Patent Publication Number: US-2023139012-A1

Title: Dynamic electrical load control

Description:
BACKGROUND 
     Embodiments described herein relate to a dynamic electrical load control device and, more particularly, to systems and methods for enhanced power supply distribution on aircrafts based on electrical loads. 
     SUMMARY 
     Traditional aircraft electrical power systems use a variety of discrete components in their distribution architecture. For example, mechanical contactors are placed between power sources for electrical bussing, fusible device or current monitoring contactors provide fault protection, and circuit breaker panels are used to disconnect the components. These discrete components are heavy and take up substantial space in the aircraft, thus leading to compromises in electrical load distribution. In an emergency situation, loads must be dropped as a whole bus, potentially reducing mission capabilities. Previous methods to avoid dropping a whole bus resulted in doubling or tripling the bussing connection, which adds significant weight to the aircraft. Accordingly, there is a need for a load control unit that can handle power input switching and sourcing to groups of individual loads. 
     One embodiment of the present disclosure provides a load control unit. The load control unit includes a first input terminal configured to receive power, a second input terminal configured to receive load information, a first output terminal configured to provide a first portion of the power to a first load, a second output terminal configured to provide a second portion of the power to a second load, a memory, and an electronic processor communicatively connected to the memory, first input terminal, the second input terminal, the first output terminal, and the second output terminal. The electronic processor is configured to measure the power received via the first input terminal, receive load parameters via the second input terminal, and dynamically control, in response to measuring the power and receiving the load parameters, at least one of the first load or the second load based on the power that is measured and the load parameters that are received. Dynamically controlling at least one of the first load or the second load includes one of shedding the at least one of the first load or the second load from the power, connecting the at least one of the first load or the second load to receive at least one of first portion of the power or a second portion of the power, or transferring the at least one of the first load or the second load between different portions of the power. 
     One embodiment of the present disclosure provides a method of dynamically performing load control using a load control unit. The method includes measuring a power received via a first input terminal of the load control unit, receiving load parameters via a second input terminal of the load control unit, and dynamically controlling, in response to measuring the power and receiving the load parameters, at least one of a first load or a second load based on the power that is measured and the load parameters that are received. Dynamically controlling the at least one of the first load or the second load includes one of shedding the at least one of the first load or the second load from the power, connecting the at least one of the first load or the second load to receive at least one of first portion of the power or a second portion of the power, or transferring the at least one of the first load or the second load between different portions of the power. 
     One embodiment of the present disclosure provides a load control system. The load control system includes a load control unit, an input power source for providing input power to the load control unit, a first load connected to a first output of the load control unit, and a second load connected to a second output of the load control unit. The load control unit is configured to measure the power and receive load parameters. The load control unit if further configured to dynamically control, in response to measuring the power and receiving the load parameters, at least one of the first load or the second load based on the power that is measured and the load parameters that are received. Dynamically control the at least one of the first load or the second load includes one of shedding the at least one of the first load or the second load from the power, connecting the at least one of the first load or the second load to receive at least one of first portion of the power or a second portion of the power, or transferring the at least one of the first load or the second load between different portions of the power. 
     Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. 
     In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and/or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input/output interfaces, and various connections (e.g., a system bus) connecting the components. 
     Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value. 
     It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and/or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed. 
     Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is diagram illustrating a load control unit, according to some embodiments. 
         FIG.  2    is a block diagram illustrating a controller for use by the load control unit, according to some embodiments. 
         FIG.  3    is a diagram illustrating the load control unit with inputs and outputs, according to some embodiments. 
         FIG.  4    is a diagram illustrating a distribution system implementing load control units, according to some embodiments. 
         FIG.  5    is a diagram illustrating an alternative load control unit, according to some embodiments. 
         FIG.  6    is a flowchart illustrating a method of dynamically controlling loads, according to some embodiments. 
         FIG.  7    is a table illustrating a look-up table for use by the controller of the load control unit, according to some embodiments. 
         FIG.  8    is a flowchart illustrating a method of dynamically controlling loads using a load control unit, according to some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Traditional aircraft electrical power systems use a variety of discrete components in their distribution architecture. For example, mechanical contactors are placed between power sources for electrical bussing, fusible device or current monitoring contactors provide fault protection, and circuit breaker panels are used to disconnect the components. These components connect and switch different power sources to the different electrical buses where circuit breakers are grouped together. These bus groupings allow for the selection of certain loads to be powered on-ground, split between different sources, or isolated when an electrical fault occurs. However, these discrete components are heavy and take up substantial space in the aircraft, thus leading to compromises in electrical load distribution. 
     Additionally, in an emergency situation, loads must be dropped as a whole bus, potentially reducing mission capabilities. Previous methods to avoid dropping a whole bus resulted in doubling or tripling the bussing connection, which adds significant weight to the aircraft. Accordingly, there is a need for a single unit that can handle power input switching and sourcing to groups of individual loads. The single unit may handle complex dynamic load control. 
     Embodiments described herein provide systems and methods for dynamic power shedding, transferring, and distribution using a load control unit. To accomplish this, embodiments described herein provide a load control unit with the ability to receive power and load parameters and to determine which loads need to be shed and which loads require power based on the received power and load parameters. 
       FIG.  1    illustrates a load control unit  100  according to embodiments described herein. The load control unit  100  includes solid state contacts  105   a,    105   b  and output channels  110   a ,  110   b.  The solid state contacts  105   a,    105   b  are connected to their respective output channels  110   a ,  110   b.  For example, solid state contact  105   a  is connected to output channel  110   a  and solid state contact  105   b  is connected to output channel  110   b.  The solid state contacts  105   a,    105   b  switch power inputs to provide power from different electrical power sources to electrical loads connected to the output channels  110   a,    110   b.  The electrical loads connected to the output channels  110   a,    110   b  include flight critical electrical loads. The separate output channels  110   a ,  110   b  allow for electrical isolation of the connected electrical loads. For example, the electrical loads connected to output channel  110   a  may be shed by disconnecting solid state contact  105   a . The electrical load connected to output channel  110   b  will be unaffected by disconnecting solid state contact  105   a,  and will remain powered by the input power via solid state contact  105   b.  The shedding and transferring of the electrical loads connected to the load control unit  100  is determined by a controller  200  (see  FIG.  2   ) based on the input power received and load parameters. 
     In some embodiments, the load control unit  100  may provide 140 Amperes (Amps)-200 Amps per output channel  110   a,    110   b.  In some embodiments, the load control unit  100  could provide current to 30 outputs per output channel  110   a,    110   b.  In these embodiments, the load control unit  100  may include 60 total outputs. In some embodiments, the load control unit  100  may weigh in the range of 10-20 pounds (lbs.) and may include dimensions of 8 inches (in.) wide, 12 in. long, and 16 in. tall. However, in some embodiments that include fewer or greater than 30 outputs per output channel  110   a,    110   b,  the weight and dimensions of the load control unit may be decreased or increased, respectively. 
       FIG.  2    illustrates the controller  200  for the load control unit  100 . The controller  200  includes a memory  205 , a processor  220 , a communication interface  225 , and an input/output interface  230 . The memory  205  may be a non-transitory computer-readable memory. The memory  205  may include one or more types of memory storage, such as random-access memory (RAM), flash memory, solid-state memory, or hard-drive memory. In addition, or alternatively, the controller  200  may communicate with a cloud-based storage system. The memory  205  stores a load shedding program  210  and a look-up table  215  (see  FIG.  7   ). The load shedding program  210  stores the operating parameters of the load control unit  100 . For example, the load shedding program  210  may store the current status of the input power sources and the electrical loads that are connected to the load control unit  100  so the processor  220  can control dynamic load shedding and transferring based on the stored load shedding program  210 . The look-up table  215  stores operational guidelines for the load control unit  100 . The look-up table  215  will be described with respect to  FIG.  7   . The load shedding program  210  receives the status of the input power sources and the electrical loads via the input/output interface  230 . 
     The processor  220  controls the solid state contactors  105   a,    105   b  to shed, transfer, or connect the electrical loads based on the input from the load shedding program  210  and the look-up table  215 . In some embodiments, the communication interface  225  is used by the controller  200  to communicate with other load control units. For example, the aircraft may include other load control units in addition to the load control unit  100 . In some embodiments, the load control units may communicate with each other to provide power outputs to loads that require multiple load control units. 
       FIG.  3    illustrates the load control unit  100  with inputs and outputs. The power contacts  105   a,    105   b  receive input power from independent power sources  305   a,    305   b.  The output channels  110   a,    110   b  are coupled to electrical loads  320   a,    320   b.  In some embodiments, the output channels  110   a,    110   b  may be coupled to more than one load per output channel. For example, output channel  110   a  may be coupled to between one and thirty electrical loads and output channel  110   b  may be coupled to between one and thirty electrical loads. Thus, the load control unit  200  may provide power to between two and sixty electrical loads. The load control unit  100  includes a first communication port  310  that receives and sends information to other load control units. Additionally, the load control unit  100  includes a second communication port  315  that receives monitoring input from various systems on the aircraft. 
     The first communication port  310  communicates with other load control units. For example, communication between the load control units may include a status of a load control unit or a request from another load control unit to transfer, shed, and/or connect an electrical load. The second communication port  315  receives monitoring input for various systems on the aircraft. For example, inputs may include statuses of the engine of the airplane and the flight equipment, as well as user inputs by a person on the aircraft, and any other electronics that require power distribution. 
       FIG.  4    illustrates an airplane power distribution system  400 . The power distribution system  400  includes independent input power sources  405  (similar to independent power sources  305   a,    305   b ) and load control units  410   a,    410   b,    410   c  (similar to load control unit  100 ). In some embodiments, one of the load control units may be a master unit that communicates to the other load control units what dynamic load control they are to perform. Alternatively, or additionally, in some embodiments the load control units may be controlled by a control unit on the aircraft. In some embodiments, the load control units are independent of one another and thus, do not communicate with one another. 
     The independent input power sources  405  are independent input power sources that may or may not be connected to one another. For example, the independent input power sources  405  may include multiple, distinct generators that may output alternating current (AC) power. The AC power from the independent input power sources  405  is received by the load control unit  410   a,    410   b,    410   c  via AC electrical buses  430   a,    430   b,    435   a,    435   b,    440   a,    440   b.  These AC electrical buses  430   a,    430   b,    435   a,    435   b,    440   a,    440   b  transmit power from generators on the aircraft. For example, the aircraft may include a plurality of 45 kilovolt-amperes generators that output 115/200V at 400 Hz. These AC power sources generate the power needed by the electrical loads on the aircraft. At least one AC electrical bus is connected to a power contact of a load control unit, and in some embodiments, each power contact of the load control unit receives power from a different AC electrical bus. For example, the first AC electrical bus  430   a  provides power to both power contacts within the first load control unit  410   a  and a second AC electrical bus  440   a  also provides power to both power contacts within the first load control unit  410   a.  In some embodiments, the load control units  410   a,    410   b,    410   c  may be powered by the independent input power sources  405 . 
     In some embodiments, the load control units  410   a,    410   b,    410   c  may each include a battery (not shown) that provides backup power to that unit. Additionally, or alternatively, in some embodiments, the load control units  410   a,    410   b,    410   c  may receive backup power from a dedicated generator, based on the configuration of the aircraft that the load control units  410   a ,  410   b,    410   c  are used on. In some embodiments, the independent input power sources  405  provides power to backup power sources. For example, the power distribution system  400  includes a battery power distribution unit  425  that stores power from the independent input power sources  405  as DC power. 
     The output channels of the load control units  410   a,    410   b,    410   c  output a set amount of power to the electrical loads including flight critical power loads  415   a,    415   b,    415   c.  For example, the current output to the electrical loads may be in the range of 120-160 Amps. The first load control unit  410   a  may selectively output power to a first flight critical power load  415   a  via output line  445   a  coupled to a first output channel of the load control unit  410   a.  The first flight critical power load  415   a  may also receive power from a permanent magnet generator  460 . The first load control unit  410   a  may also selectively output power to a second flight critical load  415   b  via output line  445   b.  The second flight critical power load  415   b  may also selectively receive power from the second load control unit  410   b  via output line  450   a.  The first channel of the second load control unit  410   b  provides power to a backup battery  420  via output line  450   b . The output of the backup battery  420  is connected to output line  450   a  in order to help keep the second flight critical power load  415   b  powered in the event that the second load control unit  410   b  sheds the electrical load of its first output channel. The second output channel of the second load control unit  410   b  may selectively output power to a third flight critical power load  415   c  via output line  450   c.  The third load control unit  410   c  may selectively output power to the third flight critical power load  415   c  via output line  455   a,  to the first flight critical power load  415   a  via output line  455   b,  and to the third flight critical power load  415   c  via output line  455   c.    
     The flight critical power loads  415   a,    415   b,    415   c  may selectively receive power from multiple load control units in the case that one load control unit must shed the load of the flight critical load, such that the flight critical load is still receiving power from the input power sources via a second load control unit. 
       FIG.  5    is an alternative load control unit  500 , according to one embodiment. In some embodiments, there may only be one load control unit, thus the load control unit  500  may not receive input communication from other load control units and may not output communication to other load control units. The load control unit  500  includes power contacts  505   a,    505   b  and output channels  510   a,    510   b.  The power contacts  505   a,    505   b  receive input power from power sources  515   a,    515   b.  The output channels  510   a,    510   b  selectively output power to electrical loads  520   a,    520   b.  The load control unit  500  receives monitoring input from the aircraft via the communication port  525 . 
       FIG.  6    is a flowchart illustrating a method  600  for dynamically controlling loads using a load control unit. The method  600  may be implemented by the load control unit  100  of  FIGS.  1  and  3   , the load control units  410   a,    410   b,    410   c  of  FIG.  4   , and/or the load control unit  500  of  FIG.  5   . The method  600  may be executed by a controller, such as controller  200 , to control load shedding and distribution according to embodiments described herein. 
     At block  605 , the controller  200  receives condition inputs. For example, condition inputs may include available power input sources and the power they provide, information regarding blown fuses, and/or inputs that increase electrical loads. In some embodiments, condition inputs may include user inputs by a person on the aircraft. 
     At block  610 , the controller  200  communicates with other load control units. For example, the controller  200  may receive a request from a load control unit for assistance in providing power to an electrical load. The controller  200  may also receive input from a load control unit to provide power to a load that that load control unit needs to shed. 
     At block  615 , the controller  200  performs dynamic control via the load control unit  100  based on the received condition inputs and the communication with the other load control units. For example, the controller  200  may access the look-up table  215  and determines what to do with the electrical loads based on the input information and the content of the look-up table  215 . In some embodiments, dynamic control via the load control unit  100  includes shedding loads, transferring loads to alternate input power sources, and isolating faults within the electrical loads. For example, the controller  200  may access the look-up table  215  and determine that the first electrical load  320   a  receiving power from the first output channel  210   a  needs to be shed. The controller  200  then operates the first power contact  105   a  to cut-off the flow of power to the first electrical load  320   a.  As another example, the controller  200  may access the look-up table  215  and determine that the second power source  305   b  cannot handle providing power to the second electrical load  320   b.  Thus, the second power contact  105   b  is switched to allow power to flow from the first power source  305   a  to the second electrical load  320   b.  Controlling the electrical loads based on the dynamic control is done instantaneously and simultaneously, such that loads do not experience interruptions. 
       FIG.  7    illustrates an exemplary look-up table  700  for use by a controller (e.g., controller  200 ) of a load control unit (e.g., load control unit  100 ). The look-up table  700  includes input conditions  705  and corresponding control outputs  710 . In some embodiments, the look-up table may be defined by a user. As one example according to embodiments described herein, if the controller  200  determines that the first power source  305   a  is not providing power (i.e., “Power Source A Down”), then the controller  200  instructs the first power contact  105   a  operate to transfer power from the second power source  305   b  to the first electrical load  320   a  (i.e., “Transfer Load 1”). 
     Additional input conditions and additional control outputs to those illustrated in  FIG.  7    are contemplated. For example, an input condition  705  could result in a load control unit creating a virtual dual sourcing to an electrical load utilizing only one wire from two separate input power sources. As another example, the input condition  705  may be an operating temperature and the control output  710  may correspond to various temperature regulating components being shed (e.g., shedding heaters when the ambient temperature is above a temperature threshold). As another example, the input condition  705  may be a predetermined mission and the control output  710  may correspond to electrical load(s) that may be low priority to the predetermined mission such that electrical load(s) with low priority may be shed and high priority mission equipment may remain powered or may receive additional power. 
       FIG.  8    is a flowchart illustrating a method  800  for dynamically controlling loads using a load control unit. The method  800  may be implemented by the load control unit  100  of  FIGS.  1  and  3   , the load control units  410   a,    410   b,    410   c  of  FIG.  4   , and/or the load control unit  500  of  FIG.  5   . The method  800  may be executed by a controller, such as controller  200 , to control load shedding and distribution according to embodiments described herein. 
     At block  805 , the method  800  includes the controller  200  measuring a power received via a first input terminal of the load control unit. In some embodiments, the power may be received by at least one of the power contacts  105   a,    105   b  of the load control unit  100 . In some embodiments, the controller  200  may measure the power received with a sensor (e.g., a current transformer, Hall effect sensor, or other suitable power measurement sensor). The power may be measured within the load control unit  100  at an input and then provided to the processor  220  via a data bus link, such as the first communication port  310  (see e.g.,  FIG.  3   ). 
     At block  810 , the method  800  includes the controller  200  receiving load parameters via a second input terminal of the load control unit. In some embodiments, the load parameters are received by the communication ports  310 ,  315  of the load control unit  100 . 
     At block  815 , the method  800  also includes the controller  200  dynamically controlling, in response to measuring the power and receiving the load parameters, at least one of a first load or a second load based on the power that is measured and the load parameters that are received. Dynamically controlling the at least one of the first load or the second load includes one of: shedding the at least one of the first load or the second load from the power, connecting the at least one of the first load or the second load to receive at least one of a first portion the power or a second portion of the power, or transferring the at least one of the first load or the second load between different portions of the power. In some embodiments, the first load is connected to the first output channel  110   a  and the second load is connected to the second output channel  110   b.  In other embodiments, the first load is one of a first plurality of loads (e.g., twelve loads) connected to the first output channel  110   a  and the second load is one of a second plurality of loads (e.g., twelve loads) connected to the second output channel  110   b.    
     In some examples, the method  800  may further include the controller  200  receiving a first control input. In some embodiments, the first control input is received via the first solid state contact  105   a.  The method  800  may further include the controller  200  connecting the first portion of the power to the first load based on the first control input. The method may further include the controller  200  receiving a second control input. In some embodiments, the second control input is received via the second solid state contact  105 . The method may further include the controller  200  connecting the second portion of the power to the second load based on the second control input. 
     The method  800  may further include the controller  200  dynamically controlling at least one of the first load or the second load based on a look-up table. For example, the controller  200  may use the look-up table  700 . The controller  200  may perform the similar dynamic control as mentioned above with respect to block  815  based on input conditions corresponding to the load parameters and control outputs defining the dynamic control in the look-up table  700 . 
     Thus, embodiments described herein provide, among other things, dynamic electrical load transferring and shedding. Various features and advantages are set forth in the following claims.