Current-Sensing Power Module Assembly for Aircraft
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Solution Overview
Problem
Conventional power distribution systems in aircraft require separate IGBT assemblies and current sensors, leading to inefficient space utilization, increased weight, and complexity due to separate mounting and potential for higher vibration levels.
Innovation Solution
A current-sensing power module assembly integrating an IGBT assembly and a Hall Effect current sensor in an elongated, low-profile configuration with shared mounting features, ensuring electrical isolation and electromagnetic shielding, allowing for combined operation and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If separate IGBT assemblies and current sensors are used, then electrical isolation and functionality are maintained, but space utilization is inefficient and weight increases
Solution Approach 1:
The patent combines the IGBT assembly and Hall Effect current sensor into a single integrated current-sensing power module assembly. The IGBT assembly with its housing and output terminal is merged with the Hall sensor assembly, allowing both components to occupy a compact, space-efficient configuration while maintaining their electrical isolation and functional independence.
2Reliability
If separate mounting is used for IGBT and current sensor, then installation flexibility is maintained, but assembly complexity and vibration resistance decrease
Solution Approach 1:
The patent integrates the mounting structures of both the IGBT assembly and Hall sensor assembly into a unified mounting system. Shared mounting features and a common housing structure provide enhanced mechanical stability and vibration resistance, while simplifying the overall mounting process compared to separate installations.
3Weight of stationary object
If integrated assembly is used, then space and weight are reduced, but manufacturing and assembly precision requirements increase
Solution Approach 1:
The patent introduces intermediate mounting features and alignment structures that facilitate precise positioning of the Hall sensor relative to the IGBT output terminal. These intermediary elements act as mediators that simplify the alignment process during manufacturing, reducing the actual precision requirements despite the integrated design.
4Area of stationary object
If current sensor is positioned downstream from IGBT, then current sensing functionality is achieved, but spatial separation increases system footprint
Solution Approach 1:
The patent positions the Hall Effect current sensor such that it is nested within or adjacent to the IGBT assembly housing. The sensor's aperture is configured to receive the output terminal, creating a compact nested arrangement where the current sensing function is achieved without increasing the overall system footprint, as one component is effectively housed within or integrated into the other's spatial envelope.
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
This integration results in space savings, reduced weight, improved vibration resistance, and streamlined replaceability, enabling higher power density and efficiency in aircraft power distribution systems.
Implementation Method 1
A Hall Effect sensor is a transducer that generates an output signal in response to a magnetic field. Electricity carried through a conductor will produce a magnetic field that varies with traversing the conductor, and a Hall sensor can be used to measure the current without interrupting the circuit.
Data Source
AI summary
A current-sensing assembly that includes a power module, for providing switchable power, having a current output extending through and directly away from the top exterior surface of the power module, a Hall sensor, capable of measuring current traversing through a conductor, having an opening, and the current output extending through the opening.