High reliability power supply configuration and testing
View Patent ↗Disclosed is a power supply system having a minimum of two power supplies that are together configured to supply at least a specified level of power when one of the power supplies is in an offline condition. When in operation, a self-test control circuit causes one of the power supplies to enter an offline condition and a power interruption protection circuit of the offline power supply is tested. While the offline power supply is being tested, the remaining power supplies provide sufficient power to whatever loads may be present.
1. A power supply system, comprising:
a set of power supplies consisting of a first, second and third power supplies disposed on an aircraft, each power supply having a power factor correction (PFC) portion, a DC-DC conversion portion, and a output control portion;
wherein the PFC portion of the first power supply has a Phase A input configured to receive Phase A of three-phase power having Phase A, Phase B and Phase C, and having a Phase B return;
wherein the PFC portion of the second power supply has a Phase B input configured to receive Phase B of the three-phase power and having a Phase C return;
wherein the PFC portion of the third power supply has a Phase C input configured to receive Phase C of the three-phase power and having a Phase A return;
each of the power supplies being configured in parallel with respect to each of the other power supplies;
wherein together the power supplies are configured to supply a predetermined amount of power when one of the power supplies is in an offline state and the remaining power supplies are in an online state;
a self-test control circuit, connected to each of the power supplies individually, configured to, when all of the power supplies are initially in an online state, cause a first one of the power supplies to enter an offline state and test at least one power interrupting function of the first one of the power supplies; and
wherein the self-test control circuit is configured to return the first one of the parallel power supplies to the online state when testing of the first one of the power supplies is complete and no critical condition is detected or to remain in an offline state if a critical condition is detected; and
then cyclically test the power interrupting functions of the remaining power supplies.
2. The power supply system of claim 1 the self-test control circuit is configured to flag problematic conditions that it detects when the power supplies are tested.
3. The power supply system of claim 1 wherein the cyclical testing is continuously conducted at a predetermined temporal interval.
4. The power supply system of claim 1 wherein the cyclical testing is conducted when the power supply system is first initiated.
5. The power supply system of claim 1 wherein the self-test control circuit is configured to flag one of the power supplies for future maintenance if the self-test control circuit detects a non-critical condition and is further configured to cause the one of the power supplies to remain in an offline condition if the self-test control circuit detects a critical condition.
6. The power supply system of claim 1 wherein the power interrupting functions include ground fault interruption (GFI) protection.
7. The power supply system of claim 1 wherein the self-test control circuit has three input sensors, one associated with each of the PFC portions of the first, second and third power supplies; and wherein the self-test control circuit has three output sensors, one associated with each of the output control portions of the first, second and third power supplies.
8. The power supply system of claim 7 wherein the Phase B return of the PFC portion of the first power supply is coupled with the Phase B input of the PFC portion of the second power supply, the Phase C return of the PFC portion of the second power supply is coupled with the Phase C input of the PFC portion of the third power supply, and the Phase A return of the PFC portion of the third power supply is coupled with the Phase A input of the PFC portion of the first power supply.
9. A method of testing a power supply system, comprising the steps of:
providing a set of power supplies consisting of a first, second and third power supplies, disposed on an aircraft, each power supply having a power factor correction (PFC) portion, a DC-DC conversion portion, and a output control portion;
wherein the PFC portion of the first power supply has a Phase A input configured to receive Phase A of three-phase power having Phase A, Phase B and Phase C, and having a Phase B return;
wherein the PFC portion of the second power supply has a Phase B input configured to receive Phase B of the three-phase power and having a Phase C return;
wherein the PFC portion of the third power supply has a Phase C input configured to receive Phase C of the three-phase power and having a Phase A return;
wherein each power supply is connected in parallel with respect to the other power supplies, wherein together the power supplies are configured to supply a predetermined amount of power to at least one load;
providing a self-test control circuit connected to each of the power supply individually;
operating the two power supplies in an online condition to supply power to the at least one load;
causing through the self-test control circuit a first of the power supplies to enter an offline state;
testing at least one power interrupting function of the first of the power supplies while the remaining power supplies continue to provide power to the loads;
returning the first of the power supplies to an online condition if no critical condition is detected during the step of testing or remaining the power supply in an offline state if a critical condition is detected; and
cyclically testing the power interrupting functions of the remaining power supplies by repeating the steps of causing a power supply to enter an offline condition, testing, and returning the power supply to an online condition.
10. The method of claim 9 , further comprising the steps of:
flagging any critical or non-critical conditions for maintenance.
11. The method of claim 9 wherein testing is stopped if a critical condition is detected in any of the power supplies that are tested.
12. The method of claim 9 wherein the self-test control circuit has three input sensors, one associated with each of the PFC portions of the first, second and third power supplies; and wherein the self-test control circuit has three output sensors, one associated with each of the output control portions of the first, second and third power supplies.
13. The power supply system of claim 9 wherein the power interrupting protection functions include GFI protection.
14. The method of claim 9 , wherein the cyclical testing is repeated after a predetermined temporal interval.
15. The method of claim 9 , wherein the cyclical testing is performed when the power supply system is first initiated.
16. The power supply system of claim 9 wherein the Phase B return of the PFC portion of the first power supply is coupled with the Phase B input of the PFC portion of the second power supply, the Phase C return of the PFC portion of the second power supply is coupled with the Phase C input of the PFC portion of the third power supply, and the Phase A return of the PFC portion of the third power supply is coupled with the Phase A input of the PFC portion of the first power supply.