1. Phantom Works - HSV Arc Fault Programmable Solid State Circuit Breaker with Damaged Wire Detector/Locator
John H. Blumer
Boeing Huntsville

2. 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

3. 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
On Orbit
30 May 2002

4. 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

5. 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.
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 28Vdc 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.
DPSSPC Functional Prototype
Design Accomplishments
Patent Pending (09/842,967).
Foreign patent applied for.
28V 10A version assembled, tested and in demonstration stage.
Proved that multiple SSPC outputs could be controlled and monitored using a single microcontroller.
Design Status
Can be readily modified for 28V 20A, 120Vdc or 270Vdc operation without relay out of PCB.
Built using COTS materials.
Studies to upgrade for space environment applications.
Design is a test bed for Silicon Carbide (SiC) technology. 2
30 May 2002

6. Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module
AC PSSCB/S Characteristics
Output configurable:
120VAC, 25A 1phase
60HZ, 400Hz and variable frequency
Gang together for multi-phase operation
Drive Y or Delta configurations
Zero crossing and Phase detection.
AC PSSCB/S WITH ARC DETECTION/DWDL MODULE
DC PSSCB/S Characteristics
Output configurable:
28VDC, up to 25A
Outputs can be paralleled for higher current operation
120VDC versions available
270VDC versions being evaluated
New Technology Applications for AC and DC
IGBT alternative for higher voltage and current switchgear
SiC MOSFET devices will be integrated and evaluated upon availability 2
DC PSSCB/S WITH ARC DETECTION/DWDL MODULE
30 May 2002

7. AC Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module
Power Input
Power Common
Power Output
Solid State Switch Devices and Temperature Sensors
DWDL Module Power Output Interface
Secondary Power Interface
Switch/Monitor Module
Controller Module
Arc Fault Detector and Damaged Wire Detector/Locator Module
CANbus Interface
RS232 Interface
Secondary Power Module (optional)
30 May 2002

8. Programmable Solid State Circuit Breaker/Switch (PSSCB/S) With Arc Detection And Damaged Wire Detector/Locator Module
AC and DC PSSCB/S Common Features
Boeing Invention Disclosure No “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.
Serial data bus interface. (RS232 and CANbus)
Modular component design
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. 2
30 May 2002

9. Arc Fault Detection And Damaged Wire Detector/Locator Module
Module Functional Makeup
The AFD and DWDL Module consist of
Arc Fault Detector Module
Boeing Invention Disclosure No
Damaged Wire Detector/Locator Module
Boeing Invention Disclosure No
GFCI Circuitry
Design Concept Base
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
This approach is applicable to AC and DC devices.
Detects parallel and series arcs.
GFCI monitoring.
Damaged wire detector utilizes Time Domain Reflectometry (TDR) practices. 2
30 May 2002

10. PSSCB/S Trip Curve Embedded Trip Curve Capabilities 30 May 2002
Firmware configurable trip curve.
Maximum current limiting is component dependent.
Trip time in current limit depends on voltage drop across MOSFET. 2
30 May 2002

11. PSSCB/S Trip Curve Established Trip Curve Modeling 30 May 2002
Standard circuit breaker curve. 2
30 May 2002

12. Phantom Works - HSV PSSCB/S, AFD and DWDL Module In-System Maintenance Interface

13. PSSCB/S Control and Analysis Display
PSSCB/S Maintenance Display
Allows for control and testing of power devices in-system from the maintenance testing equipment without having to enter a vehicle.
Maintenance personnel can analyze fault data and set operating parameters from the maintenance testing equipment.
Fault data can be time stamped by the master control system and stored for further analysis.
The type of fault is indicated on this display. 2
30 May 2002

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