Fault Interrupt Module with Threshold Counting for Heated Floor Panels
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Solution Overview
Problem
Conventional ground fault interrupt circuits fail to function properly on heated floor panels in aircraft due to inherent capacitance, causing false tripping when reactive current flows from heater elements to the skin, and are unable to detect dielectric breakdown effectively.
Innovation Solution
A fault interrupt module that monitors the difference in current between the input power line and neutral return line, allowing some reactive current while detecting faults, and terminates power to the load for a short time upon each fault occurrence, indefinitely if a threshold number of consecutive faults are detected, using a combination of detector circuits, timers, counters, and a solid-state relay to manage power flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power is terminated indefinitely after a fault, then safety is improved, but nuisance faults cause unnecessary permanent power loss
Solution Approach 1:
The patent implements periodic action by providing only temporary power termination for the first few fault occurrences, then transitioning to indefinite termination only after a threshold number of consecutive faults. This periodic approach allows the system to handle nuisance faults temporarily without permanent disruption, while still ensuring safety through eventual permanent termination if faults persist
Solution Approach 2:
The patent applies beforehand cushioning by allowing a certain number of fault occurrences before implementing permanent power termination. This cushioning mechanism protects against nuisance faults that may occur temporarily, while still providing ultimate safety protection if the faults represent a genuine hazard that persists over time
2Reliability
If a threshold-based fault counting system is implemented, then nuisance faults are handled appropriately, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical or analog fault counting mechanisms with electronic digital counting circuitry. The use of electronic counters and microprocessors to track fault occurrences and implement threshold-based responses significantly reduces physical complexity while maintaining or improving the accuracy of fault handling compared to traditional mechanical approaches
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 fault interrupt module effectively prevents false power terminations and detects dielectric breakdown in heated floor panels by allowing expected reactive current loss, reducing the size and weight of the circuit and handling nuisance faults without permanent power loss, while interfacing with any load and accommodating variations in power frequency.
Implementation Method 1
The detector circuit is configured to detect faults as a difference in current between an input power line and a neutral return line
Implementation Method 2
The counter circuit configured to increment a fault count each time a fault is detected by the detector circuit
Implementation Method 3
The switch circuit configured to terminate power to a load upon the fault count reaching a threshold count within a threshold time period
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A fault interrupt module includes a detector circuit (14), a counter circuit (26), and a switch circuit (34). The detector circuit is configured to detect faults as a difference in current between an input power line and a neutral line. The counter circuit configured to increment a fault count each time a fault is detected by the detector circuit, and the switch circuit is configured to terminate power to a load upon the fault count reaching a threshold count within a threshold time period.