Battery Power Control Unit for High-Voltage DC Fault Isolation
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Solution Overview
Problem
Current protection solutions for high-voltage DC power networks in aircraft are inadequate due to differences in transient current profiles and energy dynamics compared to AC networks, and existing systems are unsuitable for managing high-power short-circuit currents and thermal runaway risks from capacitive sources like batteries.
Innovation Solution
A battery power control unit with multiple connections, sensors, and contactors, along with a control unit to manage and isolate faults, prevent short-circuit currents, and maintain power supply continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional AC-based protection solutions are used for high-voltage DC networks, then existing protection infrastructure can be maintained, but the protection is inadequate due to different transient current profiles and energy dynamics in DC networks
Solution Approach 1:
The patent applies parameter changes by transitioning from AC-based protection parameters to DC-specific parameters. The control unit monitors DC transient current profiles, voltage levels, and energy dynamics specific to DC networks, adjusting protection thresholds and response characteristics to match DC network behavior rather than AC characteristics.
Solution Approach 2:
The control unit acts as an intermediary between the battery, power distribution unit, and protection systems. It mediates the protection function by receiving data from multiple sources (current sensors, voltage sensors), processing DC-specific parameters, and coordinating the actions of protection devices (contactors, fuses) to provide adaptive DC network protection.
2Use of energy by moving object
If high-power batteries are used to increase energy capacity, then on-board energy storage is improved, but thermal runaway and short-circuit current risks increase
Solution Approach 1:
The control unit performs preliminary actions by continuously monitoring battery parameters (temperature, voltage, current) before thermal runaway occurs. It detects early signs of battery distress and preemptively activates protection measures (isolating the battery via contactors, triggering fuses) to prevent thermal runaway development.
Solution Approach 2:
The system implements feedback through continuous monitoring of battery temperature, voltage, and current by dedicated sensors. The control unit receives this feedback data, compares it against safety thresholds, and automatically adjusts protection device states (contactor opening/closing, fuse activation) to maintain battery safety while maximizing energy utilization.
3Reliability
If short-circuit protection devices are made larger to handle high currents, then current interruption capability is improved, but device mass and size increase
Solution Approach 1:
The protection function is segmented into multiple distributed protection devices (contactors at different locations, multiple fuses in series) rather than relying on a single large interrupter. Each device handles a portion of the protection task, allowing smaller, lighter individual components that collectively provide adequate short-circuit protection for the entire battery system.
Solution Approach 2:
The control unit serves as an intelligent intermediary that coordinates the operation of multiple smaller protection devices. It manages the timing and sequencing of contactor operations and fuse activations, enabling lightweight distributed protection architecture to achieve the same current interruption capability as traditional single-point protection with heavy equipment.
4Reliability
If multiple protection devices are deployed to isolate faults, then fault isolation effectiveness is improved, but system complexity increases
Solution Approach 1:
The control unit is designed as a universal multi-functional device that performs multiple protection tasks: monitoring multiple sensors, controlling multiple contactors, managing fuse operations, and coordinating fault isolation across different battery modules. This centralized intelligence simplifies the overall system by consolidating control logic into a single device rather than distributing complexity across multiple independent protection systems.
Data Source
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AI summary
A control unit for controlling the power of a battery (1) comprising at least two incoming connections (2, 4) carrying a DC voltage and two outgoing connections (5a, 5b) delivering a DC voltage, a first incoming connection (2) being connected to a first current sensor (2a) and to a high-voltage busbar (8) via a protection member (2c), the high-voltage busbar being connected to a first outgoing connection (5a) via a first controlled fuse (2b) and a second current sensor (2d), and to a second outgoing connection (5b) via a second controlled fuse (3b) and a third current sensor (3d), a control means (9) is also configured to switch the protection member (2c), the first controlled fuse (2b) or the second controlled fuse (3b) based on received measurements so as to isolate an electrical fault.