Solid State Power Contactor for Aircraft Reliability
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Solution Overview
Problem
Conventional electro-mechanical power distribution systems in aircraft face reliability issues due to mechanical failures, particularly when handling high current and voltage loads, leading to potential electrical power interruptions and system failures.
Innovation Solution
The implementation of a solid state power contactor system with flexible power overlays and a controller module that enables bidirectional switching, allowing for selective interconnection of power sources with electrical loads, and is physically interchangeable with conventional electro-mechanical contactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electro-mechanical contactors are used for power distribution, then the system can handle high current and voltage loads, but mechanical failures occur leading to reduced reliability
Solution Approach 1:
The patent replaces electro-mechanical contactors with solid-state power electronic devices that use semiconductor switches (such as IGBTs or MOSFETs) to control power distribution. This substitution eliminates mechanical moving parts, contacts, and arc suppression components, thereby eliminating mechanical failures while maintaining the ability to handle high current and voltage loads through electronic switching.
2Reliability
If solid state switches are implemented, then mechanical failures are reduced, but the device form must be redesigned for interchangeability
Solution Approach 1:
The patent changes the physical form factor and mounting parameters of the solid-state power contactor to match the dimensions, mounting hole patterns, and terminal configurations of conventional electro-mechanical contactors. This allows the solid-state device to be directly interchangeable with existing electro-mechanical contactors without requiring modifications to the aircraft power distribution system infrastructure, while maintaining improved reliability through solid-state technology.
3Speed
If conventional electro-mechanical switchable power devices are used, then the form factor is standardized, but switching speed is limited and fault detection is slow
Solution Approach 1:
The patent replaces mechanical switching mechanisms with solid-state power electronic switches controlled by a microcontroller or digital signal processor. This enables switching speeds in the microsecond or nanosecond range, compared to the millisecond-range switching of electro-mechanical contactors. The control system incorporates fault detection algorithms that continuously monitor switch operation, current flow, and voltage levels, enabling rapid detection and response to faults.
Data Source
AI summary
A power device can include a first conductive terminal, a second conductive terminal, a power overlay having a conductive backplane and solid state switches, and a controller module configured to selectively operate the solid state switches to enable conductive communication between the first conductive terminal and the second conductive terminal.