closed space, and an electrical connection shunt for connecting a pair of fixed contacts (371, 372) to each other is arranged in the closed space.

2. The high voltage DC distribution board according to claim 1, characterized in that: The protection component (200) comprises a pressure spring, which is used to push the connection shunt toward the fixed contacts (371, 372).

3. A high voltage DC distribution board as claimed in claim 1 or 2, comprising a pre-charging function.

4. A high voltage direct current (HVDC) power distribution unit installed between an energy storage unit and a high voltage direct current (HVDC) busbar of an aircraft, the power distribution unit comprising a panel as claimed in any one of claims 1 to 3.

5. The power distribution unit according to claim 4, characterized in that: The energy storage unit is a battery or a supercapacitor.

6. A power distribution network for an aircraft, comprising the high voltage direct current power distribution unit according to claim 4 or 5.

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