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very little relationship to how the Ballistic Breaker works.

Wednesday, April 24, 2013

PCT Patent application link & status report on Ballistic Breaker™

The Ballistic Breaker is called a "commutating circuit breaker" in both my US and PCT (Patent Cooperation Treaty) patent applications. I decided to post my (now published) PCT patent application here to make it easy to access. The PCT patent application also adds a little bit more subject matter and a few more claims over my earlier US patent application.

The patent application applies to numerous implementations of the basic concept: 
  • linear motion actuation or rotary actuation; 
  • multiple stages can be used to divide the voltage so as to allow high voltage ballistic breakers with many stages;
  • gradation of the resistivity of trailing edges of the electrodes to further inhibit arcing upon electrode separation;
  • motion can be actuated by springs, gas pressure, stepper motors, or stretched wire or fibers (for example);
  • Use of correlated magnetic domains to accurately define the on state of the circuit breaker (subsidiary to US patent 8,098,122 to Correlated Magnetics);
  • Use of piezoelectric actuators as super-fast releases.

For a quick introduction to Ballistic Breakers, check these links: 



I recently filed a continuation-in-part US utility patent application that is based on both my February 6, 2012 US patent application and my PCT patent application, but adding in a bit more IP and two more claims.

Wednesday, March 20, 2013

My comment on the Energy Innovation by Statoil blogsite today

Ian said:

New Scientist and Statoil asked specifically what will have the largest near future impact, not what could. Not sure the winner and runner-ups reflect this important distinction



I commented:

On the positive side of this, I hope that 50 years from now we can look back and realize just what saved us. My leading candidates:

1) LENR (by that I specifically mean the nuclear fusion reactions of nickel with light (normal) hydrogen; if that works out it will surely be the most important thing.

2) If not that, then I'm betting on a supergrid to save us.

When the shit hits the fan, there will be a panicky rush for solutions. Unfortunately only proven technologies will qualify for panic funding. My goal is to have my invention elpipes ready when that moment arrives; see www.elpipe.com

Friday, March 15, 2013

I filed my "Continuation-in-Part" US Patent Application today

Each major redrafting of this patent has been a big improvement. First, my US patent application was filed on February 6, 2012, based on three prior provisionals. Then I greatly improved on that, and also added some new subject matter and claims in my PCT patent application, filed October 1, 2012. This "Continuation-in-Part" US patent application filed today added two new claims from the PCT (it is now 37 claims), and I am very happy with it. I believe it is valid, but I do expect challenges will be made by the examiner that probe at the relationship between Ballistic Breakers and two particular prior technologies:

  1. Automatic tap changers for AC transformers
  2. Rheostats
I expect the examiner to find a few patents I missed, because the old patents are hard to search. 

Wednesday, January 23, 2013

My "Startup Pivot" from elpipes to Ballistic Breaker


My inter-related inventions on high capacity HVDC transmission are key enablers for a supergrid. And a supergrid is the key to developing an energy economy based on aggregating numerous non-dispatchable generation resources (wind, solar, tidal). Both inventions (elpipes and Ballistic Breakers) are simple and seem obvious once you hear of them, yet both are revolutionary innovations. These innovations could make it practical to share hundreds of gigawatts (GW) of power across Europe, Asia, or North America, for example (this is the order of magnitude of new transmission needed to create a renewable energy economy), and that vision motivated me to pursue elpipes starting in 2008, after Obama's election victory.

Elpipes combine a pair of pipelines similar to gas pipelines with high capacity power lines that can move inside the pipes with features of a train. An elpipe is a very heavy high voltage DC (HVDC) power line that can carry more power than any overhead power line, with lower transmission loss. To do this, elpipes use more than 10 times as much conductor as the largest overhead lines; an elpipe is made up of heavy rigid conductors that are effectively the rail cars of an elpipe train. The elpipe train can run on conventional rails, or it can be designed to run inside a pipeline. An elpipe train could be thousands of kilometers long, yet the entire elpipe train would be fabricated at one location, then rolled into the conduit like a very long, low speed electric train. This method of installation splits the project into three parts: building the conduit, which is either a rail line or a gas pipeline; fabrication of the “elpipe cars” in a factory process; and assembly of the “elpipe cars” into a train at one single point of assembly (in a clean room environment, with sophisticated quality control inspection equipment deployed). This is very good for both cost of the elpipe and for reliability of the splices. Read more about elpipes at www.elpipe.com; I pursued elpipes for two years, and everyone with money said it is "too big, too long term" for venture funding. I came close to a deal with ABB to pursue elpipes in a strategic partnership in September 2010, but that was blocked by one ABB senior executive, Willi Paul. Shortly after this, I invented the Ballistic Breaker; this invention woke me up at 3:30 AM October 2, 2010. I have continued to work on my big dream of elpipes, though my focus is now on Ballistic Breakers.

The other missing piece of the puzzle for enabling a supergrid besides a high capacity underground conductor (elpipes) is a very high capacity low cost circuit breaker for HVDC power. The power electronic HVDC circuit breakers being offered by ABB are too expensive and too lossy to work at the scale needed in development of a supergrid. Ballistic Breakers are my second surprisingly simple innovation: these devices enable DC circuit breakers to be developed at any voltage and power level (they get bigger as power level goes up). Although I invented Ballistic Breakers for HVDC, they have an immediate market in medium voltage DC; in fact, Ballistic Breakers are key enablers for DC grids at all size scales, from vehicles to data centers to microgrids to the supergrid. So I have made the classic "startup pivot" and am now pursuing MVDC Ballistic Breakers with initial market: big motors.

I am also quite interested in applying Ballistic Breakers to DC data centers, which are growing rapidly. In this application, the low switching transients of Ballistic Breakers is especially important. For most data center installations, the desirable voltage level is only 380 volts. This low voltage implies a lot of amps (2632 amps/MW), which also is an opening for elpipes, since some data centers consume as much as 300 MW. In this application, a very high ampacity low voltage elpipe could be part of the data center power delivery system.

Tuesday, January 8, 2013

Tesla was on track to invent the Ballistic Breaker

Nikola Tesla is one of my heroes, though I hope to have more business sense than him. When I was writing my US patent application on Ballistic Breakers (*here is an excerpt) it worried me greatly that there might be some very old prior art (which is impossible to find in an online patent search). On a whim, realizing that Tesla was brilliant, I decided to browse through Tesla's 111 US patents on the odd chance that one of his patents might be relevant. In fact, Tesla's US Patent 382,845 is one of the closest prior art patents, and creates a link between my work and one of the great pioneers in electricity.

The story behind US patent 382,845 is truly interesting, and I only know part of it. Tesla came over to the US at Thomas Edison's invitation, and agreed to Edison's proposal that he work on a bounty basis (I got this from a Tesla biography). Edison wanted Tesla to figure out how to stop the commutators of DC motors and/or generators from sparking, and offered him (verbally) a $50,000 bounty if he could succeed. The resultant US patent 382,845 is the only one of Tesla's patents that deals with DC power at all. Edison never paid the bounty which led to Tesla breaking off the relationship and becoming Edison's sworn rival. This patent reveals a remarkably simple way to suppress the commutator arcing, which I also use in the Ballistic Breaker: just behind the conductive brush that makes contact with the rotating commutator is an insulating material (a mica board) that is in contact with the conductive brush, and is squeezed against the commutator as well. This leaves no room for the spark in effect, and arcing is suppressed; a remarkably simple and effective solution. Tesla's patent is remarkable in another way: it is the only patent I have ever seen that is half assigned (to Charles F. Peck); I assume that there is an interesting story behind that as well.

I believe that if egoic considerations had not gotten in the way, Edison and Tesla might have continued to work together. Had that happened, I believe Tesla would have invented the commutating circuit breaker 120 years ago. This was one of the next problems that needed to be solved to make wide area DC power transmission & distribution practical. Instead, Tesla never looked back at DC power and his inventions ushered in the age of AC. DC power equipment quickly became a backwater technology, and there was little innovation until the modern age of HVDC and DC microgrids. By that time vacuum tubes and transistors had been invented, and recent work on DC circuit breakers has mostly used these innovations. My invention Ballistic Breakers goes back to basics and picks up a thread of innovation that was abandoned by Tesla long ago.

Monday, November 12, 2012

ABB ANNOUNCES WORLD'S FIRST CIRCUIT BREAKER FOR HVDC

This announcement appeared on numerous websites on November 8, 2012:
ABB ANNOUNCES WORLD'S FIRST CIRCUIT BREAKER FOR HVDC
Switzerland-based ABB today announced that it has developed the world’s first circuit breaker for high voltage direct current (HVDC), solving what it says has been “a 100-year-old electrical engineering puzzle and paving the way for a more efficient and reliable electricity supply system.” The breakthrough holds promise not just for renewables development but also for all types of generation that nations and regions wish to transmit over long distances, including under large bodies of water. Read More »


There were many followup analyses after ABB's announcement, but the above link to Power Magazine was my favorite, and they got quotes from the right people!

This paper from the 2011 CIGRE conference in Bulogna describes their breaker concept pretty well. Here is a diagram of the breaker:

EP2550713 - A HYBRID CIRCUIT BREAKER30.01.2013
H02H 3/02
10711216ABBRESEARCH LTD DEMETRIADES GEORGIOS
The present invention relates to a hybrid circuit breaker (1) for interrupting a fault current in an electrical circuit <snip>. HERE is a link to the US publication of the PCT application.

Their new device appears to fall under the above PCT patent, but the pictire (above) from the Bulogna paper is much better for inderstanding how it works than the patent document. Although the auxiliary switch shown above is an IGBT, I believe that could also be a more recent innovation: IGCTs (integrated gate commutated thyristorsIGCTs were first introduced in shipboard DC circuit breakers (for 980 volt service) by ABB Marine in 2011). The fast electromechanical switch could be of several designs (ABB has several patents in this area; my personal favorite is US patent 6,636,134). 

The 2 ms delay that ABB cites in operation of their breaker (which is quite fast compared to most prior art breakers) is not the time until current stops flowing, but the time at which di/dt changes sign and the current starts being reduced.  This delay is due to the fast mechanical switch, which must open far enough to prevent restriking an arc before the main IGBT array can be opened. Patents have not yet issued, and I think the ABB breaker may in fact not be patentable in general over Lian's US patent 3,534,226 (assigned to Hughes Aircraft), which is also the closest prior art to my Ballistic Breaker patent application


The ABB device works in this way: there is a parallel circuit between three pathways: in the middle is a series connected IGBT array that is capable of shutting off the HVDC circuit and withstanding an overvoltage higher than the normal line voltage. In this series-connected IGBT array, each IGBT component is shunted through a metal oxide varistor (MOV) that allows current to flow when voltage goes above a selected level. All the component IGBTs of the IGBT array could be switched off simultaneously; in this case there would be a rather large voltage spike as the voltage rises at least 50% over normal voltage to activate the string of series-connected MOVs. Note though that the individual IGBTs can also be switched off sequentially to control the over voltage during breaking of the circuit. (The overvoltage is due to insertion of resistance into the circuit; absorption of inductive energy by the MOVs is not instantaneous, so the voltage rises each time resistance increases, follwed by decay. The big headache with any circuit breaker but especially an HVDC circuit breaker, is that the line inductance can vary a lot depending on where the short is located. ABB's method of rapid adaptive switching was clearly anticipated in Lian's patent from 1970; the switching times for the various IGBTs can be varied to control the switching transients and the times allowed for dcay between switching events to squelch the inductive energy in the flowing current in an optimized manner. Altenatively, one can just make a worst case assumption and switch on that basis (this is what happens in a Ballistic Breaker).  Or (most crudely) all the IGBTs in the array can be switched simultaneously, in which case the MOVs control the switching surge (but not very well). 

By controlling the switching of the IGBTs the voltage transient due to the voltage rising high enough to push current through the MOVs is split into many small parts, which can keep the overvoltage quite low if the timing of closing the IGBTs is properly controlled. Collectively, the MOVs must have enough capacity to absorb all the magnetic energy stored in the line, which can be hundreds of MJ, implying that the MOV array weighs a metric ton or so for a long HVDC line. An individual MOV begins to conduct around 1.5X the normal line current, so if all the IGBTs were switched simultaneously the voltage during shutoff could go to ~1.5-2X the normal line voltage. However, by controlling the switching time of the individual IGBTs the voltage switching transient could be much lower. This part of the breaker (the IGBT array) in isolation is the "power electronic breaker" to which Ram Adapa refers in the Power Magazine article cited above. 

The much lower resistance of the single IGBT or IGCT used for commutation means the on-state losses are (according to ABB's CIGRE paper) in the low tens of kW for a 2kA, 320kV HVDC line; if we take that to mean 40kW on-state loss in the commutating IGCT/IGBT, that implies only ~0.005% of transmitted power. This is much better than the on-state loss for an IGBT-based switch in which all the current flows all the time through the entire IGBT array, for which the on-state loss would be ~0.25% of power at full rated power. The ABB breaker is much better than that, and does indeed usher in an era where large interconnected high power HVDC grids (supergrids) can be protected by circuit breakers. I believe ABB's breaker will more expensive than my Ballistic Breaker or a hybrid Ballistic Breaker, which follows the same idea as ABB's design of using a fast switch to do the first commutation to the device which ultimately opens the circuit. I welcome ABB's innovation as the first viable HVDC circuit breaker, and I look forward to competing with them.

ABB's approach cuts the on state power losses, because in the on state, most of the power only goes through the low loss low voltage IGCT or IGBT, but makes an even more expensive circuit breaker than a simple IGBT-based switch with MOVs (what Ram Adapa mentioned in the Power Magazine article cited above. This is no doubt a big advance from the prior art DC circuit breaker of US patent 3,809,959 (from ASEA before they joined Brown-Boveri to form ABB), but it is not true to say it is the "world's first circuit breaker for HVDC." It is true to say it is more compact and faster than the prior art methods, though I think the story put out by ABB that faster action (5 ms versus 50 ms) is crucial to create a workable HVDC grid is debatable (see this post by Gregor Czisch). The prior art ASEA method is widely deployed in HVDC schemes today, to shut down one leg of a bipole HVDC scheme when needed (so that the other leg can still operate as a monopole with ground return in case of a fault on one leg of the scheme). 

ABB's HVDC circuit breaker may not be cost competitive with an HVDC Ballistic Breaker (my invention, see www.ballisticbreaker.com), once I get funding to build one. The use of power electronics requires liquid cooling, and a high degree of redundancy. If I am correct, the cost of ABB's Hybrid HVDC Breakers will be about 25% of the cost of a VSC AC/DC converter station, or about $35/kW 
(AC circuit breakers at 200kV cost ~ $.15/kW for comparison); this is high enough that it will still be impossible economically to place ABB hybrid HVDC circuit breakers between every set of next neighbor power taps on main lines of the supergrid (which may well carry ~30 GW) in the future. The supergrid needs something much less expensive to make full circuit protection (as is routine in the HVAC transmission grid) feasible economically. The Ballistic Breaker is that device.



FYI, here is a video on the circuit breaker’s operation:

And here is an interview with Claes Rytoft, head of ABB's Power Transmission Group:

Other links are here: