Minimal Interruption DC Power Supply via Solid State Controller
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Solution Overview
Problem
Aircraft electrical systems experience prolonged downtime due to power interruptions, requiring a restart of the startup sequence when power is restored, which increases downtime and disrupts system operations.
Innovation Solution
A minimal interruption power source switching method that monitors DC bus power characteristics, activates a switching power source when necessary, and deactivates it when conditions are safe, using a solid state remote power controller and electrical contactors to manage power distribution between primary and secondary sources, with a communication line for coordinating with other controllers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power is interrupted to switch between power sources, then power source switching is achieved, but system downtime increases and operations are disrupted
Solution Approach 1:
The patent introduces a DC/DC converter as an intermediary device between the first DC power source and the second DC power source. This converter enables seamless power transfer by converting power from the first source to match the second source's characteristics, allowing contactor switching to occur without interrupting power delivery to the electrical component. The intermediary converter absorbs the switching transition, preventing downtime.
Solution Approach 2:
The system performs preliminary actions by pre-charging the second DC power source and pre-positioning contactors before the actual switching event. The controller monitors both power sources and prepares the second source to immediately take over when the first source needs to be disconnected, ensuring no gap in power supply occurs during the transition.
2Ease of operation
If contactors are used to switch power sources, then power distribution is controlled, but switching interruptions occur during the transition
Solution Approach 1:
The DC/DC converter serves as a mediator that bridges the gap created by contactor switching. While contactors mechanically open and close to switch between power sources, the DC/DC converter continuously provides converted power during the transition period, mediating the interruption and maintaining continuous power flow to the electrical component.
Solution Approach 2:
The system maintains continuity of useful action by having the DC/DC converter operate continuously during the switching process. The converter keeps converting power from the first DC source to the second DC source throughout the contactor transition, ensuring that the electrical component receives uninterrupted power despite the mechanical switching occurring in the background.
3Adaptability or versatility
If power switching occurs during electrical component operation, then power source redundancy is utilized, but the startup sequence must be restarted increasing downtime
Solution Approach 1:
The DC/DC converter enables continuity of useful action during power source switching, maintaining stable voltage and current delivery to the electrical component throughout the transition. This stability prevents the electrical component from detecting the power switch as a failure condition, allowing it to continue its startup sequence or operation without interruption or restart.
Solution Approach 2:
The patent replaces the mechanical switching approach (direct contactor switching between power sources) with an electronic conversion approach using the DC/DC converter. This substitution eliminates the hard interruptions associated with mechanical switching, as the electronic converter can transfer power smoothly without the contactor opening-closing cycle that causes power gaps and system resets.
Data Source
AI summary
A DC power distribution system and method includes a solid state remote power controller that connects a switching power source to a DC bus when the DC bus is switching power sources thereby providing a nearly uninterrupted power supply to the DC bus.