U.S. patent application number 09/911751 was filed with the patent office on 2003-01-23 for serviceable power modules for a power distribution assembly.
Invention is credited to Beneditz, Bruce D., Cooney, Robert C., Dickey, John A., Metzler, Mark W..
Application Number | 20030016520 09/911751 |
Document ID | / |
Family ID | 25430795 |
Filed Date | 2003-01-23 |
United States Patent
Application |
20030016520 |
Kind Code |
A1 |
Cooney, Robert C. ; et
al. |
January 23, 2003 |
SERVICEABLE POWER MODULES FOR A POWER DISTRIBUTION ASSEMBLY
Abstract
A power distribution assembly (PDA) includes AC and/or DC power
modules and control modules that are installed within a chassis
that is mounted to a vehicle, such as an aircraft. Each module
includes a wiring harness connector and a control connector for
attachment to a motherboard. A wiring harness is externally mounted
to the chassis to provide a simplified connection for the wiring
harness connector. The modules can be individually and selectively
removed from the chassis for repair or replacement without having
to remove the entire PDA from the aircraft. This is accomplished by
simply removing the module from the chassis, thereby disconnecting
the aircraft interface and motherboard connectors for the selected
modules. Also, a common PDA can be utilized on different types of
aircraft by installing desired modules within the chassis. Thus,
the number and type of modules are selected to meet predetermined
specifications for a specific aircraft and then installed within a
PDA common to all aircraft
Inventors: |
Cooney, Robert C.;
(Janesville, WI) ; Dickey, John A.; (Rockford,
IL) ; Metzler, Mark W.; (Davis, IL) ;
Beneditz, Bruce D.; (Roscoe, IL) |
Correspondence
Address: |
CARLSON, GASKEY & OLDS, P.C.
400 WEST MAPLE ROAD
SUITE 350
BIRMINGHAM
MI
48009
US
|
Family ID: |
25430795 |
Appl. No.: |
09/911751 |
Filed: |
July 23, 2001 |
Current U.S.
Class: |
361/826 |
Current CPC
Class: |
H05K 7/1449 20130101;
H05K 7/1457 20130101 |
Class at
Publication: |
361/826 |
International
Class: |
H02B 001/20 |
Claims
We claim:
1. A power distribution assembly comprising: a chassis for
attachment to a vehicle; a wiring harness externally mounted to
said chassis; and a plurality of modules for installation within
said chassis with each module including a first connector for
attachment to a motherboard and a second connector for attachment
to said wiring harness wherein each module is selectively
detachable from said chassis for repair or replacement without
requiring removal of the other modules.
2. The assembly according to claim 1 wherein said chassis defines a
plurality of installation slots for receiving said modules.
3. The assembly according to claim 2 wherein there are more
installation slots formed within said chassis than modules
installed within said chassis.
4. The assembly according to claim 2 wherein each module includes a
plurality of solid state power controllers for controlling multiple
DC and/or AC loads within a single module.
5. The assembly according to claim 4 including a predetermined
number of solid state power controllers unique to each of said
modules with some of said predetermined number of solid state power
controllers having a fixed amp per load setting, some of said
predetermined number of solid state power controllers having a
programmable amp per load setting, or all of said solid state power
controllers having a programmable amp per load setting.
6. The assembly according to claim 5 wherein said second connector
includes a plurality of pins for connecting said solid state power
controllers to a cable from said wiring harness to identify loads
serviced by said cable.
7. The assembly according to claim 6 wherein said programmable
amp-per-load settings are set based on cable load
identification.
8. The assembly according to claim 1 wherein said first and second
connectors are mounted to opposite ends of said module.
9. The assembly according to claim 8 wherein said second connector
includes a plurality of configuration pins with both power contacts
and signal contacts.
10. The assembly according to claim 9 wherein said power contacts
provide a power feed to said module and provide output power to
loads requiring high current and wherein said signal contacts
provide output power to loads requiring low current and provide
said configuration pins for said loads.
11. The assembly according to claim 9 wherein said wiring harness
includes a plurality of cables with each cable being strapped to
use said configuration pins to uniquely identify each cable.
12. The assembly according to claim 8 wherein said wiring harness
includes separate busses for AC loads and DC loads.
13. The assembly according to claim 1 wherein said first and second
connectors are mounted on a common end of each of said modules.
14. The assembly according to claim 13 wherein first and second
connectors are generally simultaneously mated with said motherboard
and wiring harness respectively when each of said modules is
installed within said chassis.
15. The assembly according to claim 13 wherein said second
connector is keyed to ensure the proper module is being installed
within said chassis.
16. The assembly according to claim 13 wherein said wiring harness
is mounted on an exterior end of said chassis.
17. The assembly according to claim 13 wherein said wiring harness
includes an AC bus and a DC bus that is wired separately from said
AC bus.
18. The assembly according to claim 17 wherein DC loads are shared
between said DC bus and an essential bus wired separately from both
said buses.
19. The assembly according to claim 1 wherein said chassis includes
a control section and a power module section.
20. The assembly according to claim 19 wherein said control section
includes a first plurality of installation slots for receiving
control boards and said power module section includes a second
plurality of installation slots for receiving said power
modules.
21. The assembly according to claim 20 wherein said second
plurality of installation slots is transverse to said first
plurality of installation slots.
22. The assembly according to claim 20 wherein said second
plurality installation slots is parallel to said first plurality of
installation slots.
23. The assembly according to claim 20 wherein said control boards
are shop replaceable units and said power modules are line
replaceable modules.
24. The assembly according to claim 20 wherein said first plurality
of installation slots are intermixed amongst said second plurality
of installation slots.
25. The assembly according to claim 1 including a mounting plate
for each modules to enclose said module within said chassis.
26. The assembly according to claim 25 including at least one
fastener for securing said plate and said module to said
chassis.
27. The assembly according to claim 25 wherein said mounting plate
includes an identification portion for identifying the type of
module enclosed by said mounting plate.
28. A method for distributing power from a vehicle power
distribution assembly having a chassis with a plurality of
installation slots for receiving modules comprising the steps of:
(a) externally mounting an aircraft wiring harness to the chassis;
(b) attaching a motherboard connector to each module; (c) attaching
an aircraft interface connector to each module; (b) installing one
module into one slot by mating the motherboard connector to a
motherboard and mating the aircraft interface connector to the
aircraft wiring harness to form a selectively detachable connection
to allow the modules to be removed from the chassis for repair or
replacement without requiring removal of the other power
modules.
29. The method according to claim 28 further including installing a
predetermined number of modules into the installation slots wherein
the predetermined number varies depending upon vehicle
application.
30. The method according to claim 28 further including selectively
removing modules for repair or replacement without removing the
power distribution assembly from the vehicle.
31. The method according to claim 28 including attaching the
motherboard and wiring harness connectors on a common side of the
modules.
32. The method according to claim 31 including simultaneously
connecting the motherboard connector to the motherboard and the
aircraft interface connector to the aircraft wiring harness when
the module is inserted within the installation slot.
33. The method according to claim 31 including keying the aircraft
interface connector to ensure that the correct module is being
installed within the correct installation slot.
34. The method according to claim 31 including mounting the wiring
harness on an inwardly facing external surface portion of the
chassis.
35. The method according to claim 28 including attaching the
motherboard and wiring harness connectors on opposite sides of the
module.
36. The method according to claim 28 including separating the
wiring harness into an AC bus and a DC bus with both busses being
independently wired from each other.
37. The method according to claim 28 including separating the
chassis into a control section having a first plurality of
installation slots for receiving control modules and a power
section having a second plurality of installation slots for
receiving the power modules.
38. The method according to claim 37 including orientating the
first plurality of installation slots parallel to the second
plurality of installation slots.
39. The method according to claim 38 including orientating the
first plurality of installation slots transversely to the second
plurality of installation slots.
40. The method according to claim 28 including controlling multiple
DC and/or AC loads within a single power module with solid state
power controllers.
41. The method according to claim 28 including utilizing some fixed
solid state power controllers and some programmable solid state
power controllers for each power module.
42. The method according to claim 41 including identifying service
loads for the power module by connection of the wiring harness
connector to the wiring harness.
43. The method according to claim 42 including programming the
programmable solid state power controllers after identification of
the service loads.
44. The method according to claim 28 further including installing a
predetermined number of power modules into the installation slots
with some modules providing AC power and some modules providing DC
power.
45. The method according to claim 28 including utilizing all
programmable solid state power controllers for each controller.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to a power distribution assembly that
utilizes multiple power and control modules that can be easily
removed for repair or replacement without requiring removal of all
modules.
[0002] Typically vehicles, such as an aircraft, utilize a secondary
power distribution assembly (SPDA) to distribute power from a
primary source to various aircraft systems. An SPDA includes a
chassis that is mounted within the vehicle and which houses
multiple power modules that are used to power the aircraft systems.
These power modules can be solely DC modules, solely AC modules, or
a combination of DC and AC modules installed within a common SPDA.
Control modules are also housed within the SPDA, for functions such
as communications, microprocessing, etc. The power modules interact
with the control modules to provide proper communication and
control of power for each of the aircraft systems.
[0003] Traditionally, a SPDA includes an internally mounted wiring
harness for connecting multiple power cables from the various
aircraft systems to the proper power module. Each different type of
aircraft includes a specially designed SPDA that includes power
modules that meet that aircraft's predetermined specifications.
Thus, each different SPDA requires a different wiring harness
design and power module configuration, resulting in proliferation
of components.
[0004] One disadvantage with previous SPDA designs is that a module
is considered to be a shop replaceable unit (SRU), i.e., when a
module fails, the entire SPDA must be removed from the aircraft in
order to repair or replace the module. This repair is performed in
a service shop. This requires disconnecting multiple aircraft
systems when only one specific system's module is inoperable. Once
the defective module has been replaced, all of the modules within
the SPDA must be reconnected to their respective systems with each
connection requiring post-repair verification. This can involve
testing thousands of connections resulting in significant time and
labor costs.
[0005] It is desirable to provide an improved SPDA with modules
that are line replaceable modules (LRMs) such that each module can
be individually removed from the SPDA chassis without requiring
removal of the SPDA from the aircraft or removal of other modules
from the SPDA. It is also desirable to provide a common SPDA that
can be used on different aircraft types. The SPDA should be able to
utilize any combination of AC and/or DC power modules with separate
AC and DC busses incorporated into the aircraft wiring harness in
addition to overcoming the above referenced deficiencies with prior
art systems
SUMMARY OF THE INVENTION
[0006] The subject invention provides a modular design for a power
distribution assembly including a secondary power distribution
assembly (SPDA). The SPDA includes AC and/or DC power modules and
control modules that are installed within a vehicle mounted
chassis. The modules can be individually and selectively removed
from the chassis for repair or replacement without having to remove
the entire SPDA from the aircraft. Further, modules can be grouped
into families for installation into a specific vehicle type. Thus,
a common SPDA can be used for all vehicle types by simply changing
the power module family to meet the vehicle's specifications.
[0007] Each power module includes a connector for attachment to an
aircraft wiring harness and a control connector for attachment to a
motherboard. The aircraft wiring harness is external to the SPDA
and connects directly to the individual module wiring harness
connector. The modules can be individually and selectively removed
from the chassis for repair or replacement without having to remove
the entire SPDA from the aircraft by simply removing the module
from the chassis thereby, disconnecting the wiring harness and
motherboard connectors for the selected modules. AC and/or DC
modules can be used in a common SPDA and separate AC and DC buses
are maintained.
[0008] The chassis includes a plurality of installation slots for
receiving the modules. Typically, there are more installation slots
than modules installed within the chassis such that multiple
vehicle types can utilize a common SPDA. After each module is
installed within a slot, a protective mounting plate is optionally
installed over each module to enclose the module within the
chassis. The mounting plate includes an identification portion for
uniquely identifying the module covered by that plate.
[0009] In one embodiment, aircraft interface and control connectors
are mounted to opposite ends of the power module. The aircraft
interface connector has both power contacts and signal contacts.
The power contacts provide a power feed to the power module and
provide output power to loads requiring high current. The signal
contacts provide output power to loads requiring low current and
provide the configuration pins for the loads serviced by the
respective module.
[0010] In another embodiment, aircraft interface and control
connectors are mounted on a common end of the module. The aircraft
interface and control connectors are simultaneously mated with the
motherboard and aircraft wiring harness respectively when each of
the power modules is installed within the chassis. The connectors
are keyed to ensure the proper power module is being installed in
each slot within the chassis.
[0011] In another embodiment, the chassis includes a control
section and a power module section. The control section includes
installation slots for receiving control modules and the power
module section includes installation slots for receiving the power
modules. In one orientation, the control module installation slots
are transverse to the power module slots, while in an alternate
orientation the control module and power module slots are parallel
to each other.
[0012] These and other features of the present invention can be
best understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic view of a secondary power distribution
system incorporating the subject invention.
[0014] FIG. 2 is a top view of one embodiment of the secondary
power distribution system of FIG. 1.
[0015] FIG. 3 is a front view of the secondary power distribution
system of FIG. 2.
[0016] FIG. 4 is a schematic view of an alternate embodiment
incorporating the subject invention.
[0017] FIG. 5 is an exploded view of an alternate embodiment
incorporating the subject invention.
[0018] FIG. 6 is a perspective view of a chassis from the
embodiment of FIG. 5.
[0019] FIG. 7 is a perspective view of a power module from the
embodiment of FIG. 5.
[0020] FIG. 8 is a top view of an alternate embodiment of a
module.
[0021] FIG. 9 is a perspective view of an alternate embodiment with
a removable cover.
[0022] FIG. 10 is a perspective view of an alternate embodiment,
similar to FIG. 4 but showing the modules of FIG. 8.
[0023] FIG. 11 is a perspective rear view of the embodiment shown
in FIG. 5.
[0024] FIG. 12 is a perspective view of one embodiment of the
subject invention for the configuration shown in FIG. 10.
DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT
[0025] Referring to FIG. 1, a vehicle power distribution system is
shown generally at 10. This system 10 is used in a vehicle, such as
an aircraft, and includes a secondary power distribution assembly
(SPDA) 12 that distributes power from a primary source 14 to
various aircraft systems 16, such as fuel, hydraulic, and brake
systems. The subject invention is preferably incorporated into an
SPDA system, however, the invention could also be used in other
power distribution systems.
[0026] The SPDA includes a chassis 18 that is installed within the
aircraft and a wiring harness 20 that is externally mounted to the
chassis 18. The wiring harness 18 can be configured for AC and/or
DC power distribution. When both AC and DC power are required, the
wiring harness 20 provides an AC bus 22 that is independently wired
from a DC bus 24 as schematically shown in FIG. 1. Further, in some
configurations, the DC load is shared between the DC bus 24 and an
essential bus 26. The DC bus 24 and essential bus 26 also need to
be maintained separately in the aircraft and SPDA wiring harness
20.
[0027] The SPDA 12 includes multiple modules, shown in FIG. 2, that
are installed within installation slots 28 in the chassis 18. The
modules are installed within the installation slots 28 in a similar
manner as plug-in cards for attachment to a universal motherboard
in a personal computer. For the subject SPDA 12, some of the
modules are control boards 30 and some of the modules are power
modules 32 that can be selectively and individually detached from
the chassis 18 for repair or replacement without requiring removal
of the other power modules 32. The control boards 30 are related to
such operations as analog input, discrete input/output,
communications, microprocessors, etc. The control boards 30 are
considered to be shop replaceable units (SRUs).
[0028] The subject SPDA 12 can have more installation slots 28
formed within the chassis 18 than are necessary for the number of
power modules 32 required for the application. For example, FIG. 2
shows one (1) empty installation slot 28. This design configuration
provides a common SPDA 12 that can be used on different types of
aircraft. Families of power modules 32 are formed to meet the
predetermined specifications for each unique aircraft. Thus,
aircrafts that require solely DC power modules would have a DC
power module family and aircrafts that require both AC and DC power
modules would have a dual power module family. The appropriate
modules 32 are selected to form the desired family and then the
modules 32 are installed within the chassis 18 that is common to
all aircraft types to meet the aircraft's specifications. Using
standard modules 32 in this manner reduces cost and design time
while still providing design flexibility.
[0029] Being able to selectively and individually remove power
modules 32 for repair and replacement also reduces aircraft
downtime as well as providing decreased labor and maintenance
costs. This design makes the power modules 32 line replaceable
modules (LRMs), meaning that the power modules 32 can be separately
removed without requiring removal of the entire SPDA 12 from the
aircraft as has been traditionally done. Traditionally, when the
entire SPDA is removed, all systems are disconnected just to repair
a power module that affects only one system or a small subset of
systems. This results in thousands of electrical connections that
have to be verified and tested once the SPDA is re-installed within
the aircraft, which is time consuming and labor intensive. The
subject SPDA 12 with LRM power modules 32 significantly reduces the
post-repair verification time because only that specific module's
connections need to be verified.
[0030] Each power module 32 includes a motherboard connector 34 for
attachment to a motherboard 36 and an aircraft interface connector
38 for attachment to the wiring harness 20. The connection to the
motherboard 36 provides an interface to the microprocessor control
board 30. The microprocessor control board 30, through the use of
configuration pins in the motherboard connector 34 or through
communication over the motherboard 36, knows the type of module 30
or 32 that is being connected to the SPDA 12 within the respective
installation slot 28. If the microprocessor is designed
appropriately, the microprocessor can control remotely located
power modules, which would allow load control to be located as
close as possible to the actual load system.
[0031] To provide flexibility, each power module 32 can be of many
different types. One type of module utilizes Solid State Power
Controllers (SSPCs) 40 to control multiple loads. Some of the SSPCs
40a have a fixed amp per load setting and/or some of the SSPCs 40b
have a programmable amp per load setting. The combination of fixed
40a and programmable 40b SSPCs is tailored to the specific
application.
[0032] Also, as discussed above, the power modules 32 can control
AC loads. The size and quantity of the SSPCs 40 on any given power
module 32 is set according to a desired specification and the SPDA
12 is designed such that a variety of power modules 12 is supported
including any combination of AC and DC modules.
[0033] The aircraft interface connector 38 for attachment to the
wiring harness 20 has both power contacts 42 and signal contacts
44. The power contacts 42 provide the power feed to the power
module 32 and provide output power to those loads that require high
current. The signal contacts 44 provide output power for low
current loads and provide configuration pins for the loads. The
wiring harness 20 includes cables that are strapped using the
configuration pins to identify each cable uniquely from other
cables. Thus, a single power module 32 can have SSPCs 40b
programmed to different current levels as determined by the load
requirements. When the aircraft interface connector 38 is mated to
the power module 32, the module 32 is programmed for the specific
loads on that cable.
[0034] The aircraft interface connector 38 is preferably a
combination subminiature-D connector, however other similar know
connectors in the art can also be used. This type of connector is
preferred because it is available in a filtered pin version for
improved electromagnetic interference (EMI) and high infra-red
frequency (HIRF) performance.
[0035] As shown in FIG. 2, the aircraft interface 38 and
motherboard 34 connectors are mounted to opposite ends of the power
module 32. This provides a protected connection to the motherboard
36 while providing the load connection at the free end of the SPDA
12. This configuration provides several benefits. For example,
because the wiring harness is externally mounted to the chassis 18,
heat generation is external to the SPDA 12 as opposed to being
inside the unit, which will result in improved thermal performance.
The externally mounted wiring harness 20 also simplifies bus
separation. The AC harness is easily kept separate from the DC
harness due to the power module configuration. Interface concerns
associated with the wiring harness 20 are now external to the SPDA
12, which simplifies the protection requirements of the SPDA
12.
[0036] As shown in FIG. 3, each free end of a power module 32 has a
metal mounting plate 46 attached to the module 32 and the aircraft
interface connector 38. The mounting plate 46 includes an
identification portion 48 that identifies the type of module 32
mounted inside the chassis in that installation slot 28.
Preferably, the mounting plate 46 includes a pair of fasteners 50
that secure the power module 32 to the SPDA chassis 18. Once all
power modules 32 have been installed in the installation slots 28,
the mounting plates 46 form a cover. This cover protects the
modules 32 from debris and other external contaminants and provides
a conductive barrier. Blank mounting plates 52 are used to cover
empty installation slots 28.
[0037] While FIG. 2 shows a configuration where the control boards
32 are mounted transversely to the power modules 32, alternate
configurations could also be used. For example, in FIG. 4, the
power modules 32 and control boards 30 are parallel to each other.
In this configuration, the chassis 18 is wide and shallow as
opposed to narrow and deep. The control boards 30 would have
motherboard connectors 34, aircraft interface connectors 38 and
mounting plates 46 similar to those of the power modules 32.
[0038] In the preferred embodiment, shown in FIGS. 5-7, the
aircraft interface connector 38 and motherboard connector 34 are
located on the same end of each power module 32. In this
configuration both connectors 34, 38 are mated nearly
simultaneously when the module 30, 32 is installed within the
chassis 18. This reduces the overall number of connectors and
reduces assembly time and cost. The motherboard connector 24 is the
same for each installation slot 28 within the chassis. Thus, any
type of module can be installed in any slot 28. The aircraft
interface connector 38 is keyed to ensure that the appropriate
power module 32 is being installed within each slot 28.
[0039] FIG. 5 shows a populated SPDA 12 with one module 32 left for
installation. The aircraft wiring harness 20 is externally mounted
on the rear of the chassis 18 to provide the benefits discussed
above. In addition, locating the wiring harness 20 on the back or
inside portion of the SPDA 12 reduces the possibility of damage to
the wiring harness 20 and connectors 34, 38.
[0040] FIG. 6 shows the mating connectors on the motherboard 36
near the back part of the chassis 18 for internal connection. FIG.
7 shows an individual module 32 with both the aircraft interface
connector 38 and the motherboard connector 34 on the same end. As
each power module 32 is inserted into each slot 28, the motherboard
connector 34 mates with the motherboard 36 and the aircraft
interface connector 38 mates with the aircraft wiring harness 20
nearly at the same time. The mounting plate 46 is then fastened
into place.
[0041] In an alternate embodiment, the modules 32 are secured to
the chassis 18 using lever actuated inserter/extractors 60, shown
in FIG. 8. A stiffener 62 is also included to reduce vibrations.
The operation and structure of the lever actuated
inserter/extractors 60 and stiffeners 62 is well known and will not
be discussed in detail. A removable cover 64, shown in FIG. 9, is
then secured to the chassis 18 to enclose the modules 32.
[0042] FIG. 10 shows lever actuated power modules 32 and control
modules 30 in a parallel configuration similar to that of FIG. 4.
The control modules 30 have motherboard connectors 34 and aircraft
interface connectors 38 similar to those of the power modules 32.
Further, the control modules 30 and power modules 32 can be
intermixed with each other as shown.
[0043] FIG. 11 shows an aircraft wiring harness 20 with an external
mount on the rear of the chassis 18 similar to that of FIG. 5.
Locating the wiring harness 20 on the back or inside portion of the
SPDA 12 reduces the possibility of damage to the wiring harness 20
and connectors 34, 38. FIG. 12 shows the chassis with the
motherboard connectors 34 and the aircraft interface connectors
38.
[0044] The subject invention provides an SPDA 12 that includes LRM
modules 32. The modules 32 can be replaced without having to remove
the SPDA 12 from the aircraft, which saves a significant amount of
time. Post-repair verification is significantly reduced because
only the replaced module's connections need to be verified.
Further, the SPDA 12 has the capability to provide power to both AC
and DC loads and keeps the respective busses separate in the
aircraft wiring and to the SPDA.
[0045] The aforementioned description is exemplary rather that
limiting. Many modifications and variations of the present
invention are possible in light of the above teachings. The
preferred embodiments of this invention have been disclosed.
However, one of ordinary skill in the art would recognize that
certain modifications would come within the scope of this
invention. Hence, within the scope of the appended claims, the
invention may be practiced otherwise than as specifically
described. For this reason the following claims should be studied
to determine the true scope and content of this invention.
* * * * *