Phantom Works HSV Arc Fault Programmable Solid State

Phantom Works - HSV Arc Fault Programmable Solid State Circuit Breaker with Damaged Wire Detector/Locator John H. Blumer Boeing Huntsville John. h. blumer@boeing. com 3 January 2001

System Vision It is the vision of the Power Management and Distribution System Team to develop a suite of power system building block products (Programmable Solid State Circuit Breakers, Arc Fault Protection Devices, Damage Wire Detectors/Locators and Wire Inspection Systems) that will provide the Safety, Quality, Reliability and Cost Effectiveness required by our customers for use on Aircraft, Ground, Sea and Industrial Platforms. Thrust To license or partner the building block products for production to a vendor and/or vendors that will support the Power Management and Distribution System Teams System Vision. 30 May 2002 2

Legacy • The legacy for this technology is the Solid State Power Controller Module operational on the International Space Station - 50 Line Replaceable Units (LRU) in Production - 12 Completed - 6 On Orbit 30 May 2002 3

Legacy (continued) • The Arc Fault Programmable Solid State Circuit Breaker is a Boeing funded technology. - One patent pending - Foreign Patent Application - Three invention disclosure, submitted in 2002 • Design and integration of electrical interconnect system on many aircraft, space and ground platforms. • Developed methods to characterize airplane load inrushes, generated arcs for study and standardized arc test methodologies. • Application Specific Integrated Circuits (ASIC) design capabilities. 30 May 2002 4

Digitally Programmable Solid State Power Controller - Demonstrator The Digitally Programmable Solid State Power Controller was developed as a base for a power management and distribution system to meet the needs of future and existing platforms requirements for safe circuit protection devices on aircraft, space platforms, automobiles and the power industry. DPSSPC Functional Prototype This generation of Solid State Power Control and Distribution Technology is currently patent pending. Functional demonstrations were given to show the diversity of the design. This demonstration is 28 Vdc 1 to 10 Amps and is capable of controlling sixteen (16) output channels. The proven functions of this design is being integrated into the next generation smaller and cost efficient packages. Design Accomplishments n Patent Pending (09/842, 967). n Foreign patent applied for. n 28 V 10 A version assembled, tested and in n demonstration stage. Proved that multiple SSPC outputs could be controlled and monitored using a single microcontroller. Design Status n Can be readily modified for 28 V 20 A, 120 Vdc or 270 Vdc operation without relay out of PCB. n Built using COTS materials. n Studies to upgrade for space environment applications. n Design is a test bed for Silicon Carbide (Si. C) technology. 30 May 2002 5

Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module AC PSSCB/S Characteristics n Output configurable: – 120 VAC, 25 A 1 phase – 60 HZ, 400 Hz and variable frequency – Gang together for multi-phase operation – Drive Y or Delta configurations n Zero crossing and Phase detection. AC PSSCB/S WITH ARC DETECTION/DWDL MODULE DC PSSCB/S Characteristics n Output configurable: – 28 VDC, up to 25 A – Outputs can be paralleled for higher current operation n 120 VDC versions available n 270 VDC versions being evaluated New Technology Applications for AC and DC n IGBT alternative for higher voltage and current switchgear n Si. C MOSFET devices will be integrated and evaluated upon availability DC PSSCB/S WITH ARC DETECTION/DWDL MODULE 30 May 2002 6

AC Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module Power Input Power Common Solid State Switch Devices and Temperature Sensors Power Output DWDL Module Power Output Interface Secondary Power Interface Switch/Monitor Module Controller Module CANbus Interface RS 232 Interface Arc Fault Detector and Damaged Wire Detector/Locator Module Secondary Power Module (optional) 30 May 2002 7

Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module AC and DC PSSCB/S Common Features n Boeing Invention Disclosure No. 02 -0526 “A Remotely Programmable Solid State Circuit Breaker/Switch With Integrated Arc Detector And Damaged Wire Detector/Locator for AC or DC Applications” Microcontroller controlled Solid State Power Controller (SSPC). Integrated overcurrent, over/under voltage and over/under temperature monitoring. User selectable current, voltage and temperature limits from Maintenance Testing Equipment. Integrated Arc Fault, GFCI and Damaged Wire detection. n n n Serial data bus interface. (RS 232 and CANbus) n Modular component design n n n n – Interface Module – Controller Module – Switch Monitor Module – Arc Detection/DWDL Module – Secondary Power Module (Optional) Safety issues: – Output pulldown when switch is OFF – Ground Fault Circuit (GFCI) Interrupt protection – No startup if DWDL detects cable or connector changes – No re-startup if arc event was previously detected – Output placed in safe mode in case of microcontroller failure Can be integrated into rack systems. Reduces weight through cable reduction by being at load locatable. Provides health and operating status to system. Can be be controlled without a serial data interface via discrete ON/OFF and TRIP INDICATOR signals. Watchdog circuitry for placing switch in safe mode due to microcontroller failure. Soft-start up circuitry. Firmware upgradable via serial maintenance port. 30 May 2002 8

Arc Fault Detection And Damaged Wire Detector/Locator Module Functional Makeup The AFD and DWDL Module consist of n Arc Fault Detector Module – Boeing Invention Disclosure No. 02 -0528 n Damaged Wire Detector/Locator Module – Boeing Invention Disclosure No. 02 -0527 n GFCI Circuitry Design Concept Base n The PSSCB/S provides arc fault protection via: – Monitoring for an arc signature – Ground Fault Circuit Interrupt (GFCI) – Current Limiting capability of PSSCB/S – Output shutdown via PSSCB/S upon arc event n This approach is applicable to AC and DC devices. n Detects parallel and series arcs. n GFCI monitoring. n Damaged wire detector utilizes Time Domain Reflectometry (TDR) practices. 30 May 2002 9

PSSCB/S Trip Curve Embedded Trip Curve Capabilities n Firmware configurable trip curve. n Maximum current limiting is component dependent. n Trip time in current limit depends on voltage drop across MOSFET. 30 May 2002 10

PSSCB/S Trip Curve Established Trip Curve Modeling n Standard circuit breaker curve. 30 May 2002 11

Phantom Works - HSV PSSCB/S, AFD and DWDL Module In-System Maintenance Interface 3 January 2001

PSSCB/S Control and Analysis Display PSSCB/S Maintenance Display n Allows for control and testing of power devices in-system from the maintenance testing equipment without having to enter a vehicle. n Maintenance personnel can analyze fault data and set operating parameters from the maintenance testing equipment. n Fault data can be time stamped by the master control system and stored for further analysis. n The type of fault is indicated on this display. 30 May 2002 13

Damaged Wire Detector/Locator Maintenance and Analysis Display DWDL Maintenance Display n Left view shows data stored from initial training session on a fifty foot wire with load. n Right view shows data from a short that is located approximately 12 1/2 feet down the same fifty foot wire with load. n Maintenance personnel can train the DWDL Module and analyze fault data from the maintenance testing equipment. n Additional testing can be initiated from the maintenance testing equipment without having to enter a vehicle or disconnect cables to hookup wire testing equipment 30 May 2002 14