Solid-State Arc Isolation for Reusable Short-Circuit Contact Protection

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Solution Overview

Problem

Existing contactor systems in aerospace power distribution face challenges in preventing arcing during short circuit events, with current fail-safes being non-reusable and requiring replacement after activation.

Innovation Solution

A high voltage contact control system utilizing solid state arc prevention elements that divert current through a bypass path, allowing for reusable arc protection without the need for replaceable fuses, and includes a controller to manage the operation of these elements in different modes to minimize arcing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fuses or pyrofuses are used to prevent arcing during short circuit events, then arc protection is provided, but the devices become one-time use and require replacement after activation

Engineering Contradiction:

Improvearc protectionVSAvoidreplacement requirement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent replaces traditional mechanical fuses with solid-state arc prevention elements that use electronic switching mechanisms. These solid-state devices can be reset and reused after activation, eliminating the need for replacement while maintaining arc protection functionality during short circuit events

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The solid state arc prevention elements are designed to be recoverable after use. After preventing an arc during a short circuit event, the devices can be reset to their original state through controlled discharge and resetting of their internal circuitry, allowing them to be reused rather than discarded like traditional fuses

Inventive Principle:

Principle #34Discarding and recovering

2Ease of repair

If solid state arc prevention elements are used to provide reusable protection, then ease of repair is improved, but device complexity increases

Engineering Contradiction:

ImprovereusabilityVSAvoidcontrol system

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The controller is pre-programmed with detection algorithms and control logic that automatically activate the solid state arc prevention elements when short circuit conditions are detected. This preliminary programming eliminates the need for complex real-time decision-making circuitry, simplifying the overall device complexity while maintaining advanced functionality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system incorporates feedback mechanisms where the controller continuously monitors system parameters and automatically adjusts the operation of solid state arc prevention elements based on detected conditions. This closed-loop feedback simplifies control by using straightforward sensor-controller-actuator relationships rather than complex control algorithms

Inventive Principle:

Principle #23Feedback

3Reliability

If arc prevention elements operate in linear mode to minimize arcing, then arc protection is improved, but energy consumption increases

Engineering Contradiction:

Improvearc preventionVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The solid state arc prevention elements operate in periodic cycles, switching between active arc prevention mode and standby mode. During normal operation, they remain in low-power standby state, and only activate in linear mode when arc prevention is actually needed, thereby minimizing overall energy consumption while maintaining reliable arc protection when required

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system uses partial action by operating the arc prevention elements in linear mode only for the minimal time necessary to prevent arcing during short circuit events. After the hazardous condition is eliminated, the elements quickly return to their normal low-power state, using energy only when absolutely necessary for safety

Inventive Principle:

Principle #16Partial or excessive action

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 effectively reduces or eliminates arcing in main contacts during short circuits, enabling reusable protection and non-destructive testing, thus improving reliability and reducing maintenance costs.

Implementation Method 1

a first solid state arc prevention element that can operate in at least two modes; a second solid state arc prevention element connected in series with the first solid state arc prevention and that can operate in at least two modes

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12362121B2Solid state parallel arc isolating device

Publication Date: 2025.07.15 HAMILTON SUNDSTRAND CORP

AI summary

A high voltage contact control system includes main contacts on positive and negative feeder lines and a short circuit protection system configured between the positive feeder line and the negative feeder line. The short circuit protection system is configured to be operably connected between the positive and negative feeder lines and configured to selectively provide a bypass path between the positive feeder line and the negative feeder line to divert current away from the first and second contacts. The short circuit protection system includes first and second state arc prevention elements that can operate in at least two modes. The bypass path is established by having one of the arc prevention elements in a fully on mode and another either fully on or in a linear mode.