Semiconductor DC Circuit Breaker with Pulse Injection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing DC circuit breakers are not well-suited for aircraft electrical distribution systems due to high voltage risks of arcing, size, weight, and slow response times, which traditional mechanical quenching methods attempt to address but increase size and weight further.

Innovation Solution

A semiconductor-based circuit breaker arrangement that uses a semiconductor switching device, pulse injection circuit, current sensor, and control circuit to inject a pulse current opposing the main current, reducing it below a threshold for the semiconductor device to interrupt, thus controlling the circuit breaking process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional electro-mechanical circuit breakers are used, then they can provide electrical protection, but they have slow response time and increased risk of arcing at higher voltage levels

Engineering Contradiction:

Improveelectrical protection capabilityVSAvoidresponse time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the electro-mechanical switching mechanism with a semiconductor switching device (such as an IGBT or MOSFET). This solid-state device can switch on and off extremely rapidly (in microseconds or nanoseconds), eliminating the mechanical inertia and contact bounce issues of traditional breakers. The semiconductor device is controlled by gate signals that can be generated and removed almost instantaneously, providing the fast response time needed for modern high-voltage DC protection while eliminating arcing risks associated with mechanical contacts.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Object-affected harmful factors

If mechanical quenching is used to address arcing risk, then arcing may be reduced, but the size and weight of the system increases

Engineering Contradiction:

Improvearcing riskVSAvoidsystem weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent eliminates the need for mechanical quenching mechanisms by using a semiconductor switching device that opens the circuit without mechanical contact separation. Since there are no mechanical contacts, there is no arcing to quench. The semiconductor device simply stops conducting current when the gate signal is removed, providing inherent arc-free operation. This eliminates the need for heavy mechanical quenching structures, arc chambers, and associated cooling systems, thereby significantly reducing system weight.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental operating parameters of the circuit breaker by transitioning from high-voltage mechanical switching to low-voltage semiconductor switching. The semiconductor device is controlled by low-power gate signals (typically a few volts and milliamps) that control the flow of high-voltage DC current. This parameter change allows the use of compact, lightweight semiconductor components rather than heavy mechanical switching mechanisms with associated quenching systems.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional electro-mechanical circuit breakers are used, then they can interrupt current, but their size and weight are relatively large

Engineering Contradiction:

Improvecurrent interruption capabilityVSAvoidcircuit breaker weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent replaces the entire electro-mechanical structure with a compact semiconductor switching device. The semiconductor device can be mounted on a small printed circuit board or integrated into a compact housing, eliminating the need for heavy mechanical linkages, contact assemblies, spring mechanisms, and magnetic quenching systems. The control circuitry for the semiconductor device is also much more compact than the control mechanisms required for electro-mechanical breakers, resulting in a overall significant reduction in size and weight while maintaining or improving current interruption capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution provides faster response times, reduced arcing risk, and a more compact, lightweight design suitable for aircraft systems, effectively interrupting DC currents while minimizing physical size and weight, and can be used in any DC transmission line application.

Implementation Method 1

an inductive coupling between the pulse generating circuitry and the transmission line arranged to inductively inject pulse currents generated by the pulse generating circuitry into the transmission line

Methodology Applied

Scientific EffectInductive coupling: Electromagnetic Induction

Data Source

PatentUS11482854B2Direct current (DC) circuit breaker

Publication Date: 2022.10.25 HAMILTON SUNDSTRAND CORP

AI summary

There is disclosed a circuit breaker arrangement for interrupting a current flowing through a direct current (DC) transmission line including a semiconductor switching device and a pulse injection circuit configured to inductively inject into the transmission line a pulse current that opposes the current flowing through the transmission line to thereby reduce the current in the transmission line to cause the semiconductor switching device to turn-off to interrupt the path for the current flow through the transmission line.