Distributed engine cable suitable for comprehensive environment and preparation method thereof

Abstract

The invention provides a distributed engine cable suitable for a comprehensive environment, and belongs to the technical field of aviation generator cables. The cable system aims at overcoming the defects of a traditional aero-engine cable system in the aspect of adapting to different extreme environments such as mould, salt mist and damp heat of a fan cabin and high temperature and aging of a core cabin. The cable comprises a connector with a tail accessory, a wire bundle, a fan cabin section protection sleeve with a nylon yarn sheath, a wave-proof sleeve and a heat shrink tube, a core cabin section protection sleeve with a polytetrafluoroethylene corrugated tube, a wave-proof sleeve and an aramid fiber sheath, and a branching tube. The fan cabin section protective sleeve is fixed on the tail accessory and the branching pipe through a steel cable tie, and is sealed by using a mold shrinkage sleeve; and the core cabin section protective sleeve is fixed on the branching pipe, the tail accessory and the three-way branching pipe through a steel cable tie. According to the design, the fan cabin section protective sleeve and the core cabin section protective sleeve of the cable can effectively cope with various severe working conditions in the fan cabin section and the core cabin section, and meanwhile, the installation process is simplified.

Description

Technical Field

[0001] The present invention relates to the technical field of aviation generator cables, and in particular to a distributed engine cable suitable for comprehensive environments and a preparation method thereof. Background Art

[0002] In modern aircraft engine design, cable systems are critical components for ensuring signal transmission and power supply between engine components. Traditional aircraft engine cables typically utilize an integrated design, connecting to the controller via one or more integrated junction boxes or master terminals. However, with the continuous improvement of aircraft engine performance, especially the increase in the number of engine accessories, this traditional design faces numerous challenges.

[0003] Because the engine fan compartment and core compartment face different environmental conditions, such as the fan compartment often being exposed to harsh environments such as mold, salt spray, and humidity, while the core compartment is frequently exposed to extreme conditions such as high temperature and aging, cables must possess specific protective capabilities to adapt to these different operating environments. Existing cable solutions often cannot simultaneously meet these two distinct environmental requirements, resulting in the need to equip different compartments with different types of cables, which are spliced ​​together using connectors. This not only increases the number of cables and system complexity, but also increases installation and maintenance costs.

[0004] To address these issues, there is an urgent need for a distributed engine cable system that can adapt to diverse environmental conditions. This system not only accommodates multiple environmental protection requirements within a single structure, but also simplifies installation, reduces system complexity, and improves overall reliability and ease of maintenance. To this end, this paper proposes a novel distributed engine cable design suitable for diverse environments, aiming to address the aforementioned deficiencies in the existing technology. Summary of the Invention

[0005] In order to make up for the above shortcomings, the present invention provides a distributed engine cable suitable for comprehensive environments, which adopts an integrated distributed design concept, corresponds to different cable structures in different engine compartment sections, and meets the use requirements of the fan compartment and the core compartment at the same time.

[0006] The present invention is realized by the following technical solution: a distributed engine cable suitable for comprehensive environments, applied to the engine fan compartment and the engine core compartment, the technical points of which are: Includes several connectors with tail accessories, wiring harnesses connecting the tail accessories, fan compartment protective covers, core compartment protective covers and branch pipes; The fan compartment protective cover comprises a nylon sheath, a wave-proof cover and a heat shrink tube which are sequentially sleeved on the wire bundle; The core compartment protection cover includes a polytetrafluoroethylene corrugated tube, a wave-proof cover, and an aramid cover which are sequentially sleeved on the wire bundle; the fan compartment protection cover and the core compartment protection cover are connected via a branch pipe; The fan compartment protection cover is fixed to the wave-proof cover on the tail accessories and the branch pipe by steel tie, and the heat shrinkable tube is fixed to the wave-proof cover by blowing and shrinking. The molded sleeve for fixing the fan compartment protection cover is also blown and shrunk on the tail accessories and the branch pipe; The core compartment protection cover fixes the polytetrafluoroethylene bellows, wave-proof cover and aramid cover to the branch pipe, tail accessories and three-way branch pipe respectively through steel tie bands.

[0007] Furthermore, the present application also proposes a method for preparing the above-mentioned cable, the technical key points of which are as follows: Step 1: Connect the wire harness to the connector of the fan compartment, install the fan compartment protective cover, pass the other end of the wire harness through the branch pipe, fix the two ends of the fan compartment protective cover to the rear attachment of the connector and the branch pipe respectively, and blow-shrink the cover on the rear attachment and the branch pipe; Step 2: Install the core compartment protective cover and the three-way branch pipe on the core compartment wire harness in sequence, and fix the two ends of the core compartment protective cover to the branch pipe and the three-way branch pipe respectively; Step 3: Install the core compartment protective cover on the wire bundle branching from the three-way distribution pipe, connect the end of the wire bundle to the connector of the core compartment, and fix the two ends of the core compartment protective cover to the tail accessories of the three-way distribution pipe and the connector respectively.

[0008] Beneficial effects and features of the present invention: This design solution's fan compartment protective cover is resistant to mold, salt spray, and humid heat in the fan compartment; the core compartment protective cover is designed to withstand the core compartment's high temperature and aging conditions. Furthermore, the protective structures of both compartments are effectively resistant to harsh operating conditions such as vibration, shock, electromagnetic interference, and lightning. Compared to existing technologies, this solution reduces the number of cables and system complexity, lowering installation and maintenance costs and improving system reliability and durability. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 It is an enlarged cross-sectional schematic diagram of part A of the present invention; Figure 3 It is an enlarged cross-sectional schematic diagram of part B in the present invention; Figure 4 It is an enlarged cross-sectional schematic diagram of part C in the present invention.

[0010] The main parts in the figure are as follows: 1. Connector; 2. Tail accessories; 3. Wire harness; 4. Nylon sheath; 5. Wave-proof sleeve; 6. Heat shrink tubing; 7. Polytetrafluoroethylene corrugated tube; 8. Aramid sheath; 9. Branch pipe; 10. Steel tie.

[0011] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work. The other drawings obtained are all within the scope of protection required by the present invention. DETAILED DESCRIPTION

[0012] A distributed engine cable system suitable for comprehensive environments, especially suitable for applications in the aviation field that need to adapt to different operating environments such as fan cabin (mold, salt spray, humidity and heat) and core cabin (high temperature, aging and other extreme conditions). Figure 1-4 , the contents of the present invention are described in detail through specific embodiments. Example

[0013] A distributed engine cable suitable for a comprehensive environment, used in an engine fan compartment and an engine core compartment, comprising: a plurality of connectors 1 with tail attachments 2, a wire harness 3 connecting the tail attachments 2, a fan compartment section protective cover, a core compartment section protective cover, and a branch pipe 9; The fan compartment protective cover comprises a nylon sheath 4, a wave-proof cover 5 and a heat shrink tube 6 which are sequentially sleeved on the wire bundle 3; The core compartment protection cover includes a polytetrafluoroethylene bellows 7, a wave-proof cover 5, and an aramid cover 8 which are sequentially sleeved on the wire harness 3; the fan compartment protection cover and the core compartment protection cover are connected by a branch pipe 9; The fan compartment protective cover is fixed to the wave-proof cover 5 on the tail attachment 2 and the branch pipe 9 by steel tie 10. The heat shrink tube 6 is fixed to the wave-proof cover 5 by blowing and shrinking. The molded shrink sleeve 11 used to fix the fan compartment protective cover is also blown and shrunk on the tail attachment 2 and the branch pipe 9. The core compartment protection cover fixes the polytetrafluoroethylene bellows 7, the wave-proof cover 5 and the aramid sheath 8 to the branch pipe 9, the tail attachment 2 and the three-way branch pipe 12 through steel tie ties 10 respectively.

[0014] Key components and function description: Connector 1: used to electrically connect the wiring harness 3 to an external device.

[0015] Tail attachment 2: A part of connector 1 that provides mechanical fixation and support.

[0016] Wire harness 3: Contains multiple wires responsible for signal transmission and power supply.

[0017] The fan compartment protective cover includes a nylon sheath 4, a wave-proof cover 5, and a heat shrink tube 6, and is used to protect against mold, salt spray, humidity, and other environments.

[0018] Nylon sheath 4: wear-resistant, provides mechanical strength Anti-wave sleeve 5: copper material, used for electromagnetic protection and to guide interference current Heat shrink tubing 6: Provides better sealing protection to resist mold growth and salt spray and moisture intrusion Core compartment protective cover: It consists of a polytetrafluoroethylene bellows 7, a wave-proof cover 5, and an aramid sheath 8, and can cope with extreme conditions such as high temperature and aging.

[0019] PTFE bellows 7: wear-resistant and high temperature-resistant, providing mechanical strength and certain sealing protection Anti-wave sleeve 5: copper material, used for electromagnetic protection and to guide interference current Aramid sheath 8: wear-resistant and high temperature-resistant, provides mechanical strength and resists radiation aging Branch pipe 9: used to transfer the fan compartment protective cover and the core compartment protective cover.

[0020] Steel tie 10: secures the connection between the layers of the protective cover.

[0021] Molded sleeve 11: seals and protects the end of the protective sleeve and releases mechanical stress.

[0022] Three-way branch pipe 12: realizes the branching and integration of wire bundles in the core compartment.

[0023] The present application also proposes a method for preparing the above-mentioned cable, which comprises the following steps: Step 1: First, electrically connect the wire harness 3 to the connector 1 of the fan compartment and ensure mechanical fixation. Next, sequentially install the nylon yarn sheath 4, wave-proof sleeve 5, and heat shrink tubing 6 on the wire harness 3 to form a fan compartment protective cover. Use steel cable ties 10 to securely secure the wave-proof sleeve 5 to the tail attachment 2 and the branch pipe 9. Then, use a dedicated tool to heat and shrink the heat shrink tubing 6 so that it tightly wraps around the wave-proof sleeve 5, enhancing its waterproof and dustproof properties. Finally, blow the shrink sleeve 11 onto the tail attachment 2 and the branch pipe 9, respectively, to ensure the end is sealed and release mechanical stress.

[0024] Step 2: Install the core compartment protective cover and the three-way branch pipe 12 on the wire harness 3 of the core compartment in sequence. First, install the polytetrafluoroethylene bellows 7 on the wire harness 3, followed by the wave-proof cover 5, and finally the aramid sheath 8 to form the core compartment protective cover. Use steel cable ties 10 to first firmly fix the polytetrafluoroethylene bellows 7 to the branch pipe 9 and the three-way branch pipe 12. Similarly, use steel cable ties 10 to firmly fix the wave-proof cover 5 and finally the aramid sheath 8 to the branch pipe 9 and the three-way branch pipe 12. Ensure that each layer fits tightly to ensure the stability and protection of the overall structure.

[0025] Step 3: Install the core compartment protective cover (including the PTFE bellows 7, surge protector 5, and aramid sheath 8) on the wire bundle 3 branching from the tee branch pipe 12. Electrically connect the ends of this wire bundle 3 to the core compartment connector 1. Then, use steel tie ties 10 to secure the ends of the core compartment protective cover to the tee branch pipe 12 and the rear attachment 2 of the connector 1, respectively, using the same method used for securing the core compartment protective cover in Step 2.

Claims

1. A distributed engine cable suitable for comprehensive environments, used in engine fan compartment and engine core compartment, characterized by: It comprises a plurality of connectors (1) with tail attachments (2), a wiring harness (3) connecting the connectors (1), a fan compartment protective cover, a core compartment protective cover and a branch pipe (9); The fan compartment protective cover comprises a nylon yarn cover (4), a wave-proof cover (5), and a heat shrink tube (6) which are sequentially sleeved on the wire bundle (3); The core compartment protection cover comprises a polytetrafluoroethylene corrugated tube (7), a wave-proof cover (5), and an aramid cover (8) which are sequentially sleeved on the wire bundle (3); the fan compartment protection cover and the core compartment protection cover are connected via a branch pipe (9); The fan compartment protective cover fixes the wave-proof cover (5) to the tail attachment (2) and the branch pipe (9) through a steel tie (10); the heat shrink tube (6) is fixed to the wave-proof cover (5) by blowing and shrinking; and a molded cover (11) for fixing the fan compartment protective cover is also blown and shrunk on the tail attachment (2) and the branch pipe (9); The core compartment protective cover fixes the polytetrafluoroethylene bellows (7), the wave-proof cover (5) and the aramid sheath (8) to the branch pipe (9), the tail attachment (2) and the three-way branch pipe (12) respectively through steel tie bands (10).

2. A method for preparing the cable according to claim 1, characterized in that: The following steps are involved: Step 1: Connect the wire harness (3) to the connector (1) of the fan compartment, install the fan compartment protective cover, pass the other end of the wire harness (3) through the branch pipe (9), fix the two ends of the fan compartment protective cover to the tail attachment (2) of the connector (1) and the branch pipe (9), and blow-dry the shrink sleeve (11) on the tail attachment (2) and the branch pipe (9); Step 2: Install the core compartment protection cover and the three-way branch pipe (12) on the core compartment wire bundle (3) in sequence, and fix the two ends of the core compartment protection cover to the branch pipe (9) and the three-way branch pipe (12) respectively; Step 3: Install the wire bundle (3) branching from the three-way branch pipe (12) on the core compartment protective cover, connect the end of the wire bundle (3) to the connector (1) of the core compartment, and fix the two ends of the core compartment protective cover to the three-way branch pipe (12) and the tail attachment (2) of the connector (1) respectively.

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