Arc Damage Detection Using Power-Time Modeling in Aircraft Circuits

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Solution Overview

Problem

Existing systems in aircraft power generation and conversion units lack effective methods to assess and mitigate damage from electrical arcs, which can lead to thermal damage and potential fire hazards.

Innovation Solution

A method and system for detecting electrical arc damage by receiving input indicative of electrical power over time, modeling the amount of damage using regression or machine learning models, and comparing it to a predetermined threshold to flag warnings or initiate inspections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional high current detection and system shutdown is used, then system safety is improved, but thermal damage to cold plate or walls occurs during detection latency

Engineering Contradiction:

Improvesystem safetyVSAvoidthermal damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary damage assessment by calculating estimated melt depth based on arc current, duration, and material properties before actual damage occurs. This allows proactive warning and mitigation actions to be taken during the arc event, reducing thermal damage to cold plates and chassis walls before the conventional shutdown response can occur.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors arc characteristics (current, duration, power) and provides real-time feedback on damage potential through melt depth calculations. This feedback loop enables dynamic adjustment of protective actions, allowing the system to respond appropriately to the actual severity of each arc event rather than relying solely on fixed threshold-based shutdowns.

Inventive Principle:

Principle #23Feedback

2Object-affected harmful factors

If arc detection and shutdown latency is reduced, then thermal damage is minimized, but detection system complexity increases

Engineering Contradiction:

Improvethermal damageVSAvoiddetection system complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The system replaces complex hardware-based rapid detection mechanisms with software-based damage assessment calculations. By using regression models and machine learning algorithms to estimate melt depth from standard electrical measurements (current, duration, power), the system achieves rapid damage assessment without requiring additional sensors or complex detection hardware, thus minimizing thermal damage while avoiding increased device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If real-time damage modeling is implemented, then damage assessment accuracy is improved, but computational requirements increase

Engineering Contradiction:

Improvedamage assessment accuracyVSAvoidcomputational energy

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The system changes the computational approach from complex real-time thermal simulations to streamlined regression-based calculations that estimate melt depth using key arc parameters (current, duration, power, material properties). This parameter-based approach maintains damage assessment accuracy while dramatically reducing computational energy requirements, enabling implementation in embedded aircraft power conversion systems with limited processing resources.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively predicts potential damage from electrical arcs, allowing for timely interventions such as breaking the circuit and issuing warnings, thereby reducing the risk of thermal damage and fire hazards in aircraft power systems.

Implementation Method 1

Using the regression model can include modeling transient heat transfer resulting from the electrical arc

Methodology Applied

Scientific EffectTransient heat transfer: Conduction (thermal)

Implementation Method 2

These short circuits can result in a large amount of energy dissipated to a power conversion assembly, resulting in thermal damage

Methodology Applied

Scientific EffectThermal energy dissipation: Joule Heating

Data Source

PatentUS20250139332A1Systems and methods for arc damage detection

Publication Date: 2025.05.01 HAMILTON SUNDSTRAND CORP

AI summary

A method of detecting electrical arc damage includes receiving input indicative of electrical power as a function of time in an electrical arc. The method includes using the input to model an amount of damage caused by the electrical arc, and comparing the amount of damage to a predetermined threshold. The method includes flagging a warning in response to the amount of damage exceeding a predetermined threshold. The method can include breaking a circuit to stop the electrical arc. Flagging the warning can include signaling to an operator to inspect a unit potentially damaged by the electrical arc. The method can include inspecting the unit potentially damaged by the electrical arc.