The high-power solid-state power controller (SSPC) will be a critical component for the future electrified aircraft propulsion system. This article presents the development of a 1 kV 500 A bidirectional dc SSPC using SiC power modules and transient voltage suppression (TVS) diodes. The design procedure and implementation of the SSPC are presented in detail and the system level influence is discussed. Due to the limited power of a single switch, parallel and/or series connections of switches are necessary for high-power SSPCs, and the corresponding challenges are investigated with possible solutions. In addition, the high peak-to-average clamping voltage ratio caused by Ldi/dt of the turn-off current commutation and foldback characteristics of high-power TVS diodes is addressed. Finally, the testing setups for the high-power SSPC are presented, and all key functions are tested for the SSPC. The power rating and the specific power of the developed SSPC are superior to state-of-the-art counterparts to show the advantage of the developed one. 

Development of High-Power Bidirectional DC Solid-State Power Controller for Aircraft Applications

Shipboard DC systems, a Critical Overview: Challenges in Primary Distribution, Power Electronics-based Protection, and Power Scalability

Power distribution using latching current limiters (LCLs) [also known as solid-state power controllers (SSPCs)] is very common for 28- and 50-V bus voltage distribution on European satellite platforms. However, 100-V and even higher voltage distribution platforms generally do not employ the same approach as lower bus voltage platforms since the commonly employed p-MOSFET devices are not well suited for such voltage levels. This work introduces an LCL for 100-V distribution units using a composite power device consisting of a low-voltage p-MOSFET device and a high-voltage, normally-ON silicon carbide junction field effect transistor (SiC JFET). The description of the circuit and the experimental validation using a hypothetical class-2 (2.2–2.8 A), 100-V, LCL is discussed. In addition, in this work, two interesting characteristics are also proposed and validated, and automatic control of the tripping time depending on the overload severity and soft starts for capacitive inrush currents. Robustness and fast reaction, less than 500 ns under short-circuit conditions, have been demonstrated, as well as tight current regulation during overload faults. 

Latching Current Limiter for Space Platform Power Distribution Using a Low-Voltage p-MOSFET and a Normally-ON SiC JFET

Abstract During early phases of aircraft development, overall systems design is performed to estimate relevant system design parameters such as mass, power consumption, and compliance with architectural requirements (redundancy). The GeneSys software framework has been developed for parametric modeling of aircraft on-board systems for overall systems design. To this end, model-based architecture definition, topology generation (components positioning and connections routing), and system sizing are conducted. The topology generation is currently performed using design templates containing knowledge-based heuristics derived from systems topologies of existing aircraft. However, using such design templates limits their generic application to novel aircraft models because exceptions for geometric differences between these models need to be implemented. This especially applies to the topology generation of power supply systems (electric, hydraulic) due to their high number of interfaces to consumer systems. To overcome these limitations, an automated routing method is presented in this paper as a generic approach for topology generation. With this method, the system topology is generated based on a defined routing network, which comprises areas of the aircraft for allowed components positioning and connections routing. Using Dijkstra’s algorithm, the shortest path connections are found within the established routing network. Furthermore, boundary conditions for routing, for instance adding a cost function for power segregation, can be defined. An assessment of the automated routing method applied on the electric power supply system is performed using qualitative parameters such as the capability to adapt the routing network. Quantitative parameters like cable length and system mass are assessed as well. 

Assessment of an auto-routing method for topology generation of aircraft power supply systems

A Half-bridge-active-clamp (HBAC) converter is used as an alternative to replace Dual active bridge (DAB) converter for 540V/28V on-board grid in more electric aircraft applications. The HBAC converter provides an opportunity to reduce the turn-ratio of the high frequency transformer compared to DAB converter with reduced current stress on the low voltage side benefit from a current-fed LV bridge. HBAC converter shows a much better performance both on efficiency and volume compared to conventional DAB converter. In addition, a Model Predictive Control (MPC) method for LV output current regulation is proposed based on HBAC converter with the aim of achieving fast dynamic performance. 

Half-Bridge-Active-Clamp Converter with High Step-down Capabilities for More Electric Aircraft Applications

Solid-state power controllers (SSPCs) have been received increasing attention as they can configure the electrical system and protect the system by fast tripping mechanism at the same time. Although the high-voltage direct current (HVDC) electrical system can bring sustainable savings on the cables’ weight and losses, the protection can be considerably challenging. SSPCs have been successfully utilized for 28V DC aircraft onboard network. However, high-voltage ones are impeded by the vast over-voltage and the excessive losses generated from SSPC switching. This paper tries to fill this gap and presents the development of high-power SSPCs for a ±270VDC network of a future turboprop aircraft. Comprehensive designs of proper over-voltage suppression along with SSPC thermal management are presented in this paper. Besides, a comparative study on the SSPC device is carried out. Two prototypes, including a single MOSFET module and paralleling several discrete MOSFET devices, are built and then tested in the experiment. It has been validated that the proposed voltage clamping design cannot only effectively suppress the over-voltage, but also limit the SSPC temperature increase during switching for both candidates. After comparing the conduction losses, maximum junction temperature, power density, weight and volume, the single device solution is recommended as a preferable SSPC option for future aircraft.

/pdf/development-of-high-current-solid-state-power-controllers-3ffjqo01uj.pdf

Development of High-Current Solid-State Power Controllers for Aircraft High-Voltage DC Network Applications

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Development of High-Current Solid-State Power Controllers for Aircraft High-Voltage DC Network Applications