Community Research and Development Information Service - CORDIS


FUSES 2014 Report Summary

Project ID: 641336
Funded under: FP7-JTI
Country: France


Project Context and Objectives:
During the all history of electricity, have been the fuses present. Moreover, each time that electricity stepped progress and brought up new dangers, these were cleared by solution including fuses.
Today, because of new applications, because of globalization and environmental regulations, bills of requirements for fuses are changing. And any one of us is asked to improve and adapt the technologies but they are, nevertheless, always based on the same fundamental principle.
At the same time, there is a strong trend in new designs of aircrafts towards the More Electric Aircraft (MEA) concept. This fact is mainly due to the replacement of mechanical, pneumatic and hydraulic equipments by partially or completely electrical systems. This factor has provoked increase of require electric power. Besides, these changes provide a better system performance thanks to increased reliability, reduced maintenance, increased efficiency on energy conversion and therefore improved efficiency of aircraft in general.
Greater utilization of DC power distribution within aircraft systems is still largely prevented by the significant challenge of developing DC protection systems. Aeronautics power distribution systems are usually protected by active switching components, driven by electronics (RCCBS, for instance). In order to reduce response time and simplify protection driving, devices are being considered for Cleansky HVDC network (540VDC). This study may lead to future aircraft projects. The objective of the CfP is to develop, test and deliver devices adapted to high DC voltage networks to be integrated into aircraft EPDS (Electrical Power Distribution System).

Project Results:
The first work package has be dedicated to the design and optimisation of a fuse module fitting as much as possible with starting specifications. The base technology used has been the Mersen silver technology. New dimensions and geometries have been considered to fit with the required current. As starting point, a state of the art review of existing aeronautics fuses and current limiting solutions have been performed with the contribution of all partners. On state specification, fault current available in the DC circuit, time current curve needed to meet bill of requirement have been studied to draft a technical solution. The strategy to be used for the study has been set-up. It has impacted both WP1 and WP2.
For WP1 Mersen experience in the fuse element design allows to shape the time current curve in order to meet certain gates. A fuse element with a new reduce sections area that will allow to test the new design against the bill of requirement has been designed.
The second work package has been dedicated to the design and optimisation of a SiC semiconductor current limiter fitting as much as possible with starting specifications. The base technology used has been the CSIC JFET technology previously developed and tested by the project partners. New devices dimensions and geometries have been considered to fit with the required specifications and some process technology adjustments have been necessary.
The starting specifications have been analysed and compared with the performances of existing SiC current limiter developed by the 3 project partners in previous works. From this initial analysis, several optimisation axes have been defined for the next phase of design and optimisation of the targeted device. This analysis have been done by all 3 partners.
For WP2&3 , 2D simulation work with numerical simulator has been done by INSA Lyon in order to adjust the device basic cell geometry of the device to the specs. The possibility to change some doping or etching profiles in the technology has been consulted to CSIC partner. Once defined the basic cell geometry, both INSA Lyon and CSIC have draw the photolithography masks set using a common software. Current limiter as well as technological and electrical test structures have been included on the mask set. Some preliminary processing test have been performed in order to adjust possible doping or etching profiles changes. Once the photolithography mask set, device fabrication started in the CSIC clean room. There will be two fabrication batches shifted of 2 months in order to correct possible deviations occurring during the processing.

Potential Impact:
For WP1 Simulations have been used to verify the fuse design .Mersen DC labs in Europe and US will allow us to speed up the testing. Due to the availability of the lab different fuse solutions will be tested and results will be evaluated against the bill of requirements. Mersen is already supplying products qualified with DO160 standard to aeronautics industries and own the facilities to perform electrical and environmental engineering tests. After test analysis of the first fuses batch, a redesign will be considered for the second production batch. We will use our current engineering manufacturing area to manufacture this new fuse. We can foresee the use of silver or bi-metal element, ceramic body and as a filler sand to quench the energy during clearing. Two production batches will be processed

For WP2 the labs of the three partners will be used to make a full testing, including engineering DO160 testing, of the SiC current limiter hybrid module. Most electrical testing will be done by INSA Lyon and CSIC while the environmental testing will be performed by Mersen. The final modules will be produced and delivered by Mersen to the clean Sky partners in charge of EPDS demonstrator. Mersen will support the integration of the modules in the final demonstrator.
All the partners will assess the Clean Sky partners on the testing of the modules.


Tel.: +33241961540
Record Number: 182052 / Last updated on: 2016-05-25
Information source: SESAM