Virtual Electronic Circuit Breaker for Aerospace Power Distribution
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Solution Overview
Problem
Current circuit control devices in aerospace power distribution systems, such as thermal circuit breakers and Solid State Power Controllers, are either bulky and labor-intensive or cost-prohibitive for higher power loads due to the need for numerous metal-oxide-semiconductor field-effect transistors.
Innovation Solution
A virtual electronic circuit breaker (VECB) system utilizing an electrical relay and control circuit with a microprocessor and driver for load and wire protection, capable of detecting overcurrent and short circuits, and optionally including a ground fault interrupt detection unit, allowing for software-set overcurrent rating changes and using conventional, cost-effective components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal circuit breaker and power relay are used in series, then load and wire protection and load control functions are provided, but the system becomes bulky and labor intensive for installation and troubleshooting
Solution Approach 1:
The patent combines the thermal circuit breaker and power relay into a single integrated housing, merging two separate protective devices into one compact unit. This reduces the overall bulk of the system and simplifies installation by eliminating the need to install and coordinate two separate devices, while maintaining both load/wire protection and load control functions.
Solution Approach 2:
The integrated device performs multiple functions simultaneously: it provides thermal overload protection, short-circuit protection, and load control switching all within a single unit. This multi-functionality eliminates the need for separate protective devices and reduces system complexity while maintaining comprehensive protection capabilities.
2Reliability
If Solid State Power Controller is used, then load and wire protection and load control functions are provided, but the system becomes cost prohibitive for higher power loads due to high number of MOSFETs required
Solution Approach 1:
The patent employs conventional, cost-effective components such as standard power relays and off-the-shelf control circuits instead of expensive solid-state power controllers with numerous MOSFETs. This approach significantly reduces manufacturing costs for higher power applications while maintaining reliable protective functions through proven, affordable technology.
Solution Approach 2:
The patent changes the operational parameters and component selection to use conventional power relays rated for higher power loads rather than solid-state MOSFET-based controllers. This parameter change in component type and power handling capability achieves cost-effectiveness for high power applications without sacrificing protective functionality.
3Ease of manufacture
If conventional power relays are used for higher power loads, then cost effectiveness is improved, but relay lifespan may be reduced due to arc formation
Solution Approach 1:
The patent introduces an RC snubber circuit as an intermediary protective element connected across the power relay contacts. This snubber circuit absorbs voltage spikes and suppresses arc formation during relay switching, thereby protecting the conventional power relay from damage and extending its operational lifespan while maintaining cost-effectiveness.
Solution Approach 2:
The RC snubber circuit provides beforehand cushioning by pre-positioning protective components that absorb and dissipate voltage transients and arc energy before they can damage the relay contacts. This preventive measure extends relay life without adding significant cost to the overall 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
The VECB system reduces project costs and complexity, enabling efficient control of 1-phase AC, 3-phase AC, or DC power with minimal hardware changes, and extends relay lifespan by preventing arc formation, making it suitable for high-cycle applications while maintaining cost-effectiveness.
Implementation Method 1
an RC snubber can be used to suppress voltage transients and arc formation that can damage the relay and shorten its lifespan
Data Source
AI summary
A virtual electronic circuit breaker having an electrical relay and a control circuit, the control circuit including a load and wire protection (“OC”) detection unit, a microprocessor and a driver. The OC detection unit is configured to monitor a power flow and the electrical relay is effective to control it. The driver is effective to cause the relay to stop the power flow upon receipt of a deactivation command. The OC detection unit is effective to cause the driver to receive a deactivation command if the OC detection unit senses that a short circuit condition or an overload condition exists. The microprocessor of the control unit is configured so as to be capable of, at least, receiving input from the OC detection unit and sending output to the driver.