Generic high-voltage DC electrical distribution panel

Abstract

The invention relates to a high-voltage DC electrical distribution panel for the installation of two electromechanical power contactors either in series or in parallel. Locations for the installation of the chambers for the fixed and mobile contact terminals of the two contactors are arranged on a first of the main surfaces of the panel, while locations for the installation of the complementary assemblies for the two contactors are arranged on the second main surface of the panel, each complementary assembly comprising a motor that is intended to activate the contact terminals of the relevant contactor. On the first of the surfaces, there is an installation location free of contact terminal chambers and fixed contacts at this location are protected by a protective housing incorporating a shunt which ensures continuity of the power connection. This device improves the isolation of live parts while offering greater compactness.

Description

[0001] Description

[0002] Title of the invention: Generic high voltage continuous electrical power distribution board

[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 cut-off device with a pre-charging resistor.

[0008] Figure 1 represents the general block diagram of an example 10 of such a BPMU.

[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 needs from discrete elements mechanically integrated.

[0012] In its patent application FR 22 01421, the Applicant proposed a generic electrical distribution board which integrates a significant number of components while allowing adaptation to the need for distribution and precharging use in a high voltage DC network.

[0013] A top view of an example 40 of the generic power distribution board of patent application FR 22 01421 is shown in Figure 2 and a bottom view is shown in Figure 3.

[0014] According to this generic power distribution board, the contactors (e.g. Kp, Kn contactors) are integrated into the board 40 which serves as a mechanical support for the assembly to make the solution compact and minimize electrical and mechanical interfaces. The motors, auxiliary contacts and beam of the moving part are on one side of the board, while the contact chambers (fixed and moving) are on the other side of the board.

[0015] 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 may be, for example, vacuum chambers or oil-filled chambers.

[0016] On the first surface 41 of the board are also mounted power terminal blocks 31a, 31b, 34a, 34b to connect the board to the power distribution circuit, to the source on the one hand and to the load or to the network on the other hand. Insulating screw protection caps 32a, 32b, 35a, 35b are provided to avoid the risk of short circuit between the two polarities by external object.

[0017] On the second surface 42 of the plate are mounted complementary sets of contactors, 48a, 48b, and other components. According to the example shown in Figure 2, the other components include: a current probe 52, two resistors 54, 55, and a precharge contactor 56. Still other components (for example a fuse) may be present but are not shown.

[0018] 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.

[0019] This generic board 40 can be used to implement the circuit shown in Figure 1, as well as other circuits. The generic board allows, in particular, the arrangement of the complementary sets of contactors according to two orthogonal orientations allowing the motors to activate contact terminals of different subsets of the contact chambers and thus to achieve parallel or series configurations of the contactors. Fixing points 60, and screws 61 allow the complementary sets of contactors, 48a, 48b to be fixed according to the desired configuration (in series or in parallel).

[0020] The components arranged on the second major surface 42 of the plate 40 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 dimensioned to allow the arrangement of the complementary assemblies of the contactors according to the two orthogonal orientations, a first orientation according to which each of the motors of the complementary contactor assemblies activates the terminals of a respective first sub-assembly of the contact terminal chambers, and a second orientation according to which each of the motors of the complementary contactor assemblies activates the terminals of a respective second sub-assembly of the contact terminal chambers, the contact chambers of the first and second sub-assemblies being aligned according to respective orthogonal directions.

[0021] The center distances of the contactor chambers and the center distances of the complementary contactor assemblies are sized 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.

[0022] Thus, the modular generic board with integrated contactors on a power board and allowing two layout configurations facilitates 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 for optimization of the mass and volume of the function. The modularity of the solution also makes it possible to meet different needs thanks to the proposed configurations which make it generic.

[0023] However, the generic board 40 also allows the production of circuits which require only two contactors, i.e. circuits which omit either Kp or Kn, in which case it is possible to remove, for each omitted contactor, two contact chambers at the locations provided on the surface 41 of the board. Figure 4 shows the area 47a of the generic board where the fixed contacts 37 are then found 1 ; 372when a contact chamber is not mounted at one of the locations provided on the surface 41 of the plate: in the example shown in Figure 4, the contact chamber 45a has been omitted from the device.

[0024] As seen in Figure 4, when there is no contact chamber mounted at one of the locations provided on the surface 41 of the plate, the fixed contacts are left uninsulated and the power connection is interrupted. Until now, to protect the fixed contacts in such a case, it has been proposed to mount an insulating cover 50 on the surface 41 of the plate, this insulating cover 50 covering the area 35a where the fixed contacts are located. To ensure the power connection, a power bar 30 is added to the assembly as well as associated fixing elements 39 (power stud, etc.). Such a configuration is shown in Figure 5 (which represents the case where the contact chamber 45b has been omitted from the device).

[0025] This earlier approach therefore involves adding electrical connection parts (terminals, bar, hardware) and an insulating cover to cover the fixed contacts, which increases the size of the device. Such an arrangement is shown in Figure 5.

[0026] Furthermore, the power bar shown in Figure 5 has mechanical assemblies to make electrical connections in the event that a two-contactor configuration is used. These connections cannot be completely insulated and therefore have exposed, bare live metal parts. This can be dangerous for maintenance operators or be the source of an electrical fault if a metallic foreign body is present in this area.

[0027] The present invention aims to overcome the drawbacks mentioned above.

[0028] Statement of the invention

[0029] 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, including to allow adaptation which involves the absence of a moving contact at one of the mounting locations provided on the board.

[0030] These aims are achieved by a high-voltage DC electrical distribution board, characterized in that: on a first of the major surfaces of the board are provided locations for mounting the fixed and movable contact terminal chambers of two electromechanical contactors, a pair of fixed contacts being provided at each contact chamber mounting location, while on the second major surface of the board are arranged locations for mounting the complementary assemblies of the two contactors, these assemblies each comprising a respective motor intended to activate the contact terminals of one of the respective contactors, a protection component is mounted at at least one of the contact chamber mounting locations, in place of the movable contact,said protective component comprising: an insulating cover defining with the surface of the plate a closed space comprising an electrical connection shunt arranged to connect the pair of fixed contacts together.,

[0031] The plate according to the configuration shown above allows for the best possible integration, and allows the fixed contacts to be connected in a reduced space requirement.

[0032] In a preferred embodiment, the protective component of the aforementioned high-voltage electrical distribution board comprises a pressure spring arranged to press the connection shunt against the fixed contacts. In this way, the continuity of the current path is ensured with increased reliability.

[0033] 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.

[0034] 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 bus (HVDC) of an aircraft. Advantageously, the storage unit may be a battery or a supercapacitor. The invention also relates to an electrical power distribution network of an aircraft comprising an electrical power distribution unit as mentioned above.

[0035] Brief description of the figures

[0036] 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:

[0037] [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,

[0038] [Fig. 2] Figure 2 shows a top view of a generic high voltage DC distribution board, with complementary power contactor assemblies arranged in a first orientation,

[0039] [Fig. 3] Figure 3 shows a bottom view of the high voltage distribution board of Figure 2,

[0040] [Fig. 4] Figure 4 shows an exposed, fixed contactor area of ​​the lower surface of the DC high voltage distribution board of Figure 2,

[0041] [Fig. 5] Figure 5 shows a power bar used in the prior art to protect the fixed contactor area,

[0042] [Fig. 6] Figure 6 is a diagram showing a board provided, on one side, with a power bar according to Figure 5 and, on the other side, with a protection component according to an embodiment of the invention, and

[0043] [Fig. 7] Figure 7 is a sectional view of an example of the protective component shown in Figure 6.

[0044] Description of the embodiments

[0045] The invention is based on the configuration of a high-voltage electrical distribution board so as to integrate a large number of components therein, while allowing adaptation to the need for use, distribution and precharging in a high-voltage DC network, including an adaptation involving the absence of a contact terminal chamber at one of the locations provided on the board.

[0046] 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.

[0047] As described in patent application FR 22 01421, the plate is designed so that the contactors Kp and Kn can be mounted in two orientations on the same plate thanks to a judiciously chosen geometry and center distances. To this end, on one of the major surfaces of the plate, locations are provided for the mounting of four contact chambers housing the fixed and moving contact terminals of the contactors Kp and Kn. However, depending on the application, it may be necessary to use only one of the two contactors Kn and Kp.

[0048] According to one example, the board houses 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, 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 the Kp / Kn and K1 contactors and for managing current measurements.

[0049] According to this example, since the device only houses one of the two contactors Kn and Kp, there is no need to mount all four chambers of the fixed and movable contact terminals. More precisely, a movable contact can be omitted. On the board there is therefore a contact terminal chamber mounting location which is devoid of a contact chamber. Since a pair of fixed contacts is arranged at this location, according to an embodiment of the invention, a new component is provided to protect the fixed contacts and ensure the power connection. This is a component which corresponds to a subassembly which protects the fixed contacts, and which integrates an electrical shunt (a conductive connection, for example a metallic connection) in place of the movable contact positioned to be seated on the fixed contacts.

[0050] This solution allows for configurability of the board while securing the electrical connections since the connection created by the shunt is covered and completely isolated.

[0051] Figure 6 represents a board 100 which integrates a protection component 200 according to an embodiment of the invention, as well as a power bar 30 according to the approach illustrated by Figure 5. A rectangle R in Figure 6 indicates the region corresponding to the configuration according to the embodiment of the invention.

[0052] In order to simplify the presentation, elements similar to those shown in Figures 2 to 5 are designated in Figure 6 by equivalent references preceded by the number 1 (thus, for example, the contact chamber 146a of Figure 6 is equivalent to the contact chamber 46a of Figure 3). The description of the elements concerned is therefore omitted or shortened below.

[0053] In Figure 6, the two configurations are presented side by side in order to allow a visual comparison between these configurations and, thus, a better appreciation of the advantages arising from the invention, in particular in terms of the reduced volume occupied by the solution according to the invention. However, those skilled in the art will understand that, in practice, it is preferable to use only the solution provided by the invention, i.e., protection components 200 at all contact terminal chamber mounting locations which are devoid of a contact chamber / moving contact.

[0054] The protection component 200 is an element which comprises a conductive connection (for example a narrow metal plate 212 according to the example of FIG. 7) arranged to serve as a power connection shunt, that is to say to ensure the power connection by connecting the fixed contacts which are found at the contact chamber mounting location where this protection component 200 is mounted. The protection component 200 also comprises an insulating cover 201.

[0055] Figure 6 shows the difference in integration and volume between the current solution and the embodiment of the invention in rectangle R. The assembly of the elements on the left corresponds to the previous state with a power bar that is bare and exposed. The assembly presented on the right shows the embodiment proposed to optimize the space requirement and eliminate the live bar.

[0056] The proposed embodiment makes it possible to eliminate the power stud 139 and the power bar 130 not covered with insulation, as well as the insulating cover 150.

[0057] The plate 100 comprises a plate 110 which serves as a mechanical “structure” to support the assembly. According to one embodiment of the invention, the plate 110 is made of epoxy, for example of type FR4 or FR5.

[0058] The 100 board accommodates the following components:

[0059] - power terminal blocks 31 a, 31 b, 34a, 134b to connect the board to the power distribution circuit, to the source on the one hand, and to the load or network on the other hand

[0060] - insulating screw protection caps 32a, 32b, 35a, 35b to avoid the risk of short-circuiting between the two polarities by an external object

[0061] - contactor chambers 46a, 46b, 46A, 46b, and

[0062] - the protection component 200 which corresponds to a sub-assembly with integrated shunt.

[0063] As can be seen in Figure 6, the use of the protection component 200 allows for a reduction in the number of parts and better integration, which provides mass savings and makes modularity as simple as possible. Standardization adapted to the different configurations of the generic high voltage direct current (HVDC) electrical power distribution board of the power contact shunt subassembly 200 is then possible.

[0064] Figure 7 shows a sectional view of an exemplary embodiment of the protection component 200 of Figure 6. According to this example, the protection component 200 is composed of the following elements:

[0065] - a mobile connection bar 212: power transfer between the two contact pads.

[0066] - a retaining nut 213: fixing between the movable bar and the translation axis

[0067] - a contact pad 214: transfer of power to the HV power bars and the moving contact, and - an axis 215, it allows bonding by translation and maintaining contact pressure between the pads and the power bars in the active state. In the rest state it guarantees detachment of the contacts.

[0068] Since it includes the power connection shunt arranged to connect the fixed contacts, and the insulation provided by a cover or the like, the protection component 200 can be modified from the example shown in Figure 7, for example according to the needs of the application or the wishes of the designer. For example, a spring can be added to ensure the assertion.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] The devices provided by the invention make it possible to reduce the number of parts and to have better integration in order to have weight savings and to make modularity as simple as possible. A standardization adapted to the different configurations of the generic high voltage direct current (HVDC) electrical power distribution board of the power contact shunt subassembly is then possible.

Claims

Demands

1. High-voltage DC electrical distribution plate (100), having two opposing major surfaces, characterized in that: on a first (41) major surface of the plate are provided locations for mounting the fixed and moving contact terminal chambers of two electromechanical contactors, a pair of fixed contacts (371, 372) being provided at each contact chamber mounting location, while, on the second (42) major surface of the plate, are arranged locations for mounting the complementary assemblies of the two contactors, these assemblies each comprising a respective motor intended to activate the contact terminals of one of the respective contactors, a protective component (200) is mounted at least at one (47a) of the contact chamber mounting locations, in place of the moving contact,said protective component (200) comprising: an insulating cover (201) defining with the surface of the plate an enclosed space comprising an electrical connection shunt arranged to connect the pair of fixed contacts (37i, 372).

2. High voltage DC electrical distribution board according to claim 1, characterized in that the protection component (200) comprises a pressure spring arranged to press the connecting shunt against the fixed contacts (37i, 372).

3. High voltage DC power distribution board according to claim 1 or 2, including a pre-charge function.

4. 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 3.

5. Electrical distribution unit according to claim 4, characterized in that the storage unit is a battery or a supercapacitor.

6. Aircraft power distribution network comprising a high-voltage DC power distribution unit according to claim 4 or 5.

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