Solid State Contactor Bus Bar Current Sensor Integration
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Solution Overview
Problem
Electromechanical contactors in aircraft electrical systems are large, heavy, and costly, making them difficult to replace when worn out, and they do not efficiently manage current flow and overcurrent conditions.
Innovation Solution
A solid state contactor assembly with solid state switches connected to bus bars via conductive plates, incorporating a current sensor that separates the bus bar into sections, a fuse connection for overcurrent protection, and a microprocessor-controlled switch control system for managing current flow and overcurrent conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromechanical contactors are used to provide electrical connections, then reliable current control is achieved, but the device becomes large, heavy, and costly
Solution Approach 1:
The patent replaces electromechanical contactors with solid-state switches that use electronic field effects rather than mechanical moving parts to control current flow. This substitution eliminates the heavy mechanical components while maintaining reliable current control through semiconductor devices connected to bus bars.
2Reliability
If electromechanical contactors are used, then current flow control is achieved, but the device becomes large and costly
Solution Approach 1:
The invention substitutes mechanical electromechanical contactor systems with solid-state electronic switches that control current through semiconductor physics rather than mechanical contact closure. This dramatically reduces device size and cost while improving reliability and eliminating the need for heavy mechanical components.
Solution Approach 2:
The patent changes the operational parameters from mechanical switching to solid-state electronic switching, utilizing the electrical properties of semiconductor materials to control current flow. This parameter change enables compact, lightweight design while maintaining effective current control functionality.
3Measurement precision
If a current sensor separates the bus bar into two portions, then current measurement capability is improved, but the bus bar structure becomes more complex
Solution Approach 1:
The patent merges the current sensor integration directly into the bus bar structure itself, creating a unified component where the sensor is embedded within or attached to the bus bar. This integration achieves precise current measurement while minimizing structural complexity by combining functions rather than adding separate components.
4Weight of stationary object
If solid state switches are used instead of electromechanical contactors, then device size and cost are reduced, but new methods for current sensing and protection are required
Solution Approach 1:
The patent combines multiple protective functions (current sensing, overcurrent protection, and bus bar structural integrity) into an integrated system where the current sensor is embedded in the bus bar and the fuse connection provides inherent protection. This merging reduces the need for separate complex protection systems while maintaining device compactness.
Solution Approach 2:
The fuse connection provides automatic overcurrent protection that operates without external control, and the integrated current sensor automatically monitors and enables protective actions. The system serves itself by having built-in protection mechanisms that activate automatically when needed, reducing the complexity of external control systems.
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 solution provides a compact, efficient, and cost-effective means to control current flow and prevent overcurrents, allowing for easy installation and removal of bus bars without specialized tools, while ensuring reliable operation and thermal management through heat sinks.
Implementation Method 1
a current sensor formed along a cross section of one of the first or second bus bar such that the current sensor separates its associated bus bar into two separate bus bar portions and such that a flow of current between the two separate bus bar portions passes through the current sensor
Implementation Method 2
a fuse connection providing a current path between distinct areas of a selected one of the first or second bus bar, wherein in response to an overcurrent condition the fuse connection terminates and prevents a flow of current between the distinct areas of the selected bus bar
Data Source
Figure 1
Figure 1a
Figure 2~8
AI summary
A solid state contactor assembly (20) includes at least one solid state switch (28) electrically connected to a first bus bar (22) via at least one conductive plate (94). The solid state switch controls a flow of current between the first bus bar and a second bus bar (24). A current sensor (32) is formed along a cross section of one of the first or second bus bar such that the current sensor separates its associated bus bar into two separate bus bar portions, and such that a flow of current between the two separate bus bar portions passes through the current sensor. A switch control (82) is operable to control the solid state switch. The switch control is in communication with the current sensor.