SSPC hardware device integrated with arc detection

Abstract

The invention provides an SSPC hardware device integrated with arc detection. The SSPC hardware device integrated with arc detection is integrated with a multi-parameter acquisition module, an arc detection processing module and an SSPC control and fault isolation module, and the SSPC control and fault isolation module comprises a power switch. The multi-parameter acquisition module is used for acquiring various electrical parameters of the power switch; and the arc detection processing module is electrically connected with the multi-parameter acquisition module and is used for performing arc detection processing according to the electrical parameters to obtain an arc detection result, and the arc detection result is used for controlling on-off of the power switch. According to the embodiment of the invention, the multi-parameter acquisition module, the arc detection processing module and the SSPC control and fault isolation module are integrated in the SSPC hardware device, so that the functions of arc detection and fault loop cut-off are realized, the size of the hardware device is prevented from being increased too much, and the SSPC miniaturization requirement in the fields of aerospace and the like is met.

Description

Technical Field

[0001] This application relates to the field of solid-state power controller technology, and more specifically to an SSPC hardware device with integrated arc detection. Background Technology

[0002] A solid-state power controller (SSPC) is a power control device that uses contactless semiconductor switches (such as MOSFETs (metal-oxide-semiconductor transistors) and IGBTs (insulated gate bipolar transistors) to integrate relay switching and circuit breaker protection functions.

[0003] In related technologies, SSPC requires an external or additionally designed arc sensor and independent processing unit to achieve arc detection. However, this approach results in an excessive increase in the size of the hardware device, which cannot meet the miniaturization requirements of SSPC in aerospace and other fields. Summary of the Invention

[0004] The embodiments of this application provide an SSPC hardware device with integrated arc detection, which aims to realize the function of arc detection while avoiding excessive increase in the size of the hardware device, so as to meet the miniaturization requirements of SSPC in aerospace and other fields.

[0005] In a first aspect, embodiments of this application provide an SSPC hardware device with integrated arc detection. The SSPC hardware device with integrated arc detection integrates a multi-parameter acquisition module, an arc detection processing module, and an SSPC control and fault isolation module. The SSPC control and fault isolation module includes a power switch. The multi-parameter acquisition module is used to acquire various electrical parameters of the power switch; The arc detection and processing module is electrically connected to the multi-parameter acquisition module and is used to perform arc detection processing based on the electrical parameters to obtain arc detection results. The arc detection results are used for the on / off control of the power switch.

[0006] In the above embodiments, by integrating a multi-parameter acquisition module, an arc detection and processing module, and an SSPC control and fault isolation module into the SSPC hardware device, the functions of arc detection and fault circuit disconnection are realized, avoiding excessive increase in the size of the hardware device, so as to meet the miniaturization requirements of SSPC in aerospace and other fields.

[0007] In one embodiment, the multi-parameter acquisition module is further configured to acquire environmental parameters of the power switch, the environmental parameters including at least one of ambient temperature, ambient humidity, and ambient air pressure; The arc detection processing module is used to perform arc detection processing based on the electrical parameters and the environmental parameters to obtain arc detection results.

[0008] In the above embodiments, by introducing environmental parameters as an auxiliary basis for arc detection, the adaptability of the SSPC hardware device in various complex and changing environments can be improved, the probability of missed alarms and false alarms can be reduced, thereby improving the protection performance of the SSPC hardware device.

[0009] In one embodiment, the arc detection and processing module includes a data processing unit; The data processing unit is used to perform the arc detection processing to output the arc detection result.

[0010] In the above embodiments, by defining the internal structure of the arc detection processing module, it is clarified that data processing units such as MCU and DSP will undertake the core computing tasks, thus providing specific and feasible hardware architecture support for arc detection.

[0011] In one embodiment, the arc detection processing module further includes an FPGA acceleration unit; The FPGA acceleration unit is electrically connected to the data processing unit and is used to perform wavelet transform processing based on the electrical parameters to obtain arc features, and to input the arc features to the data processing unit for the data processing unit to perform the arc detection processing.

[0012] In the above embodiments, the parallel computing of the FPGA acceleration unit and the heterogeneous computing architecture of the data processing unit + FPGA acceleration unit enable the arc detection processing module to balance flexibility and high performance, thereby improving the performance and response speed of the SSPC hardware device with integrated arc detection when processing complex signals.

[0013] In one embodiment, the arc detection and processing module further includes a filtering circuit, and the multi-parameter acquisition module is electrically connected to the FPGA acceleration unit through the filtering circuit; The filtering circuit is used to filter the electrical parameters before they are input to the FPGA acceleration unit.

[0014] In the above embodiments, by adding a filtering circuit, a more complete and robust signal processing chain is constructed to ensure the input quality of wavelet transform through interference suppression at the source, thereby making the extraction of arc features more accurate and ultimately improving the accuracy and reliability of arc detection in the SSPC hardware device.

[0015] In one embodiment, the multi-parameter acquisition module includes an electrical sensor, which is used to acquire the electrical parameters; The SSPC hardware device with integrated arc detection also integrates an environment adaptation module. The environment adaptation module is electrically connected to the multi-parameter acquisition module and is used to acquire the current temperature of the electrical sensor. The current temperature of the electrical sensor is used to correct the electrical parameters.

[0016] In the above embodiments, correcting the electrical parameters collected by the electrical sensor by using the temperature of the electrical sensor can greatly improve the measurement accuracy of the SSPC hardware device in a wide temperature range and the reliability of arc detection, avoiding misjudgment or missed judgment due to temperature drift.

[0017] In one embodiment, the SSPC hardware device with integrated arc detection further integrates a power supply module, which is used to supply power to the multi-parameter acquisition module, the arc detection processing module and the SSPC control and fault isolation module. The power supply module includes an electromagnetic compatibility filter, which is used to filter out electromagnetic interference in the power supply current of the power supply module.

[0018] In the above embodiments, by integrating a power supply module with an electromagnetic compatibility filter, it is ensured that all core functional modules of the SSPC hardware device can operate in a stable and clean power environment, fundamentally improving the anti-interference capability and operational reliability of the SSPC hardware device, thereby providing a guarantee for achieving accurate arc detection.

[0019] In one embodiment, the SSPC control and fault isolation module further includes a resettable fuse connected in series with the power switch.

[0020] In the above embodiments, by connecting a self-resetting fuse in series with the power switch, a physical safety barrier independent of the main control system is added to the SSPC hardware device, which can effectively prevent catastrophic consequences caused by the failure of a single component, thereby improving the safety and reliability of the entire SSPC hardware device.

[0021] In one embodiment, the arc detection processing module includes a controller local area network (Controller Area Network) interface, which is used to perform data interaction processing with the host computer of the SSPC hardware device with integrated arc detection.

[0022] In the above embodiments, the SSPC hardware device has improved compatibility, supports multiple load types, can be connected to different host computer systems via CAN, and provides data support for the health management and fault prediction of the entire system through real-time data reporting.

[0023] In one embodiment, the surface of the SSPC hardware device with integrated arc detection is covered with conformal coating.

[0024] In the above embodiments, by covering the surface of the SSPC hardware device with conformal coating, the resistance of the SSPC hardware device to harsh working environments is enhanced, ensuring the long-term stability of its electrical performance, thereby providing a guarantee for the reliable implementation of the integrated arc detection function.

[0025] The beneficial effects of the embodiments of this application are as follows: In the embodiments of this application, by integrating a multi-parameter acquisition module, an arc detection and processing module, and an SSPC control and fault isolation module into the SSPC hardware device, the functions of arc detection and fault circuit disconnection are realized, avoiding excessive increase in the size of the hardware device, so as to meet the miniaturization requirements of SSPC in aerospace and other fields. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of an embodiment of the SSPC hardware device for integrated arc detection provided in this application; Figure 2 This is a schematic diagram of an embodiment of the SSPC control and fault isolation module provided in this application; Figure 3 This is a schematic diagram of an embodiment of the multi-parameter acquisition module provided in this application; Figure 4 This is a schematic diagram of an embodiment of the arc detection and processing module provided in this application; Figure 5 This is a schematic diagram of an embodiment of the environment adaptation module provided in this application; Figure 6 This is a schematic diagram of an embodiment of the power module provided in this application. Detailed Implementation

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. In addition, in the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0029] In related technologies, SSPC hardware lacks an integrated arc detection module, requiring external or additional arc sensors and independent processing units, resulting in an increase in size of more than 20% and a signal transmission delay of ≥50ms. Furthermore, the hardware does not consider the coordination of multiple modules (detection / control / isolation) and environmental adaptability, leading to severe sensor accuracy drift in extreme environments and making it impossible to achieve rapid linkage between arc detection and isolation.

[0030] Specifically, the SSPC hardware core consists of modules such as power switches, drivers, and overcurrent protection, and only has overcurrent / overvoltage protection functions, lacking arc detection capabilities. To achieve arc detection, an external Hall current sensor, voltage probe, and independent MCU are required, resulting in increased device size, signal transmission delay, and weak electromagnetic interference resistance of external modules. Furthermore, the sensor accuracy drifts significantly at temperatures as low as -40°C, failing to meet the miniaturization and high reliability requirements of aerospace and other fields.

[0031] It can be seen that the relevant technology has the following shortcomings: 1. Low integration: Requires external testing equipment, which is bulky, costly, and has complex wiring; 2. Slow response: The signal transmission path is long, and the detection + isolation delay is ≥50ms, which cannot suppress the spread of electric arc; 3. Poor coordination: The detection, control, and isolation modules work independently, without a hardware-level linkage mechanism; 4. Poor environmental adaptability: It lacks temperature compensation and moisture-proof design, resulting in large accuracy drift and high failure rate under extreme environments.

[0032] To address this issue, this application provides an SSPC hardware device with integrated arc detection. By integrating a multi-parameter acquisition module, an arc detection processing module, and an SSPC control and fault isolation module into the SSPC hardware device, the functions of arc detection and fault circuit interruption are achieved, avoiding excessive increase in the size of the hardware device and meeting the miniaturization requirements of SSPCs in aerospace and other fields. Please refer to the detailed description below for specific solutions.

[0033] Specifically, refer to Figure 1 , Figure 1 This is a schematic diagram of one embodiment of the SSPC hardware device integrating arc detection. Figure 1The integrated arc detection SSPC hardware device integrates a multi-parameter acquisition module, an arc detection processing module, and an SSPC control and fault isolation module on a unified hardware platform. This device integrates the functions of a Solid-State Power Controller (SSPC) with arc fault detection to provide a highly integrated, highly reliable, and fast-response circuit protection solution.

[0034] This integrated arc detection SSPC hardware device is an electronic device that uses semiconductor devices (rather than mechanical contacts) to switch circuits on and off and provides intelligent protection functions, designed to replace fuses and mechanical relays. Integrated arc detection means that the arc fault detection function is built into the SSPC hardware device, rather than as an external, separate add-on module. This integrated design has significant advantages, including but not limited to: reducing the number of system components, shrinking the physical size, lowering costs, and, due to the shorter signal path, resulting in extremely low response delay from detection to action, thereby improving the timeliness and effectiveness of protection.

[0035] In the embodiments of this application, the SSPC control and fault isolation module is used to control the flow of electrical energy to perform normal power on / off tasks and to provide isolation protection when a fault is detected. Here, "control" refers to connecting or disconnecting the circuit according to external commands or internal logic; "fault isolation" refers to forcibly and quickly disconnecting the circuit when faults such as arcing, overcurrent, or short circuits are detected to protect the load and line safety. (Refer to...) Figure 2 The SSPC control and fault isolation module includes a power switch, which is a semiconductor device used to switch the main circuit current on and off. When the power switch is open, it can perform the power-off task and isolation protection, while when the power switch is closed, it can perform the power-on task and stop the isolation protection.

[0036] In some embodiments of this application, the power switch may include MOSFET (Metal-Oxide-Semiconductor Transistor), IGBT (Insulated Gate Bipolar Transistor), etc. Among them, the MOSFET may be, for example, an N-channel MOSFET, which has the advantages of fast switching speed and low on-resistance, and is suitable for most DC applications.

[0037] In some embodiments of this application, reference is made to Figure 2 The SSPC control and fault isolation module may also include a gate drive circuit, which provides sufficient voltage and current to quickly and reliably turn the power switch on and off. (See reference...) Figure 2The SSPC control and fault isolation module may also include a control logic unit, which is used to receive control commands and generate corresponding drive signals.

[0038] In the embodiments of this application, reference is made to Figure 3 The multi-parameter acquisition module is a functional module used to acquire various electrical parameters of the power switch. These parameters may include at least one of the following: current, voltage, and power of the power switch. The current can be acquired by a current sensor located in the area where the power switch is located. The current sensor can be a Hall effect sensor to achieve electrical isolation from the main circuit; or a shunt resistor can be used to obtain a high-precision current reading. The voltage can be acquired by a voltage sensor located in the area where the power switch is located. The voltage sensor can be implemented based on a resistor divider network. The power can be calculated by the power calculation unit in the multi-parameter acquisition module based on the current and voltage of the power switch; that is, the power is equal to the product of the current and voltage.

[0039] In the embodiments of this application, the arc detection processing module is electrically connected to the multi-parameter acquisition module, and is used to perform arc detection processing based on electrical parameters to obtain arc detection results. The arc detection results indicate whether an arc fault exists in the current circuit, and can be analyzed and calculated by the corresponding algorithm built into the arc detection processing module. The arc detection results are used for the on / off control of the power switch. For example, when the arc detection results indicate that an arc fault exists in the current circuit, the gate drive circuit in the SSPC control and fault isolation module can control the power switch to be disconnected. Conversely, when the arc detection results indicate that no arc fault exists in the current circuit, the gate drive circuit in the SSPC control and fault isolation module can control the power switch to be connected.

[0040] In some embodiments of this application, the specific form of the arc detection result may be, for example, binary logic level, status bit in a register, specific data packet or instruction sent through an internal communication bus, so as to determine whether there is an arc fault in the current circuit based on the arc detection result.

[0041] In some embodiments of this application, the arc detection processing can be implemented based on a variety of algorithms. For example, the arc detection processing can analyze the frequency domain characteristics of the signal (such as using fast Fourier transform (FFT) to analyze the energy of a specific frequency band), or the time domain characteristics (such as detecting the randomness and irregularity of the current waveform), or the combined time and frequency domain characteristics (such as wavelet transform), etc., to obtain the arc detection result.

[0042] In some embodiments of this application, the electrical connection between the arc detection processing module and the multi-parameter acquisition module can be implemented based on SPI (Serial Peripheral Interface) bus, I2C (Inter-Integrated Circuit) bus, or other methods. Taking SPI bus as an example, all sensors in the multi-parameter acquisition module can be connected to the arc detection processing module through SPI bus. The transmission delay of SPI bus is ≤1ms, thereby ensuring the timeliness of arc detection and fault circuit interruption.

[0043] In some embodiments of this application, the overall workflow of the SSPC hardware device with integrated arc detection is described exemplarily. Specifically, under normal operating conditions, the power switch in the SSPC control and fault isolation module is in the ON state, supplying power to the load. Simultaneously, the multi-parameter acquisition module continuously acquires various electrical parameters such as current and voltage flowing through the power switch and sends this real-time data to the arc detection processing module via an electrical connection. The arc detection processing module performs real-time analysis on the received data stream. In the absence of an arc, the arc detection processing module determines the situation is normal and does not take any action. When an arc is generated in the circuit due to a fault, the electrical parameters of the circuit will undergo drastic and characteristic changes (e.g., the appearance of a large amount of high-frequency noise), and the multi-parameter acquisition module will capture these abnormal signals. After analyzing these abnormal signals that conform to the characteristics of an arc, the arc detection processing module determines that an arc fault has occurred and immediately generates an arc detection result indicating "arc detected." This arc detection result is transmitted to the SSPC control and fault isolation module. Upon receiving the arc detection result, the control logic of the SSPC control and fault isolation module drives the power switch to switch from the ON state to the OFF state. When the power switch is in the off state, the current in the entire circuit is switched, thereby extinguishing the arc and achieving rapid fault isolation to prevent secondary disasters such as electrical fires.

[0044] As can be seen, the above embodiments of this application highly integrate the three functional modules of sensing, processing and execution into a single SSPC hardware device, forming a closed-loop, automated arc fault protection system. This system features a compact structure, rapid response and high reliability, and avoids excessive increases in the size of the hardware device, thus meeting the miniaturization requirements of SSPCs in aerospace and other fields.

[0045] In some embodiments of this application, since the generation of an electric arc introduces unique, high-frequency noise signals into the circuit, to reduce the impact of noise signals, the multi-parameter acquisition module may also collect various electrical parameters including current rate of change, voltage rate of change, and high-frequency components. The current rate of change and voltage rate of change can be obtained by performing differential operations on the acquired current and voltage signals using analog circuits, or by performing numerical difference operations after digitization. The high-frequency components can be obtained by performing band-pass or high-pass filtering on the original current or voltage signals to extract the energy of specific frequency bands characterizing the electric arc. The multi-parameter acquisition module may also include signal conditioning circuits (such as amplifiers and filters) for extracting electrical parameters such as high-frequency components.

[0046] In some embodiments of this application, to further improve the accuracy and reliability of arc detection, the multi-parameter acquisition module can also be used to acquire environmental parameters of the power switch. Environmental parameters refer to external environmental factors that may affect electrical characteristics and the likelihood of arc generation, such as at least one of ambient temperature, ambient humidity, and ambient air pressure. Therefore, referring to... Figure 3 The multi-parameter acquisition module can also integrate temperature and humidity sensors, barometric pressure sensors, etc. In the specific hardware implementation, the temperature and humidity sensors, barometric pressure sensors, etc. in the multi-parameter acquisition module can be integrated onto the main circuit board (PCB) of the SSPC hardware device, or connected to a key location near the power switch via leads. The analog or digital signals acquired by these sensors will be used as environmental parameter data and input into the arc detection and processing module.

[0047] Accordingly, the arc detection processing module can be used to perform arc detection processing based on electrical and environmental parameters to obtain arc detection results. It can be seen that by summing the electrical and environmental parameters of the power switch, the arc detection results can be made more accurate.

[0048] The following is a detailed description of the arc detection and processing module's process for detecting and processing arcs based on electrical and environmental parameters. Specifically, high humidity environments are more likely to cause insulation degradation, leading to arcing. In low-pressure environments (such as aviation or high-altitude environments), the breakdown voltage of air is reduced, making arcs easier to generate and sustain. High temperatures may accelerate the aging of equipment insulation, increasing the risk of arcing. It can be seen that the generation of arcs is closely related to environmental conditions.

[0049] Therefore, the arc detection processing module can adjust the threshold values ​​of the electrical signal characteristics used to determine the occurrence of an arc based on environmental parameters. For example, when low air pressure and high humidity are detected based on environmental parameters, the arc detection processing module can lower the high-frequency noise energy threshold of the current used to determine the occurrence of an arc fault, making the detection algorithm more sensitive and thus accurately identifying the arc in its early stages. Conversely, when low air pressure and high humidity are not detected based on environmental parameters, a relatively high high-frequency noise energy threshold of the current can be used to achieve dynamic adjustment of the threshold and avoid false alarms. Furthermore, electrical and environmental parameters can be input into a pre-trained arc detection processing model, and the arc detection results output by the arc detection processing can be received. The training process of the arc detection processing model will not be elaborated here.

[0050] As can be seen, in the above embodiments of this application, by introducing environmental parameters as an auxiliary judgment basis for arc detection, the adaptability of the SSPC hardware device in various complex and changing environments can be improved, the probability of missed alarms and false alarms can be reduced, thereby improving the protection performance of the SSPC hardware device.

[0051] In some embodiments of this application, the SSPC hardware device has advantages such as small size and high integration, which also means that the main heat-generating components such as the power switch and current sampling resistor are packaged in an extremely limited space. When the SSPC hardware device continuously carries a large current, the large amount of heat generated by the power switch and current sampling resistor will accumulate in the narrow space, causing the power switch temperature (i.e., ambient temperature) collected by the multi-parameter acquisition module to not fully represent the core junction temperature of the power switch, which may lead to premature aging, performance degradation, or even thermal runaway of the power switch.

[0052] To address this, a power derating strategy can be provided for the SSPC hardware device to temporarily limit the maximum output current of the circuit containing the power switch, achieving active and intelligent thermal protection rather than passive over-temperature shutdown. For example, when the ambient temperature of the power switch exceeds a preset first temperature threshold, the maximum output current of the circuit containing the power switch can be reduced to avoid thermal protection of the SSPC hardware device. When the ambient temperature of the power switch is less than or equal to a preset second temperature threshold, the reduced maximum output current of the circuit containing the power switch is restored to ensure normal power output of the circuit containing the power switch. The second temperature threshold is lower than the first temperature threshold.

[0053] As can be seen from the above embodiments of this application, by temporarily limiting the maximum output current of the circuit where the power switch is located, it can be ensured that the SSPC hardware device itself operates within a suitable temperature range, thereby improving the reliability and lifespan of the SSPC hardware device.

[0054] In some embodiments of this application, reference is made to Figure 4The arc detection processing module includes a data processing unit. The data processing unit is the central computing core of the arc detection processing module and is the physical entity that executes complex algorithms and logical judgments. It is a programmable processing unit or a processing unit with fixed logic functions to perform arc detection processing and output arc detection results. Specifically, the data processing unit may include at least one of a microcontroller unit (MCU), a digital signal processor (DSP), a system-on-chip (SoC), or an application-specific integrated circuit (ASIC). Using an MCU as a data processing unit offers advantages such as convenient development, lower cost, and high flexibility, and it can implement various complex arc detection algorithms, such as time-domain analysis and FFT (Fast Fourier Transform) frequency-domain analysis. Using a DSP as a data processing unit, it can execute computationally intensive algorithms such as FFT and wavelet transform more efficiently, thereby achieving shorter detection latency and higher sampling rate processing capabilities. Using an SoC as a data processing unit, it can provide higher processing performance and is suitable for processing multi-channel data simultaneously or running extremely complex algorithms (such as machine learning-based arc detection processing models). ASICs, as data processing units, have the advantages of high performance, low power consumption, and small size.

[0055] As can be seen from the above embodiments of this application, by defining the internal structure of the arc detection processing module, it is clear that the core computing tasks are undertaken by data processing units such as MCU and DSP, providing specific and feasible hardware architecture support for arc detection.

[0056] In some embodiments of this application, the high-frequency signal characteristics of an electric arc are complex and variable, easily confused with electromagnetic interference signals generated during normal operation such as motor starting, switching power supply, and wireless communication, leading to false alarms (false disconnections). To address this, the data processing unit, during the arc detection processing step, can not only analyze the frequency components of the signal (to determine if it conforms to the wide-spectrum characteristics of an electric arc), but also combine the signal's energy integral and duration in the time domain. Only when the signal simultaneously satisfies both spectral and time-domain characteristics is an arc fault determined, and a corresponding arc detection result is generated, thereby improving the accuracy of the arc detection result.

[0057] Specifically, the data operation unit can analyze the signals of the arc characteristics to determine the instantaneous energy (square of the amplitude) of each sampling point in the calculated signal. When the instantaneous energy exceeds the preset pulse trigger threshold, energy accumulation starts, and the pulse duration timer starts timing. When the instantaneous energy drops below the preset pulse trigger threshold, the energy accumulation stops, obtaining the energy integral of the signal in the time domain (i.e., the pulse energy value E_pulse), and the pulse duration timer stops timing, obtaining the pulse duration (i.e., the pulse width T_pulse).

[0058] Since the arc signal usually presents as a series of dense and random pulse trains, the number of effective energy pulses (i.e., E_pulse > Th_E and T_pulse < Th_T, where Th_E is the preset pulse energy threshold and Th_T is the preset pulse width threshold) can be counted within a slightly longer time window (such as 10 ms).

[0059] If the number of pulses within a certain unit time is greater than the preset number, it is considered a continuous noise event, and the count of the counter is incremented by 1. If the number of pulses within a certain unit time is less than the preset number, it is not considered a continuous noise event, and the count of the counter is decremented by 1. As time goes by, the count of the counter can be continuously incremented or decremented. At a certain moment, if the count of the counter is greater than the preset count threshold, it can be determined that the signal satisfies the characteristics of the arc fault in the time domain, so as to improve the ability of the arc detection process to resist instantaneous interference through the count of the counter. If the signal simultaneously satisfies the dual characteristics of the arc fault in the frequency spectrum and the time domain, it can be determined that there is an arc fault, and the corresponding arc detection result is generated.

[0060] It can be seen that in the above embodiments of the present application, by whether the signal simultaneously satisfies the dual characteristics of the arc fault in the frequency spectrum and the time domain, the corresponding arc detection result is generated, so that in a complex electrical environment, the true arc fault can be accurately and reliably identified, while avoiding the problem of false alarms.

[0061] In some embodiments of the present application, in order to accurately capture the characteristics of the arc transient signal in an extremely short time, a signal processing algorithm with a very large computational amount, such as wavelet transform, may encounter performance bottlenecks when the general data operation unit (such as MCU) processes such complex algorithms in real time. In this regard, refer to Figure 4The arc detection and processing module may also include an FPGA acceleration unit. An FPGA (Field-Programmable Gate Array) is a semi-custom circuit containing a large number of configurable logic blocks (CLBs), input / output units (IOBs), and programmable internal interconnects. It can be programmed using hardware description languages ​​(such as Verilog HDL or VHDL) to implement custom digital logic functions. Therefore, in this embodiment, an FPGA device can be used to construct a high-efficiency hardware coprocessor (i.e., an FPGA acceleration unit) specifically designed to accelerate the task of "wavelet transform processing." The "acceleration" of the FPGA acceleration unit is reflected in the fact that, through hardware parallel computing, it performs wavelet transforms much faster than sequential software execution on a general-purpose processor (such as an MCU or DSP).

[0062] Specifically, the FPGA acceleration unit can be configured to be electrically connected to the data processing unit to perform wavelet transform processing based on electrical parameters to obtain arc features, and to input the arc features to the data processing unit for the data processing unit to perform arc detection processing, so as to solve the real-time and computational efficiency problems of specific algorithms (such as wavelet transform) in arc detection.

[0063] Specifically, the FPGA acceleration unit receives the digitized electrical parameter data stream (after ADC conversion) from the multi-parameter acquisition module. The FPGA internally implements a wavelet transform hardware IP core. This IP core utilizes the FPGA's parallel computing capabilities to perform real-time, point-by-point Discrete Wavelet Transform (DWT) calculations on the input data stream to obtain the arc characteristics. The arc characteristics specifically include a series of wavelet coefficients obtained after the wavelet transform. These coefficients reflect the energy distribution of the original signal at different scales (frequency) and time locations. High-frequency transient components associated with the arc exhibit significant energy concentration on specific wavelet coefficients. These energy values, statistical characteristics of the coefficients (such as energy entropy, kurtosis, etc.), or other derived quantities constitute the arc characteristics. The FPGA acceleration unit can package these calculated feature values ​​and input them as arc characteristics to the data processing unit, eliminating the need for the data processing unit to perform complex wavelet transforms; instead, it directly performs subsequent processing on these highly condensed feature data.

[0064] As can be seen from the above embodiments of this application, the heterogeneous computing architecture of data processing unit + FPGA acceleration unit enables the arc detection processing module to balance flexibility and high performance, thereby improving the performance and response speed of the SSPC hardware device with integrated arc detection when processing complex signals.

[0065] In some embodiments of this application, reference is made to Figure 4The arc detection processing module also includes a filtering circuit, and the multi-parameter acquisition module is electrically connected to the FPGA acceleration unit through the filtering circuit. The filtering circuit is used to filter the electrical parameters before they are input to the FPGA acceleration unit, i.e., to preprocess the electrical parameters to improve signal quality, reduce the complexity and interference of subsequent processing, thereby improving the performance and robustness of the entire arc detection system. The filtering circuit may include, for example, a Kalman filter circuit composed of an FPGA submodule (e.g., EP4CE6E22C8) and an operational amplifier (e.g., LMV324) to filter out high-frequency noise in advance.

[0066] Specifically, in actual electrical systems, the acquired electrical parameter signals are often mixed with various noises and interferences, such as power frequency (50Hz / 60Hz) and its harmonics, high-frequency switching noise, etc. These interference components may mask the true characteristics of the electric arc signal or be misjudged as electric arc features, thus affecting the accuracy of subsequent wavelet transform processing. To address this, this embodiment adds a filtering circuit before the data enters the FPGA acceleration unit. The filtering circuit is an electronic circuit whose core function is to select the frequency of the signal. It allows signal components within a specific frequency range to pass through while attenuating or suppressing signal components within other frequency ranges. Therefore, the filtering circuit can be used to remove frequency components that are irrelevant to the electric arc features and may cause interference before performing computationally intensive wavelet transforms on the electrical parameters, thereby improving the signal-to-noise ratio (SNR) and providing a "cleaner" input signal for subsequent feature extraction by the FPGA.

[0067] In some embodiments of this application, the filtering circuit can be implemented using various specific technical solutions, mainly divided into two categories: digital filtering and analog filtering. Taking digital filtering as an example, the filtering circuit can be implemented using devices such as finite impulse response (FIR) filters and infinite impulse response (IIR) filters. Taking analog filtering as an example, the filtering circuit may include passive components (resistors R, capacitors C, inductors L) or active components (such as operational amplifiers), such as high-pass filters (HPF), band-pass filters (BPF), circuit topologies, etc.

[0068] Since the arc signal mainly manifests as high-frequency noise, and the strongest interference in the system is the power frequency (50 / 60Hz) and its low-order harmonics, a high-pass filter with a cutoff frequency slightly higher than the power frequency harmonics (e.g., set to several kilohertz) can be designed as the filtering circuit. This filtering circuit can effectively filter out low-frequency power frequency interference, allowing only the high-frequency components containing arc information to pass through and be sent to the FPGA for processing, thereby reducing the dynamic range requirements of the subsequent ADC and the processing burden on the FPGA.

[0069] A bandpass filter is a more targeted solution. If preliminary testing has determined that the characteristic frequencies of the arc signal are concentrated in a specific frequency band (e.g., 100kHz to 1MHz), a bandpass filter can be designed whose passband precisely covers this band. This not only filters out low-frequency power line interference but also removes irrelevant high-frequency noise, maximizing the extraction of the effective signal frequency band.

[0070] The circuit topology can be implemented using classic filter topologies such as Butterworth and Chebyshev, which will not be elaborated here.

[0071] As can be seen from the above embodiments of this application, by adding a filtering circuit, a more complete and robust signal processing chain is constructed to ensure the input quality of wavelet transform through interference suppression at the source, thereby making the extraction of arc features more accurate and ultimately improving the accuracy and reliability of arc detection in the SSPC hardware device.

[0072] In some embodiments of this application, reference is made to Figure 3 The multi-parameter acquisition module includes electrical sensors used to acquire the aforementioned electrical parameters. These electrical sensors may include, for example, current sensors and voltage sensors. (See reference...) Figure 1 and Figure 5 The SSPC hardware device integrating arc detection also integrates an environment adaptation module, which is electrically connected to the multi-parameter acquisition module and used to acquire the temperature values ​​of the electrical sensors. The temperature values ​​of the electrical sensors are used to correct the electrical parameters, thereby eliminating measurement errors caused by environmental changes through the introduction of a temperature compensation mechanism, thus improving the reliability and stability of the entire arc detection system.

[0073] Specifically, since the performance of electrical sensors drifts with changes in operating temperature, this directly affects the accuracy of signal acquisition. To ensure accurate and reliable electrical parameters are obtained under various operating environments, thereby guaranteeing the effectiveness of the arc detection algorithm, this embodiment adds an environment adaptation module to implement a temperature compensation mechanism for electrical parameters. (Refer to...) Figure 5 The environmental adaptation module can be equipped with a temperature sensor (such as an NTC (negative temperature coefficient) thermistor). By attaching the temperature sensor to the location of the electrical sensor, the temperature of the battery sensor can be collected.

[0074] Understandably, without correction of the electrical parameters, the collected electrical parameters will deviate when the SSPC device heats up due to prolonged operation or when the external ambient temperature changes drastically. For example, in the absence of an electric arc, high temperature may cause the electrical sensor to falsely report an abnormal current spike, thus triggering a false alarm.

[0075] The following is an example description of the electrical parameter correction process. Specifically, the environmental adaptation module generates a temperature correction signal, which includes the temperature of the electrical sensor. Then, the environmental adaptation module inputs the temperature correction signal to the multi-parameter acquisition module. Based on the received temperature correction signal, the multi-parameter acquisition module corrects the acquired original electrical parameters. For example, the multi-parameter acquisition module can pre-store the temperature-error characteristic curve or look-up table (LUT) of the electrical sensor. Then, based on the temperature of the electrical sensor, it calculates the gain error and zero-point drift of the electrical sensor at that temperature using a lookup table or formula. Finally, it performs mathematical operations on the acquired original electrical parameters to obtain a temperature-compensated electrical parameter that is closer to the true value. The temperature-error characteristic curve or look-up table of the electrical sensor can be obtained through calibration before the product leaves the factory.

[0076] As can be seen from the above embodiments of this application, correcting the electrical parameters collected by the electrical sensor by using the temperature of the electrical sensor can greatly improve the measurement accuracy of the SSPC hardware device in a wide temperature range and the reliability of arc detection, and avoid misjudgment or missed judgment caused by temperature drift.

[0077] In some embodiments of this application, reference is made to Figure 1 and Figure 6 The SSPC hardware device integrating arc detection also integrates a power supply module, which supplies power to the multi-parameter acquisition module, the arc detection processing module, and the SSPC control and fault isolation module via an internal bus. (Refer to...) Figure 6 The power supply module includes an electromagnetic compatibility filter, which is used to filter out electromagnetic interference in the power supply current of the power supply module to ensure that the entire SSPC hardware device can work stably and reliably in complex electromagnetic environments.

[0078] Specifically, in the operating environment of a solid-state power controller (SSPC), electromagnetic interference is abundant both internally and externally due to the rapid switching action of the power switch and fluctuations in the external power grid. This interference can couple to various functional modules through the power path, potentially causing inaccurate analog signal acquisition and errors in digital logic processing, thereby severely affecting the accuracy of arc detection and the stability of the entire device. To address this, embodiments of this application incorporate an electromagnetic compatibility filter into the power module of the SSPC hardware device to suppress noise generated by the power module itself and interference from external sources.

[0079] An electromagnetic compatibility (EMC) filter is a passive network used to suppress electromagnetic interference conducted along conductors. It can include components such as inductors, capacitors, and resistors; for example, it may include a common-mode inductor (e.g., PM734059) + X capacitor (e.g., CL21X104K). Its purpose is to construct an "electromagnetic firewall," providing bidirectional protection. Internally: To prevent high-frequency switching noise generated inside the power module from polluting the internal power supply network and to ensure that each module in the SSPC hardware device receives "clean" power.

[0080] Externally: To prevent internal noise from being conducted through the power cord and interfering with other external equipment, thus meeting electromagnetic compatibility requirements. For high-sensitivity arc detection, a low-noise power supply environment is crucial.

[0081] Electromagnetic compatibility filters can address these two types of interference by utilizing the characteristics of inductors (high impedance to high-frequency signals) and capacitors (low impedance to high-frequency signals) to provide a bypass or blocking path for the interfering signal, preventing it from continuing to propagate.

[0082] As can be seen from the above embodiments of this application, by integrating a power module with an electromagnetic compatibility filter, it is ensured that all core functional modules of the SSPC hardware device can work in a stable and clean power environment, fundamentally improving the anti-interference capability and operational reliability of the SSPC hardware device, thereby providing a guarantee for achieving accurate arc detection.

[0083] In some embodiments of this application, reference is made to Figure 6 The power module may also include a DC-DC converter, which receives a 24V / 48V input, outputs 5V to the multi-parameter acquisition module and the arc detection and processing module, and outputs 12V to the SSPC control and fault isolation module. An electromagnetic compatibility filter serves as an auxiliary circuit for the DC-DC converter.

[0084] In some embodiments of this application, in order to prevent continuous severe overcurrent or short-circuit faults caused by the failure of the power switching device itself or its control circuit, the SSPC control and fault isolation module may also include a self-resetting fuse. The self-resetting fuse is connected in series with the power switch and is integrated into the power path of the SSPC, thereby adding an independent, passive and automatically recoverable hardware protection layer. This is intended to deal with extreme situations such as catastrophic failures of the main controller or the power switch itself, thereby greatly improving the robustness and safety of the entire SSPC hardware device.

[0085] A resettable fuse is an overcurrent protection component. Unlike a one-time blown fuse, when an overcurrent fault occurs, its resistance rapidly jumps from an extremely low conducting state (milliohms) to a very high blocking state (kiloohms to megaohms), thus limiting the current in the circuit to a very small safe value. Once the fault is cleared and the relevant components have cooled down, it automatically returns to its original low-resistance conducting state without manual replacement. Its "self-resetting" characteristic improves system maintainability and availability, making it particularly suitable for applications where manual maintenance is difficult.

[0086] When selecting a resettable fuse, you can make a selection based on parameters such as the fuse's holding current (i.e., the maximum operating current that does not trigger protection), trigger current (i.e., the minimum current that guarantees it will enter the protection state), maximum voltage, and maximum fault current withstand capability, so that these parameters match the rated operating parameters of the SSPC hardware device and the characteristics of the power switch.

[0087] As can be seen from the above embodiments of this application, by connecting a self-resetting fuse in series with the power switch, a physical safety barrier independent of the main control system is added to the SSPC hardware device, which can effectively prevent catastrophic consequences caused by the failure of a single component, thereby improving the safety and reliability of the entire SSPC hardware device.

[0088] In some embodiments of this application, the arc detection processing module may further include a Controller Area Network (CAN) interface. The CAN interface is used to perform data interaction processing with the host computer of the SSPC hardware device with integrated arc detection. By introducing a standardized and highly reliable communication interface, the application scenarios and functional depth of the SSPC hardware device are greatly expanded, enabling it to be integrated into more complex distributed control systems.

[0089] The Controller Area Network (CAN) interface is a hardware and software integration that enables the SSPC hardware device to function as a node, connecting to and communicating via the CAN bus protocol. The CAN bus is a serial communication bus specifically designed for high-noise environments (such as automotive and industrial sites), offering extremely high reliability, real-time performance, and electromagnetic interference resistance. This aligns perfectly with the operating environment of the SSPC hardware device. Integrating this interface means the device is no longer a "black box," but rather an intelligent device that can be centrally monitored, remotely controlled, and diagnosticated. For example, it can report collected electrical parameters, environmental parameters, and arc detection results to a host computer, enabling the host computer to monitor the SSPC hardware device.

[0090] "Host computer" is a functional and relative concept, referring to any external device in the entire control network that is at a higher level than the SSPC hardware device and can monitor or control it. Depending on the application scenario, the host computer can be the main control unit of a vehicle / aircraft: such as the vehicle controller (VCU) of an automobile, the flight control computer (FCC) or mission management computer of an aircraft. The host computer can also be a programmable logic controller (PLC) in an industrial automation system, a centralized monitoring and data acquisition (SCADA) terminal in a power distribution system, a portable computer or dedicated handheld device used for debugging, diagnosis or configuration, etc.

[0091] The specific content of data interaction may include uplink data (status information, measurement data, alarm and fault information, response information) sent by the SSPC hardware device to the host computer, and downlink data (control commands, configuration parameters, query commands) sent by the host computer to the SSPC hardware device.

[0092] Status information is used to report whether the current power switch is in an on, off, or fault-isolated state.

[0093] Measurement data refers to electrical and environmental parameters such as load current, bus voltage, and internal temperature, which are periodically broadcast in real time.

[0094] Alarm and fault information refers to sending high-priority fault messages when abnormal conditions such as arc faults, overcurrent, overtemperature, and undervoltage are detected. The messages may contain detailed fault codes that indicate the fault type.

[0095] Response information refers to the response to query commands or control commands from the host computer.

[0096] Control commands are used to send instructions to control the power switch to be closed (ON), opened (OFF), or reset (RESET).

[0097] Configuration parameters refer to the parameters sent to the host computer during system initialization or maintenance (such as adjusting the overcurrent protection threshold of the SSPC, setting its node address on the CAN bus, etc.).

[0098] The query command is used to request the SSPC to report its current detailed status or historical fault records.

[0099] As can be seen from the above embodiments of this application, by integrating the controller local area network interface, the compatibility of the SSPC hardware device is improved, it can support multiple load types, can be connected to different host computer systems via CAN, and provides data support for the health management and fault prediction of the entire system through real-time data reporting.

[0100] In some embodiments of this application, when the load of the SSPC hardware device is a large capacitor, motor, or transformer, a surge current far exceeding the rated value will be generated at startup. The fast response of the FPGA may misinterpret this surge phenomenon as a short circuit fault, causing the power switch to immediately disconnect and the load device to fail to start.

[0101] To address this, embodiments of this application can add a pre-charge circuit, such as a pre-charge branch consisting of a low-power resistor and a bypass switch. When the SSPC hardware device supplies power to the load, it first connects this pre-charge branch to slowly charge the capacitor. Once the voltage is established, it switches to the main power path of the SSPC hardware device, fundamentally eliminating surges.

[0102] In some embodiments of this application, reference is made to Figure 5 The surface of the SSPC hardware device with integrated arc detection is covered with conformal coating. For example, all modules and the connecting lines between all modules in the SSPC hardware device with integrated arc detection are covered with conformal coating. This external protection measure enhances the moisture resistance of the SSPC hardware device, enabling it to operate stably for a long time in harsh and unpredictable real-world working environments (such as high humidity environments), thereby ensuring the reliability of its core functions.

[0103] It is understandable that electronic devices, especially SSPC hardware devices used in aerospace, automotive, or harsh industrial environments, often face challenges from harmful environmental factors such as humidity, salt spray, dust, and chemical corrosion. These factors can lead to conductor corrosion on circuit boards, decreased insulation resistance, and even dendrite formation causing short circuits, thereby causing equipment failure. To address this, embodiments of this application apply a conformal coating to the entire hardware device, providing a physical protective layer to enhance its resistance to harsh operating environments and ensure long-term stability of its electrical performance, thus guaranteeing the reliable implementation of integrated arc detection functionality.

[0104] In summary, the SSPC hardware device with integrated arc detection provided in this application has the following advantages: 1. High integration: The SSPC hardware architecture with integrated arc detection is designed, eliminating the need for external devices, reducing size and cost; 2. Fast response: The signal path is shortened through the SPI bus, reducing the detection + isolation delay to ≤20ms; and hardware-level coordination of "detection-control-isolation" is achieved to form a hardware closed loop of "sensor-processing-drive-switch", reducing intermediate delays; FPGA hardware accelerates wavelet transform, improving data processing speed. 3. High reliability: The design includes a temperature compensation mechanism for NTC thermistors and a moisture-proof coating to ensure reliability under extreme conditions. Under extreme environments (-40~85℃, 30%~90%RH), the sensor accuracy drift is ≤±0.8%, and the failure rate is ≤0.1% / 1000h.

[0105] 4. Good compatibility: Supports multiple load types and can be connected to different host computer systems via CAN.

[0106] The embodiments of this application have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the structure and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A SSPC hardware device integrating arc detection, characterized in that, The integrated arc detection SSPC hardware device integrates a multi-parameter acquisition module, an arc detection processing module, and an SSPC control and fault isolation module. The SSPC control and fault isolation module includes a power switch. The multi-parameter acquisition module is used to acquire various electrical parameters of the power switch; The arc detection and processing module is electrically connected to the multi-parameter acquisition module and is used to perform arc detection processing based on the electrical parameters to obtain arc detection results. The arc detection results are used for the on / off control of the power switch.

2. The SSPC hardware device for integrated arc detection as described in claim 1, characterized in that, The multi-parameter acquisition module is also used to acquire the environmental parameters of the power switch, including at least one of ambient temperature, ambient humidity, and ambient air pressure. The arc detection processing module is used to perform arc detection processing based on the electrical parameters and the environmental parameters to obtain arc detection results.

3. The SSPC hardware device for integrated arc detection as described in claim 1 or 2, characterized in that, The arc detection and processing module includes a data processing unit; The data processing unit is used to perform the arc detection processing to output the arc detection result.

4. The SSPC hardware device for integrated arc detection as described in claim 3, characterized in that, The arc detection and processing module also includes an FPGA acceleration unit; The FPGA acceleration unit is electrically connected to the data processing unit and is used to perform wavelet transform processing based on the electrical parameters to obtain arc features, and to input the arc features to the data processing unit for the data processing unit to perform the arc detection processing.

5. The SSPC hardware device for integrated arc detection as described in claim 4, characterized in that, The arc detection and processing module further includes a filtering circuit, and the multi-parameter acquisition module is electrically connected to the FPGA acceleration unit through the filtering circuit. The filtering circuit is used to filter the electrical parameters before they are input to the FPGA acceleration unit.

6. The SSPC hardware device for integrated arc detection as described in claim 1, characterized in that, The multi-parameter acquisition module includes an electrical sensor, which is used to acquire the electrical parameters. The SSPC hardware device with integrated arc detection also integrates an environment adaptation module. The environment adaptation module is electrically connected to the multi-parameter acquisition module and is used to acquire the temperature value of the electrical sensor. The temperature value of the electrical sensor is used to correct the electrical parameters.

7. The SSPC hardware device for integrated arc detection as described in claim 1, characterized in that, The SSPC hardware device with integrated arc detection also integrates a power supply module, which is used to supply power to the multi-parameter acquisition module, the arc detection processing module and the SSPC control and fault isolation module. The power supply module includes an electromagnetic compatibility filter, which is used to filter out electromagnetic interference in the power supply current of the power supply module.

8. The SSPC hardware device for integrated arc detection as described in claim 1, characterized in that, The SSPC control and fault isolation module also includes a self-resetting fuse, which is connected in series with the power switch.

9. The SSPC hardware device for integrated arc detection as described in claim 1, characterized in that, The arc detection processing module includes a controller local area network (Controller Area Network) interface, which is used to perform data interaction processing with the host computer of the SSPC hardware device with integrated arc detection.

10. The SSPC hardware device for integrated arc detection as described in claim 1, characterized in that, The surface of the SSPC hardware device for integrated arc detection is covered with conformal coating.

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