Generic high-voltage DC electrical distribution panel
Patent Information
- Application Number
- EP2023707136
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-02-17
- Filing Date
- 2023-02-06
- Publication Date
- 2024-12-25
AI Technical Summary
Existing electrical power distribution systems in aircraft require customized designs due to fixed configurations of components, leading to increased mass, volume, and complexity, limiting their adaptability and efficiency in high-speed networks.
A generic, modular high-voltage DC electrical distribution plate with integrated electromechanical contactors on both surfaces, allowing for two orthogonal orientations of contactor configurations to enable parallel or series connections, optimizing mass and volume while accommodating different application needs.
The modular design reduces mass and volume, enhances adaptability, and optimizes the electrical power distribution unit's efficiency by allowing configuration changes based on application needs, making it more generic and cost-effective.
Smart Images
Figure 1.1
Abstract
Description
[0001] Description
[0002] Title of the invention: GENERIC BOARD FOR DISTRIBUTION OF HIGH VOLTAGE DIRECT ELECTRICAL POWER
[0003] Technical Field
[0004] The present invention relates to the field of electrical power distribution, particularly in an aircraft, and more particularly to a generic high voltage DC electrical power distribution board.
[0005] Prior art
[0006] To distribute power in an aircraft power distribution network, electrical distribution units are generally used, equipped with electromechanical power contactors, Kn and Kp, intended to switch the HV+ and HV power lines between a source and a load. The power contactors, Kn and Kp, are used to switch the power on the one hand and to isolate the line on the other hand.
[0007] Typically, in power distribution, contactors Kn and Kp are combined with other components such as a pre-charging circuit. The pre-charging circuit is included on the HV+ power line with a contactor K1 and a power resistor R1. A current sensor is also used to measure the current in the HV+ and HV- lines in order to control contactors Kp, Kn and K1 and to ensure current protection of the distribution line. Active motor control electronics are used to control the contactors. The assembly constitutes a BPMU (Bus Power Management Unit) which can, for example, be used between a high-voltage battery and an electric motor in the case of all-electric propulsion of a small aircraft. This BPMU is an example of a high-voltage switching device with a pre-charging resistor.
[0008] Figure 1 represents the general block diagram of an example 10 of such a BPMU according to the prior art.
[0009] As can be seen in Figure 1, the BPMU 10 intended to be contained in the power distribution unit comprises a parallel branch (precharge branch 12) to the main switching element 14 Kp / Kn arranged between the electrical power source and the high and low voltage lines HV+ and HV- supplying the load. This Kp ! Kn pair of electromechanical contactors ensures galvanic isolation in the open state and a very low impedance (around a hundred mV under nominal current) in the closed state. These electromechanical contactors are conventionally controlled from a control module 16 according to voltage and / or current information recorded upstream and downstream of these contactors.
[0010] The elements of the parallel precharge branch 12, a contactor K1 and a limiting resistor R1, have an impedance defined to have a current I2 determined by the source voltage / R1 corresponding to the precharge current of the load (typically a few tens of Amperes). The contactor K1 is also of the electromechanical type to ensure galvanic isolation in the open state and also controlled by the control module 16.
[0011] The physical implementation of power distribution units is based on a housing and / or a board. The specific arrangement of the various components of the BPMU depends on the application and, therefore, the power distribution unit must be "custom-made" each time, depending on the application. Only the basic components (switches, motors, resistors, and others) are generic products and constitute the building blocks reused for applications. In short, distribution units are designed to adapt to the need from mechanically integrated discrete elements.
[0012] The prior art proposes various attempts to promote a modular approach based on the use of standardized bricks comprising reusable sub-assemblies.
[0013] Figure 2 shows a photograph of an example of a generic module 20 with contactor pattern for a power distribution matrix according to a first approach. This generic module 20, defined a priori, makes it possible to produce the necessary power interconnections according to the application case.
[0014] The module 20 shown in Figure 2 is a power distribution box integrating switches 22 arranged in a matrix, and measuring elements (not visible in the photograph). A large number of cables 24 are required to connect the switching elements 22 and the measuring elements to two terminal blocks 26 28 which are also integrated into the box. Since different applications must be provided, there are superfluous components and the mass and volume of the device are significant. Figure 3 shows a photograph of an example of a generic module 30 according to a second approach, which integrates electromechanical elements into a board itself.
[0015] The module 30 shown in Figure 3 is a plate intended for use in a power distribution unit and, according to the example shown, comprises two contactors 32 mechanically integrated into the plate to form an integral part thereof. In other words, the contactors 32 are not removable. Locations 34 are provided on the plate for other contactors but, again, in a predefined and fixed position.
[0016] Modular or integration solutions proposed so far have the disadvantage of defining "a priori" configurations for which the use case must adapt to meet the specific power distribution need. They are therefore generic only to a limited extent.
[0017] Statement of the invention
[0018] The main objective of the present invention is therefore to propose a generic, modular electrical power distribution board, with contactors integrated on the power board, configured to allow adaptation to the need for distribution and precharging use in a high voltage DC network.
[0019] These aims are achieved by a continuous high voltage electrical distribution board, having two opposite major surfaces, the board integrating two electromechanical power contactors, characterized in that:
[0020] - on a first of the major surfaces of the plate are arranged chambers for fixed and movable contact terminals of the two electromechanical contactors, while on the second major surface of the plate are arranged complementary assemblies of the two contactors, each complementary assembly of contactor comprising a motor intended to activate the contact terminals of the contactor concerned,
[0021] - and in that other components arranged on the second major surface of the plate are arranged so as to leave a free space constituting a fixing zone for the complementary assemblies of the two contactors, the fixing zone being sized to allow the arrangement of the complementary assemblies of the contactors according to two orthogonal orientations allowing the motors to activate contact terminals of different subassemblies of the contact chambers and thus to create parallel or series configurations of the contactors.
[0022] The proposed invention provides a generic modular board with integrated contactors on a power board that allow two layout configurations to allow adaptation to the need for distribution and precharging use in a high voltage DC network. The high level of integration of the components on the power board allows optimization of the mass and volume of the function. The modularity of the solution also allows to meet different needs thanks to the proposed configurations that allow it to be made generic.
[0023] Advantageously, the center distances of the contactor chambers and the center distances of the complementary sets of contactors are sized to align the contacts of the two contactors with the corresponding motors of the complementary sets of contactors according to the first and second orientation of the complementary sets of contactors.
[0024] In a preferred embodiment, on the second major surface of the plate, fixing points are provided, the number and positions of which are chosen to ensure the fixing of the complementary sets of contactors on the plate, by means of the cooperation between these fixing points on the plate and the complementary fixing elements provided on the complementary sets of contactors, whether the complementary sets of contactors are oriented according to the first configuration or according to the second configuration. This arrangement of the fixing points ensures the robust integration of the contactors to the plate while respecting the configurable nature of the assembly.
[0025] In a preferred embodiment, the aforementioned high-voltage electrical distribution board includes a pre-charging function. This configuration makes it possible to obtain a significant reduction in terms of mass and volume compared to previously proposed devices which include a pre-charging function.
[0026] The invention also relates to a high-voltage DC electrical distribution unit provided with the aforementioned high-voltage distribution board. In a preferred embodiment, the aforementioned high-voltage electrical distribution unit is mounted between a storage unit and a high-voltage DC (HVDC) bus of an aircraft. Advantageously, the storage unit may be a battery or a supercapacitor.
[0027] The invention also relates to an electrical power distribution network of an aircraft comprising an electrical power distribution unit as mentioned above.
[0028] Brief description of the figures
[0029] Other characteristics and advantages of the present invention will emerge from the description given below, with reference to the appended drawings which illustrate an exemplary embodiment thereof without any limiting character and in which: [Fig. 1] Figure 1 shows the general block diagram of an example of an electrical distribution unit equipped with electromechanical power contactors according to the prior art,
[0030] [Fig. 2] Figure 2 shows a photograph of a generic module with prior art contactor pattern,
[0031] [Fig. 3] Figure 3 shows a photograph of a prior art board incorporating non-removable contactors,
[0032] [Fig. 4] Figure 4 shows a continuous high voltage distribution board according to a preferred embodiment of the invention, with complementary power contactor assemblies arranged in a first orientation,
[0033] [Fig. 5] Figure 5 is a diagram showing the activation of the contact terminals by the motors when the complementary contactor assemblies are arranged in the first orientation,
[0034] [Fig. 6] Figure 6 shows the high voltage DC distribution board of Figure 4 seen from the left,
[0035] [Fig. 7] Figure 7 shows the high voltage DC distribution board of Figure 4 when the complementary contactor assemblies are arranged in a second orientation,
[0036] [Fig. 8] Figure 8 is a diagram showing the activation of the contact terminals by the motors when the complementary contactor assemblies are arranged in the second orientation,
[0037] [Fig. 9] Figure 9 is a bottom view of the plate according to Figure 4, and [Fig. 10] Figure 10 is a bottom view of the plate according to Figure 7. Description of the embodiments
[0038] The invention is based on the configuration of a high-voltage electrical distribution board so as to integrate a large number of components while allowing adaptation to the need for distribution and precharging use in a high-voltage DC network.
[0039] The board can be used, in particular, to produce a light BPMU whose general diagram corresponds to that shown in Figure 1. Such a light BPMU can, for example, be used between a high-voltage storage means (for example, a battery, a super-capacitor) and an electric motor in the case of all-electric propulsion of a small aircraft.
[0040] According to an example, the board houses the high-voltage DC contactor Kp on the HV+ line in this configuration, the high-voltage DC contactor Kn on the HV- line in this configuration, the high-voltage DC contactor K1 for the precharge line on the HV+ power line, the power resistor R1 for current limitation in the precharge line on the HV+ line, a current sensor on the HV+ and HV- lines, and control electronics for the contactors Kp, Kn and K1 and for managing current measurements.
[0041] Depending on the needs of the intended application, it may be advantageous for the Kp and Kn contactors to be in parallel to independently manage the HV+ and HV- power lines. On the other hand, in other application cases, it may be necessary for the Kp and Kn contactors to be in series to have double insulation of the HV+ and HV- lines. The nature of the load and the criticality of the function may call for one or other of these configurations.
[0042] According to the invention, the plate is designed so that the main contactors Kp and Kn can be mounted in two orientations on the same plate thanks to a judiciously chosen geometry and center distances. Thanks to this configuration of the plate, the contactors Kp and Kn can be placed either in parallel or in series, allowing adaptation to the need for distribution and precharging use in a high voltage DC network.
[0043] Figure 4 shows an exemplary embodiment of a generic high voltage DC electrical distribution board according to a preferred embodiment of the invention. Figure 4 represents a configuration with Kp and Kn in parallel when mounted in one of the two orientations provided, this orientation being seen from the right in Figure 4 and from the left in Figure 6. Figure 5 is a diagram showing the activation of the contact terminals of the contactors Kn and Kp according to the parallel configuration.
[0044] As illustrated in Figure 4, the contactors Kp, Kn are integrated into the plate 40 which serves as mechanical support for the assembly to make the solution compact and reduce electrical and mechanical interfaces as much as possible. The motors, auxiliary contacts and beam of the moving part are on one side of the plate, while the contact chambers (fixed and moving) are on the other side of the plate.
[0045] More particularly, the plate 40 has two opposite major surfaces, 41 and 42. On the first surface 41 are mounted four contact chambers 45a, 46a, 45b and 46b housing the fixed and movable contact terminals of the contactors Kp and Kn. To prevent electric arcs these contact chambers 45a, 46a, 45b and 46b can be, for example, vacuum chambers or oil-filled chambers.
[0046] On the second surface 42 of the plate are mounted complementary sets of contactors, 48a, 48b, and other components 52 to 58. According to the example shown in Figure 4, the other components 52 to 58 comprise: a current probe 52, two resistors 54, 55, a precharge contactor 56, and a fuse 58 (visible in Figure 6).
[0047] The complementary contactor assemblies, 48a, 48b, include the motors, auxiliary contacts and beam of the moving part of the contactors Kp and Kn. The motors are indicated by 51a and 51b on the drawings. Motor 51a activates Kp.
[0048] The components arranged on the second major surface of the plate are arranged so as to leave a free space constituting a fixing zone ZF (see FIG. 6) of the complementary assemblies 48a, 48b of the two contactors. The fixing zone ZF is dimensioned to allow the arrangement of the complementary assemblies of the contactors 48a, 48b in two orthogonal orientations. A first orientation in which each of the motors of the complementary contactor assemblies activates the terminals of a respective first sub-assembly of the contact terminal chambers 45a, 46a, 45b and 46b, and a second orientation in which each of the motors of the complementary contactor assemblies activates the terminals of a respective second sub-assembly of the contact terminal chambers 45a, 46a, 45b and 46b, the contact chambers of the first and second sub-assemblies being aligned in respective orthogonal directions.Figures 4, 6 and 9 show the first orientation of the complementary contactor assemblies 48a, 48b. According to this first orientation, the motor 51a can open or close the contact terminals arranged in the two contact chambers 45a and 46a which are arranged on the same side of the plate. The relevant sub-assembly of contact chambers comprises two contact chambers 45a and 46a which are arranged along a first line parallel to the length of the plate.
[0049] Similarly, according to this first orientation of the complementary contactor assemblies 48a, 48b, the motor 51b can open or close the contact terminals arranged in the contact chambers 45b and 46b which are arranged on the other side of the plate. The subassembly of contact chambers concerned comprises two contact chambers 45b and 46b which are arranged along a second line parallel to the length of the plate.
[0050] This first orientation of the complementary contactor assemblies 48a, 48b allows the motors to control the contactors Kp, Kn in parallel, as shown in Figure 5.
[0051] Figures 7 and 10 show the second orientation of the complementary contactor assemblies 48a, 48b. According to this second orientation, the motor 51a can open or close the contact terminals arranged in the contact chambers 45a and 45b which are arranged towards the same end of the plate. The relevant contact chamber subassembly comprises two contact chambers 45a and 45b which are arranged along a third line parallel to the width of the plate.
[0052] Similarly, the motor 51b can open or close the contact terminals arranged in the two contact chambers 46a and 46b which are arranged towards the other end of the plate. The relevant contact chamber subassembly comprises two contact chambers 46a and 46b which are arranged along a fourth line which is parallel to the width of the plate.
[0053] This second orientation of the complementary contactor assemblies 48a, 48b allows the motors to control the contactors Kp, Kn in series, as shown in Figure 8.
[0054] In order to accommodate the two orientations of the complementary contactor assemblies 48a, 48b, the other components arranged on the second surface 42 of the plate 40 move apart from each other to make room for the fixing zone ZF. The dimensions of the fixing zone ZF are large enough to accommodate the complementary contactor assemblies 48a, 48b, according to the two intended orientations. Furthermore, the positioning of the four contact terminal chambers 45a, 46a, 45b and 46b is related to the center distance of the complementary contactor assemblies 48a, 48b, in particular the center distance of the motors 51a, 51b, to align the contacts of the two contactors with the corresponding motors of the complementary contactor assemblies according to the first and second orientation of the complementary contactor assemblies.
[0055] Furthermore, the plate 40 comprises fixing points 60 suitable for mounting the complementary contactor assemblies 48a, 48b, whether the latter are oriented in the first orientation or oriented in the second orientation. More particularly, fixing points 60 suitable for cooperating with complementary fixing means 62 on the complementary contactor assemblies 48a, 48b are provided: at certain locations on the plate which correspond to the positions of the complementary fixing means 62, when the complementary contactor assemblies 48a, 48b are positioned in the first orientation, and
[0056] - at other locations on the plate which correspond to the positions of the complementary fixing means 62, when the complementary contactor assemblies 48a, 48b are positioned according to the second orientation.
[0057] According to the example of figures 4, 6 and 7, the fixing points 60 comprise smooth holes and screws 61 while the fixing means of the complementary contactor assemblies 48a, 48b comprise supports 62. Those skilled in the art will understand that other complementary fixing elements can be used on the plate and in the complementary contactor assemblies.
[0058] The proposed generic board constitutes a modular brick adaptable to the need for distribution and precharging use in a high voltage DC network. It includes contactors integrated on a power board allowing two layout configurations to allow "in series" or "in parallel" operation. The mechanical interfaces are identical for both configurations, as shown in Figures 4, 6 and 7. The modularity of the solution allows to meet different needs thanks to the proposed configurations which allow to make it generic. In addition, the proposed generic board allows to optimize the mass and the volume of the electrical power distribution unit, and a cost reduction.
[0059] According to other embodiments of the invention, a plate as described above is incorporated into an electrical power distribution unit, for example an electrical distribution unit mounted between a storage unit and a high voltage direct current (HVDC) bus of an aircraft.
[0060] According to other embodiments of the invention, an electrical power distribution network of an aircraft comprises a continuous high voltage electrical distribution unit integrating a plate as described above. The invention finds application in particular in the aeronautical industry and the automobile industry, for example in relation to a generation channel, an HVDC battery, a fuel cell, primary distribution, secondary distribution, electric propulsion, hybrid propulsion, etc.
Claims
Demands
1. A high-voltage DC electrical distribution board, having two opposing major surfaces, the board integrating two electromechanical power contactors, characterized in that: on a first of the major surfaces of the board are arranged fixed and movable contact terminal chambers of the two electromechanical contactors, while on the second major surface of the board are arranged complementary assemblies of the two contactors, each complementary contactor assembly comprising a motor intended to activate the contact terminals of one of the respective contactors, and in that other components arranged on the second major surface of the board are arranged so as to leave a free space constituting a fixing zone for the complementary assemblies of the two contactors,the mounting area being dimensioned to allow the arrangement of the complementary contactor assemblies in two orthogonal orientations, a first orientation in which each of the motors of the complementary contactor assemblies activates the terminals of a first respective subset of the contact terminal chambers, and a second orientation in which each of the motors of the complementary contactor assemblies activates the terminals of a second respective subset of the contact terminal chambers, the contact chambers of the first and second subsets being aligned in respective orthogonal directions.
2. High voltage DC electrical distribution board according to claim 1, characterized in that the center distances of the contactor chambers and the center distances of the complementary contactor assemblies are dimensioned to align the contacts of the two contactors with the corresponding motors of the complementary contactor assemblies according to the first and second orientations of the complementary contactor assemblies.
3. High voltage DC electrical distribution board according to claim 1 or 2, characterized in that it comprises fixing points on the second major surface of the board, the number and positions of the fixing points being chosen to ensure the fixing of the complementary assemblies of contactors on the board, by means of the cooperation between these fixing points on the board and complementary fixing elements provided on the complementary assemblies of contactors, whether the complementary assemblies of contactors are oriented according to the first orientation or according to the second orientation.
4. High voltage DC power distribution board according to any one of claims 1 to 3, including a pre-charge function.
5. High-voltage direct current electrical distribution unit mounted between a storage unit and a high-voltage direct current (HVDC) bus of an aircraft, said distribution unit comprising a plate according to any one of claims 1 to 4.
6. Electrical distribution unit according to claim 5, characterized in that the storage unit is a battery or a supercapacitor.
7. Aircraft power distribution network comprising a high-voltage DC power distribution unit according to claim 5 or 6.