Hybrid SiC Solid State Contactor for DC Power Distribution
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Solution Overview
Problem
Conventional electromechanical contactors in power management and distribution systems for military ground vehicles have slow response times, leading to excessive energy let-through during faults and challenges in supporting high current ratings, which complicates the implementation of solid state power controllers (SSPCs) without increasing cost and size.
Innovation Solution
A direct current generating, management, and distribution system utilizing a hybrid architecture with silicon carbide (SiC) MOSFETs and SCRs, along with active rectifiers and a unit controller that powers cycle rectifiers and switches in response to overload conditions, enabling efficient and rapid fault response while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If electromechanical contactors are used for high current circuits, then voltage drop and losses are minimized, but response time becomes excessively slow requiring many tens of milliseconds to switch
Solution Approach 1:
The patent replaces electromechanical contactors with solid state power controllers (SSPCs) using silicon carbide MOSFETs and SCRs. This substitution eliminates mechanical moving parts, reducing response time from tens of milliseconds to microseconds while maintaining low on-state resistance through parallel device configuration and advanced semiconductor material properties.
Solution Approach 2:
The patent changes the material parameter from conventional silicon-based semiconductors to silicon carbide (SiC), which enables higher switching speeds and lower on-resistance. This material parameter change allows the SSPC to achieve both fast response time and low voltage drop simultaneously, resolving the contradiction between speed and energy loss.
2Reliability
If the number of parallel SiC MOSFETs is increased to achieve higher current capability, then current rating increases, but complexity, cost and size of the SSPC increase
Solution Approach 1:
The patent employs a hybrid solid state contactor architecture combining silicon carbide MOSFETs for high-speed switching and silicon carbide SCRs for high-current handling. This composite device approach leverages the complementary strengths of different semiconductor devices, achieving high current capability (up to 1000A) without requiring excessive parallel MOSFETs, thereby controlling complexity and size.
Solution Approach 2:
The patent segments the current handling function across multiple parallel SSPC modules, each capable of handling moderate currents. This modular segmentation allows scalable current capability while keeping individual module complexity manageable. The system can activate only the necessary number of modules based on current requirements, optimizing resource utilization.
3Reliability
If electromechanical contactors are used, then high current switching is achieved, but fault response time is excessive allowing too much energy let-through into faults
Solution Approach 1:
The replacement of electromechanical contactors with solid state power controllers enables microsecond-level fault detection and response. The electronic control system can detect fault conditions and interrupt current flow almost instantaneously, dramatically reducing the energy let-through into faults compared to the tens of milliseconds required by mechanical contactors.
Solution Approach 2:
The patent incorporates real-time monitoring and feedback control in the SSPC system. Sensors continuously monitor current, voltage, and device status, feeding this information back to the control logic which can immediately respond to fault conditions. This feedback mechanism enables rapid fault detection and protection, minimizing energy let-through while maintaining system reliability.
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 system achieves improved fault tolerance and reduced size and cost by leveraging dual channel architecture and hybrid solid state contactors, enhancing the capability to handle high currents with rapid response times.
Implementation Method 1
a permanent magnet synchronous machine
Implementation Method 2
silicon carbide (SiC) metal on oxide field effect transistors (MOSFET) and silicon controlled rectifiers (SCR)
Data Source
Figure 1
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AI summary
A direct current generating, management and distribution system includes a first armature winding 112, a first active rectifier 120 having a first controller 123 and coupled to the first armature winding, a first direct current bus 135 coupled to the first active rectifier, a second armature winding 113, a second active rectifier 130 having a second controller 133 and coupled to the second armature winding, a second direct current bus 140 coupled to the second active rectifier, a unit controller 201 coupled to the first and second controllers, a first set of switches 211 coupled to the first direct current bus and to the unit controller, a second set of switches 212 coupled to the second direct current bus and to the unit controller, a third switch 213 coupled to the first direct current bus and to the unit controller and a fourth switch 214 coupled to the second direct current bus and the unit controller.