Mechanical and electrical connections of electrical machines and components in electrical systems using quick connect / disconnect connectors

Abstract

Techniques are disclosed for facilitating the mechanical and electrical connection of electrical machines and electrical components in an electrical system using connectors having quick connect / disconnect electrical connectors. Each quick connect / disconnect electrical connector can be disposed at the end of an electrical distribution cable that connects to the electrical machine or electrical component. The electrical machine, electrical component, and electrical distribution cable can have hollow coolant passages formed therein for receiving cooling fluid from a cooling device for directly cooling the electrical machine, electrical component, and electrical distribution cable.

Description

[Technical Field]

[0001] Embodiments of the present disclosure relate generally to electrical systems, and more particularly to implementing mechanical and electrical connections of electric machines and auxiliary electrical components in electrical systems including power generation and distribution using quick connect / disconnect connectors. [Background technology]

[0002] Aircraft electrical systems are one example of how electric machines and auxiliary electrical components can be integrated into an electrical system for the purposes of power generation and distribution. Typically, electric machines and auxiliary electrical components within an aircraft electrical system are connected using busbar connectors, which involve the use of mechanical fastening devices to secure at least one terminal of the machine and component in a secure position on the busbar. In this manner, generated electrical power can be distributed among the electric machines and auxiliary electrical components via the busbar connectors. The use of these busbar connectors in such aircraft electrical systems is less desirable due to the use of stronger and more integrated electric machines and components in aircraft. For example, busbar connectors can loosen in vibration environments, especially at the connections between the electric machines and components. Environmental loads can also cause misalignment of the electric machines and components. Given the emergence of stronger and more integrated electric machines employed in aircraft, the ability to make highly reliable and safe electrical connections between components and / or internal to subcomponents of a given assembly becomes paramount.

[0003] Another reason the use of busbar connectors has become less desirable is that many of the electromechanical and auxiliary electrical components are implemented in aircraft electrical systems as line replaceable units (LRUs). Generally, LRUs are modular components within an aircraft that can be replaced quickly, typically with minimal tools. To this extent, LRUs can facilitate rapid maintenance in the field rather than at a designated maintenance facility. Because busbar connectors typically involve bolted connections, their use in aircraft electrical system LRUs is not ideal because there are many bolted connections that must be disassembled and reassembled. Disassembly and reassembly of bolted connections contradicts the need to quickly replace LRUs with minimal tools. This lack of compatibility with LRUs makes the use of busbar connectors less ideal from a manufacturing and productivity perspective in future aircraft electrical systems, especially as systems become more complex and powerful in later aircraft. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] China Utility Model No. 212304032 Summary of the Invention

[0005] The following presents a simplified summary of the disclosed subject matter in order to provide a basic understanding of some aspects of the various embodiments described herein. This summary is not an extensive overview of the various embodiments. It is not intended solely to identify key features or essential features of the claimed subject matter as set forth in the claims, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Its sole purpose is to present some concepts of the disclosure in a simplified form as a prelude to the more detailed description that is presented later.

[0006] Instead of using busbar connectors or other commonly used connectors that can be used in electrical systems involving power generation and distribution, such as standard pin-type connectors, crimp connectors, brazed connectors, and mechanical connectors, various embodiments of the present invention utilize quick connect / disconnect connectors to implement the mechanical and electrical connections of electric machines and auxiliary electrical components in the electrical system, including, but not limited to, low / medium / high voltage generators, motors, inverters, energy storage devices, instrumentation, and power transmission hardware.

[0007] The application of quick connect / disconnect connectors in electrical systems allows for "plug-in" style assembly and disassembly of electrical machines and auxiliary electrical components due to their quick connect style interface. Quick connect / disconnect connectors can include, but are not limited to, spring-loaded electrical connectors, push-pull electrical connectors, and in-line voltage electrical connectors using male and female connectors.

[0008] In one embodiment, the quick connect / disconnect connector can include a spring-loaded electrical connector. A spring-loaded electrical connector having one or more louvered springs is an example of a spring-loaded electrical connector suitable for use as a quick connect / disconnect connector to facilitate mechanical and electrical connection of electrical machines, electrical components, and power distribution cables in the electrical systems of the embodiments described herein. In one embodiment, one or more louvered springs can be mounted on the male (e.g., plug) or female (e.g., receptacle, socket) portion of the connector. The louvered springs reduce insertion force and provide consistent pressure in the mated state to facilitate connection between the electrical machine, electrical component, and cable. In this manner, the louvered springs can function not only as a path for electrical current but also as a mechanical engagement between the male and female halves of the connector assembly formed between the electrical machine / electrical component and the power distribution cable connected thereto via the connector. The louvered springs in these spring-loaded electrical connectors provide a positive engagement force that maintains mechanical and electrical contact between the electrical machine / component and the power distribution cable, so that a separate mechanical joining means (i.e., mechanical fasteners) is not required.

[0009] The quick connect style interface of quick connect / disconnect connectors, such as spring louvered electrical connectors, makes these connectors suitable for use in aircraft electrical systems that integrate high power density electromechanical and electrical components. For example, various embodiments of the present invention relate to electrical systems for high voltage, high power applications. These high voltage, high power applications can include, but are not limited to, aircraft (e.g., as part of aircraft propulsion and / or power generation systems) and power generation (e.g., high voltage DC interconnections associated with power grids, solar and wind turbine implementations).

[0010] In one embodiment, a connector assembly formed between an electric machine / electrical component and a power distribution cable connected thereto via a quick connect / disconnect connector, such as a spring-loaded electrical connector (e.g., a spring louvered connector), can include hollow conductor coolant passages formed therein for receiving cooling fluid from a cooling device. In this manner, cooling fluid can be supplied to the electric machine / electrical component and the power distribution cable to directly cool the machine / component and the cable. In one embodiment, where the electric machine includes a stator and stator windings (e.g., electric motor, generator), cooling fluid from the cooling device can be used to directly cool the stator windings and phase leads emanating from the electric machine, as well as the power distribution cable and quick connect / disconnect connectors connecting to the machine. In one embodiment, where a high-voltage, high-power electrical system utilizes auxiliary electrical components, such as inverters, instrumentation and power transmission hardware, and energy storage devices, cooling fluid from the cooling device can also be used to directly cool these components.

[0011] According to one embodiment, a system is provided that includes a plurality of electric machines and components, each having a lead end, a plurality of power distribution cables for distributing electrical power among the plurality of electric machines and components, and a plurality of connectors for facilitating mechanical and electrical connection between the plurality of electric machines and components and the plurality of power distribution cables, each connector being disposed between one of the electric machines and components and a corresponding power distribution cable operative to supply electrical power thereto, each connector having a connector head extending across a portion of the corresponding power distribution cable to facilitate the mechanical connection between the one of the electric machines and components and the corresponding power distribution cable, a receptacle disposed on one of the lead ends of the electric machines and components and the corresponding power distribution cable, a plug disposed on the other of the lead ends of the electric machines and components, and a quick connect / disconnect electrical connector disposed on one of the receptacle and the plug, the quick connect / disconnect electrical connector facilitating the electrical connection between the one of the electric machines and components and the corresponding power distribution cable.

[0012] According to another embodiment, a system is provided that includes a plurality of electric machines and components, each electric machine and component having a lead end with a main phase lead thereon, the main phase lead having an interior cavity defining a hollow coolant passage formed therethrough, a plurality of power distribution cables for distributing electrical power among the plurality of electric machines and components, each power distribution cable including a hollow coolant passage therethrough, and a plurality of connectors for facilitating mechanical and electrical connection between the plurality of electric machines and components and the plurality of power distribution cables, each connector being disposed between one of the electric machines and components and a corresponding power distribution cable operative to supply electrical power thereto, each connector extending across a portion of the corresponding power distribution cable that facilitates the mechanical connection between the electric machine and component and the corresponding power distribution cable. a plurality of connectors including a connector head, a receptacle disposed on one of the main phase leads of the electric machine and the electric component and the corresponding power distribution cable, a plug disposed on the other of the main phase leads of the electric machine and the electric component and the corresponding power distribution cable, and a spring-loaded electrical connector disposed on one of the receptacle and the plug, the spring-loaded electrical connector facilitating an electrical connection between one of the electric machine and the electric component and the corresponding power distribution cable and including a protruding spring contact; and a cooling device having a cooling fluid operably coupled to the plurality of electric machines and electric components and the plurality of power distribution cables, the cooling device being configured to supply cooling fluid to the plurality of electric machines and electric components through hollow coolant passages in each of the electric machines and electric components and to supply cooling fluid to the plurality of power distribution cables through hollow coolant passages in each of the power distribution cables.

[0013] The invention will be better understood from a consideration of the following description of non-limiting embodiments with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0014] [Figure 1]1 shows a schematic diagram of an electrical system utilizing connectors including quick connect / disconnect connectors for implementing electrical and mechanical connections between power distribution cables and electrical machines and components, according to one embodiment of the present invention. [Figure 2] 1 shows a more detailed view of a quick connect / disconnect connector connected to a power distribution cable according to one embodiment of the present invention; [Figure 3] 2 shows a more detailed cross-sectional schematic diagram of the mechanical and electrical connection between an electric machine, a quick connect / disconnect connector such as a spring-loaded electrical connector having one or more louvered spring contacts, and the power distribution cable shown in FIG. 1, in accordance with one embodiment of the present invention. [Figure 4] 1 shows a more detailed schematic diagram of the mechanical and electrical connections between an electric machine, a spring loaded electrical connector having one or more louvered springs, and a power distribution cable, where the main phase leads of the electric machine and the power distribution cable have hollow coolant passages formed therein for the purpose of directly cooling the machine, the power distribution cable, and the connector, according to one embodiment of the present invention. [Figure 5] FIG. 5 shows a more detailed schematic diagram of the mechanical and electrical connection between an electric machine, a spring-loaded electrical connector having one or more louvered springs, and a power distribution cable similar to FIG. 4 but with a sealing element between the electric machine and the connector to prevent leakage of coolant fluid, according to one embodiment. [Figure 6] 6 shows a schematic diagram of an approach for preventing coolant fluid leakage according to an embodiment that is an alternative to the configuration shown in FIG. 5. [Figure 7A] 1A-1D show schematic diagrams of various configurations of male and female portions of spring-type electrical connectors having one or more louvered springs for electric machines and power distribution cables according to embodiments of the present invention. [Figure 7B] 1A-1D show schematic diagrams of various configurations of male and female portions of spring-type electrical connectors having one or more louvered springs for electric machines and power distribution cables according to embodiments of the present invention. [Figure 7C] 1A-1D show schematic diagrams of various configurations of male and female portions of spring-type electrical connectors having one or more louvered springs for electric machines and power distribution cables according to embodiments of the present invention. [Figure 7D] 1A-1D show schematic diagrams of various configurations of male and female portions of spring-type electrical connectors having one or more louvered springs for electric machines and power distribution cables according to embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] Illustrative embodiments of the invention are described more fully below with reference to the accompanying drawings, in which some, but not all, embodiments are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers may refer to like elements throughout.

[0016] The present disclosure relates generally to electrical systems, and more particularly to implementing mechanical and electrical connections of electric machines and auxiliary electrical components in electrical systems, including power generation and distribution, using quick connect / disconnect connectors. As used herein, a quick connect / disconnect connector includes any connector that facilitates quick connection and disconnection of leads and terminals from electric machines and auxiliary electrical components with a power distribution cable that has reduced insertion and removal forces to enable connection and disconnection, and does not have a mechanical fastener to make the mechanical connection between any of the elements in the electrical system. Examples of quick connect / disconnect connectors include, but are not limited to, spring-loaded electrical connectors (e.g., spring louvered electrical connectors, leaf spring like electrical connectors), push-pull electrical connectors, and in-line voltage electrical connectors that use male and female connectors.

[0017] Although various embodiments are described with respect to electrical systems including power generation and distribution in the aerospace sector, such as the aircraft industry, the mechanical and electrical connection of electrical machines and auxiliary electrical components achieved using quick connect / disconnect connectors is suitable for any application, including low, medium, or high voltages. In aircraft and aerospace applications, low voltage applications refer to voltages below 125 V dc, medium voltage applications refer to voltages in the range of 125 V to 400 V dc, and high voltage applications refer to voltages above 400 V dc. In one embodiment, the quick connect / disconnect connectors can be implemented in high power, high voltage applications where high power density electrical machines and electrical components are integrated into the electrical system. As used herein, high power means greater than 250 kW, and the gravimetric power density (i.e., power density equal to power (e.g., in kW) divided by equipment weight (e.g., in kW)) is 2 kW / kg or greater. One example of a high power, high voltage application using high power density electric machines is aircraft systems. In particular, aircraft propulsion and / or power generation systems for existing aircraft platforms, including hybrid electric aircraft, and future aircraft platforms, including electric aircraft and hydrogen aircraft, are examples of high power, high voltage applications having high density, airborne electric machines and auxiliary system components. Other implementations of various embodiments can include high voltage power generation applications, such as, for example, high voltage DC interconnections associated with power grids, solar and wind turbines.

[0018] Referring now to the drawings, FIG. 1 illustrates a schematic diagram of an electrical system 10 utilizing a connector 12, which may include quick connect / disconnect connectors, for implementing electrical and mechanical connections between a power distribution cable 14 and an electric machine 16 and an electrical component 18, in accordance with one embodiment of the present invention. In one embodiment, the electrical system 10 may be part of an aircraft electrical system used for generating and distributing electrical power onboard an aircraft. As shown in FIG. 1 , the electric machine 16 may include a motor or generator, and the electrical component 18 may include an inverter. For example, the motor / generator and inverter may be a three-phase type having three leads electrically connected to the power distribution cable 14 via the connector 12. It is understood that the electric machine 16, depicted as a motor / generator, and the electrical component 18, depicted as an inverter, are merely examples of possible electric machines and electrical components that may be used in the electrical system 10. Those skilled in the art will appreciate that the aircraft electrical system 10 may include different types of flight-capable electric machines and electrical components. Other electric machines and auxiliary electrical components may include, but are not limited to, low-, medium-, and high-voltage energy storage devices, instrumentation, and power transmission hardware. Furthermore, the number of electrical machines and components and connectors 12 shown in FIG. 1 is for clarity and ease of illustrating embodiments of the present invention and is not meant to be limiting.

[0019] In one embodiment, as shown in FIG. 1 , the electrical system 10 may include a cooling device 20 for supplying cooling fluid to the power distribution cable 14, the electric machine 16, and the electrical components 18 for cooling the following elements of the system 10: the power distribution cable 14, the electric machine 16, and the electrical components 18. In this example, the cooling device 20 may include a pump 22 configured to supply cooling fluid to a heat exchanger 24 via piping 26. During operation, the pump 22 may recirculate cooling fluid used to directly cool the electric machine 16 (e.g., the stator windings of a motor / generator stator) by directing the cooling fluid received from the electric machine through the piping 26 to the heat exchanger 24. The heat exchanger 24 dissipates heat from the cooling fluid received from the electric machine 16 via the pump 22 and the piping 26. The heat exchanger 24 may then direct the cooling fluid to the electrical components 18 through the cooling piping 26. The cooling fluid may then flow from the electrical components 18 to the electric machine 16 via the power distribution cable 14.

[0020] In one embodiment, the electrical components 18, the power distribution cable 14, and the electric machine 16 are in fluid communication through a shared coolant network 28. As used herein, the term "fluid communication" means there are passages that allow a fluid to flow. The shared coolant network 28 in FIG. 1 can include hollow coolant passages that extend through the conductors of the electrical components 18, the power distribution cable 14, and the electric machine 16. These coolant passages can be in fluid communication with piping 26 that connects to the pump 22 and the heat exchanger 24. In one embodiment, as shown in FIG. 1, the coolant network 28 can include three coolant passages that extend through the conductors of the electrical components 18, the power distribution cable 14, and the electric machine 16, corresponding to the leads of the conductors in the electric machine and electrical components that receive power via the cables. To that extent, in examples where the electric machine 16 includes a motor or generator and the electrical component 18 includes an inverter, coolant can be used to cool these elements as well as the power distribution cable 14. For example, with respect to a motor / generator, coolant can be used to cool the stator windings of the stator. Further details of the coolant passages are described below with respect to Figures 4-6.

[0021] The cooling fluid can include any of several known cooling media. For example, the cooling fluid can include a coolant in gas or liquid form, such as oil, deionized water, mineral oil, silicone oil, turbo oil, DI water, SF6, air, nitrogen, hydrogen, argon, etc. In one embodiment, the cooling fluid can include a liquid in a supercritical state, such as supercritical CO2.

[0022] The electrical system 10 of Figure 1 illustrates only one possible system for implementing electrical and mechanical connections between a power distribution cable 14, an electric machine 16, and an electric component 18 using a connector 12, which may include a quick connect / disconnect connector. The electrical system can be configured without a cooling device that directly cools the power distribution cable, the electric machine, and the electric component. For example, Figures 2 and 3 illustrate connections between the power distribution cable 14 and the connector 12, and between the cable, the connector, and the electric machine 16, respectively, without coolant passages.

[0023] For clarity, Figures 2 and 3 and 4-6 show only one conductor representing the main lead of the electric machine electrically connected to connector 12 and power distribution cable 14. It is understood that electric machine 16 and power distribution cable 14 have separate conductors for each lead associated with these elements. Thus, connector 12 has a separate quick connect / disconnect electrical connector for connecting each lead of electric machine 16 with power distribution cable 14.

[0024] 2 and 3, further details of the connector 12 will be described with reference to the main phase lead 30 emanating from the lead end 32 of the electric machine 16. As shown in FIGS. 2 and 3, the connector 12 may be disposed at one end 34 of the power distribution cable 14 opposite the other end of the cable (not shown) and capable of connecting to another electric machine 16 or electrical component 18 via the connector 12. The connector 12 may include a connector head 36 that extends over a portion of the power distribution cable 14. In one embodiment, the connector head 36 may have a first end region 38, a second end region 40 that abuts the lead end of the electric machine 16, and an intermediate region 42 that connects the first end region with the second end region. The first end region 38 may have a constant width, and the intermediate region 42 may have a width that increases from the first end region 38 to the second end region 40. As shown in FIGS. 2 and 3, the second end region 40 may have a width that is greater than the widths of the first end region 38 and the intermediate region 42. It is understood that the tapered shape of the connector head 36 is representative of shape only and is not meant to be limiting, as it is envisioned that the connector head can take on other shapes such as, for example, circular, oval, and rectilinear shapes.

[0025] In one embodiment, as shown in FIG. 3 , the interface 44 between the second end region 40 and the lead end 32 of the electric machine 16 defines a flange 46 that facilitates a mechanical connection between the electric machine 16 and the power distribution cable 14. The flange 46 can secure the mechanical connection between the electric machine 16 and the power distribution cable 14 via at least one fastener 48. The fastener 48 can include any of several well-known fastener assemblies that can facilitate a mechanical connection between two components. For example, the fastener 48 can include screws, bolts, pins, inserts, rivets, magnetic couplers, and corresponding nuts, washers, rings, etc. to secure the connection. Generally, the fastener 48 allows the connector 12 to be removed from the electric machine 16 when access to the machine is desirable, such as during maintenance and inspection.

[0026] Flange 46 may further include at least one sealing element 50 for sealing the mechanical connection between electric machine 16 and power distribution cable 14. Sealing element 50 may include any of several mechanical sealing elements that may help prevent fluid or air from leaking between electric machine 16 and power distribution cable 14 through interface 44. A non-exhaustive list of mechanical sealing elements suitable for use in this embodiment includes O-rings, pump sealants, flat gaskets, and viscous sealants.

[0027] In addition to the fasteners 48 and sealing elements 50, the connector 12 may include other elements. For example, the connector 12 may have an insulator 51 to facilitate an electrical connection between the electric machine 16 and the power distribution cable 14. As shown in FIG. 3 , the insulator 51 may be disposed between the power distribution cable 14 and the connector head 36 of the connector 12. Additionally, the insulator may be disposed between the main phase leads 30 of the electric machine 16 and an interior wall 53 of the electric machine.

[0028] 3 shows that the connector 12 may further include a female portion 52, such as a receptacle (e.g., socket), that may be disposed on one of the lead end 32 of the electric machine 16 and the end 34 of the power distribution cable 14. A male portion 54, such as a plug, may be disposed on the other of the lead end 32 of the electric machine 16 and the power distribution cable 14. It will be understood that the positions of the female portion 52 and the male portion 54 may be reversed. For example, the power distribution cable 14 may be configured with a female portion and the electric machine 16 may be configured with a male portion.

[0029] FIG. 3 illustrates that the connector 12 can further include a spring-loaded electrical connector 56 disposed on one of the female portion 52 of the electric machine 16 and the male portion 54 of the power distribution cable 14. In one embodiment, the spring-loaded electrical connector 56 can include another louvered spring contact 57 to form a multi-contact spring-louvered connector. To this extent, the spring-loaded electrical connector 56 can facilitate an electrical connection between the electric machine 16 and the power distribution cable 14 via the one or more louvered spring contacts 57. That is, the louvered spring contacts on the male portion 54 or female portion 52 of the connector can act as both a path for electrical current and a mechanical engagement between the male and female halves of the connector assembly. Because the one or more louvered spring contacts 57 provide a positive engagement force that maintains the mechanical and electrical contact, a separate mechanical mating means is not required.

[0030] In one embodiment, another louvered spring contact 57 of spring-loaded electrical connector 56 may include a bent metal sheet that forms a spring contact within power distribution cable 14 and electric machine 16. As an alternative to a louvered spring contact, spring-loaded electrical connector 56 may take the form of a leaf spring that is molded into a configuration.

[0031] 3 shows the louvered spring contacts 57 of the spring-loaded electrical connector 56 disposed on the power distribution cable 14, it is understood that this configuration represents only one possible configuration and is not meant to be limiting. For example, the position of the louvered spring contacts 57 of the spring-loaded electrical connector 56 can be reversed so that the spring contacts are disposed on the female portion 52 of the electric machine 16. Similarly, if the power distribution cable 14 is configured with a female portion and the electric machine 16 is configured with a male portion, the position of the spring-loaded electrical connector 56 can be changed according to these options.

[0032] As described above, the mechanical and electrical connection between the electric machine 16 and the electrical component 18 using the connector 12 and the power distribution cable 14 may involve providing a cooling fluid to the electric machine and the electrical component in an electrical system such as that shown in FIG. 1 . FIG. 4 illustrates an example of an electric machine 16, connector 12, and power distribution cable 14 configured to receive a cooling fluid. As shown in FIG. 4 , the power distribution cable 14 may include an internal cavity 58 defining a hollow coolant passage 60 formed therein. Additionally, the lead end 32 of the electric machine 16 may include an internal cavity 62 defining a hollow coolant passage 64 formed therein. In one embodiment, the hollow coolant passage 64 in the lead end 32 of the electric machine 16 may be in fluid communication with the hollow coolant passage 60 of the power distribution cable 14. As shown in FIG. 4 , the width of the hollow coolant passage 64 in the lead end 32 of the electric machine 16 may be greater than the width of the hollow coolant passage 60 of the power distribution cable 14.

[0033] It is understood that the width of the hollow coolant passages 64 in the electric machine 16 and the width of the hollow coolant passages 60 in the power distribution cable 14 may vary and are not meant to limit the embodiment shown in Figure 4. In general, the width of the hollow coolant passages 60 in the power distribution cable 14 and the hollow coolant passages 64 in the electric machine 16 may depend on which elements are configured with female and male portions and which of these components are implemented with spring-loaded electrical connectors 56 that include one or more louvered spring contacts 57.

[0034] 1 may be configured to supply cooling fluid to the power distribution cable 14 and the electric machine 16. In this regard, the cooling fluid passing through the hollow coolant passages 60 may cool the power distribution cable 14, while the cooling fluid passing through the hollow coolant passages 64 may cool the electric machine 16. Additionally, the cooling fluid may cool the spring-loaded electrical connectors 56. In one embodiment where the electric machine 16 is a motor or generator, the cooling fluid received from the power distribution cable 14 may be used to cool the stator windings of the stator of the motor or generator.

[0035] It is understood that the hollow coolant passages 60 of the distribution cables 14 and the hollow coolant passages 64 in the electric machines 16 do not necessarily need to be in fluid communication. For example, the hollow coolant passages 60 of the distribution cables 14 may be separate from the hollow coolant passages 64 in the electric machines 16. In such an embodiment, the cooling system may be configured to supply cooling fluid to the distribution cables 14 and the electric machines 16 separately.

[0036] In the embodiment shown in Figure 4, the louvered spring contacts 57 of the spring-loaded electrical connector 56 are located on the power distribution cable 14. As with the embodiment described with respect to Figure 3, the louvered spring contacts 57 of the spring-loaded electrical connector 56 can be configured in other locations. For example, the louvered spring contacts 57 of the spring-loaded electrical connector 56 can be inverted so that the louvered spring contacts 57 are located within the electric machine 16.

[0037] 5 and 6 illustrate an alternative arrangement for supplying coolant through hollow coolant passages 60 in power distribution cable 14 and hollow coolant passages 64 in electric machine 16, as compared to the embodiment shown in FIG. 4. In particular, the embodiment shown in FIGS. 5 and 6 is directed to preventing leakage of coolant fluid from coolant passages 60 and 64 by disposing one or more sealing elements 50 within the connector itself, between the male and female portions of the connector. To this extent, one or more sealing elements 50, which may include any of the elements described above, enable the connector to prevent leakage of coolant fluid.

[0038] As shown in both Figures 5 and 6, the female portion (e.g., 52) and the male portion (e.g., 54) can each include radially extending portions 66 and 68. The radially extending portions 66 and 68 define a flange 70, and a fastener 48, such as any of those described above, can secure the radially extending portions together. The embodiment shown in Figure 5 adds provision for an additional mechanical connection through the use of a flange extension 72 that secures the electric machine 16 and the power distribution cable 14 at a location external to the coolant passages 60 and 64. While Figures 5 and 6 do not show connector heads, it is understood that these embodiments can have connector heads for the purpose of providing insulation.

[0039] 7A-7D illustrate various example configurations that the louvered spring contacts 57 of the spring-loaded electrical connector 56 can have relative to the electric machine 16 and the power distribution cable 14, applicable to both of the embodiments shown in FIGS. 3-6. In particular, FIG. 7A illustrates an electric machine 16 configured with a female portion (e.g., a receptacle, socket, etc.) and a power distribution cable 14 configured with a male portion (plug). In this embodiment, the louvered spring contacts 57 of the spring-loaded electrical connector 56 are disposed on the power distribution cable 14 with the contacts projecting outward from the cable to a receptacle. FIG. 7B illustrates a power distribution cable 14 configured with a female portion (e.g., a receptacle, socket, etc.) and an electric machine 16 configured with a male portion (plug). In this embodiment, the louvered spring contacts 57 of the spring-loaded electrical connector 56 are disposed on the electric machine 16 with the spring contacts projecting outward from the electric machine to a receptacle within the power distribution cable 14. 7C illustrates an electric machine 16 configured with a female portion (e.g., a receptacle, socket, etc.) and a power distribution cable 14 configured with a male portion (plug). In this embodiment, the louvered spring contacts 57 of the spring-type electrical connector 56 are disposed within the electric machine 16 with the spring contacts protruding inside the power distribution cable 14. FIG. 7D illustrates an electric distribution cable 14 configured with a female portion (e.g., a receptacle, socket, etc.) and an electric machine 16 configured with a male portion (plug). In this embodiment, the louvered spring contacts 57 of the spring-type electrical connector 56 are disposed within the power distribution cable 14 with the spring contacts protruding inside the power distribution cable 14.

[0040] Although various embodiments are described primarily with reference to using quick connect / disconnect connectors including spring-loaded electrical connectors, it will be understood that other types of quick connect / disconnect connectors are suitable for use with these embodiments. For example, other quick connect / disconnect connectors having utility with various embodiments may include, but are not limited to, push-pull electrical connectors and in-line voltage electrical connectors using male and female connectors.

[0041] From the description of the exemplary embodiments presented herein, it is clear that the present disclosure demonstrates an effective solution for providing connectors that can be used in electrical systems, including power generation and distribution, that avoid the problems associated with busbar connectors or other commonly used connectors. This solution, provided by various embodiments, involves utilizing quick connect / disconnect connectors (e.g., multi-contact spring-louvered connectors) to implement the mechanical and electrical connections of electrical machines and auxiliary electrical components within the electrical system. The use of quick connect / disconnect connectors can reduce the number (and weight) of parts in an assembly and eliminate the need for complex joining (i.e., brazing) operations during manufacturing or assembly. This allows for more efficient use of existing machine size envelopes due to the reduction in parts contributing to the overall machine size. This also eliminates potential failure modes of typical electrical connections (e.g., braze cracks, loose hardware, etc.).

[0042] The use of quick connect / disconnect connectors can further serve as technology enablers in a variety of applications, including low-, medium-, and high-voltage scenarios. In one embodiment, the quick connect / disconnect connectors can have utility with high-power and high-voltage machinery. Examples can include, but are not limited to, both existing aircraft platforms (i.e., hybrid electric propulsion) and future aviation-related advancements (i.e., distributed propulsion) and power generation (e.g., high-voltage direct current interconnects associated with power grids, solar, and wind turbine implementations). Furthermore, connector styles associated with quick connect / disconnect connectors can significantly simplify replacement of LRUs on aircraft and the like, improving reliability, availability, and maintainability as well as being a key product differentiator for end users.

[0043] The foregoing description of illustrative embodiments of the present subject disclosure, including those described in the Abstract, is not intended to be exhaustive or to limit the disclosed embodiments to the precise forms disclosed. While specific embodiments and examples have been described herein for illustrative purposes, various modifications are possible that are contemplated within the scope of such embodiments and examples, as those skilled in the art will recognize. For example, parts, components, steps, and aspects from different embodiments may be combined or adapted for use in other embodiments even if not described in the present disclosure or illustrated in the figures. Thus, because certain changes can be made to the above-described invention without departing from the spirit and scope of the invention embodied herein, it is intended that all of the subject matter of the foregoing description, as shown in the accompanying drawings, should be interpreted solely as examples illustrating the inventive concepts herein, and not as limiting the invention.

[0044] In this regard, while the disclosed subject matter has been described with reference to various embodiments and corresponding drawings, it is understood that, where applicable, other similar embodiments can be used, or modifications and additions can be made to the described embodiments, to perform the same, similar, alternative, or substitute function of the disclosed subject matter without departing from the disclosed subject matter. Accordingly, the disclosed subject matter should not be limited to any single embodiment described herein, but rather should be construed broadly in accordance with the following appended claims. For example, reference to "one embodiment" of the present invention is not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the described features.

[0045] In the appended claims, the terms "including" and "in which" are used as the plain-English equivalents of the respective terms "comprising" and "wherein." Also, in the following claims, the terms "first," "second," "third," "upper," "lower," "bottom," "top," etc. are used merely as guides and are not intended to impose numerical or positional requirements on their objects. The terms "substantially," "generally," and "about" indicate conditions within reasonably achievable manufacturing and assembly tolerances relative to ideal desired conditions suitable for achieving the functional purpose of a component or assembly. Additionally, the following claim limitations are not written in, and are not intended to be construed as, means-plus-function, unless such claim limitations expressly use the phrase "means for," followed by a description of function devoid of further structure.

[0046] The foregoing includes examples of systems and methods that illustrate the disclosed subject matter. Of course, it is not possible to describe every possible combination of components or techniques. Those skilled in the art will recognize that many more combinations and permutations of the claimed subject matter are possible. Furthermore, to the extent that terms such as "includes," "has," and "possesses" are used in the Detailed Description, claims, appendices, and drawings, such terms are intended to be inclusive in the same manner as the term "comprising" is interpreted when used as a transitional term in a claim. That is, unless expressly stated to the contrary, an embodiment that "comprising," "including," or "having" an element or elements having a particular characteristic may include additional such elements that do not have that characteristic. Furthermore, the articles "a" and "an" as used in this specification and the accompanying drawings should generally be construed to mean "one or more" unless otherwise specified or unless it is clear from the context that the singular form is intended.

[0047] Examples are used herein to disclose some embodiments of the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems, and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0048] Further aspects of the invention are provided by the subject matter of the following clauses.

[0049] a plurality of electrical machines and components, each having a lead end; a plurality of power distribution cables for distributing electrical power among the plurality of electrical machines and components; a plurality of connectors for facilitating mechanical and electrical connection between the plurality of electrical machines and components and the plurality of power distribution cables, each connector being disposed between one of the electrical machines and components and a corresponding power distribution cable operative to supply electrical power thereto, each connector having a connector head extending over a portion of the corresponding power distribution cable to facilitate mechanical connection between the one of the electrical machines and components and the corresponding power distribution cable; a receptacle disposed on one of the lead ends of the electrical machines and components and the corresponding power distribution cable; a plug disposed on the other of the lead ends of the electrical machines and components; and a quick connect / disconnect electrical connector disposed on one of the receptacle and the plug, the quick connect / disconnect electrical connector facilitating electrical connection between the one of the electrical machines and components and the corresponding power distribution cable.

[0050] The system of the preceding paragraph, wherein the lead ends of one of the electric machine and electrical component and the corresponding power distribution cable include internal cavities defining hollow coolant passages formed therein, and the hollow coolant passages of the lead ends of one of the electric machine and electrical component are in fluid communication with the hollow coolant passages of the corresponding power distribution cable.

[0051] 10. The system of any preceding clause, further comprising a cooling device having a cooling fluid operably coupled to the plurality of electric machines and electric components and the plurality of power distribution cables, the cooling device configured to supply cooling fluid to the plurality of electric machines and electric components via the plurality of power distribution cables.

[0052] The system of any preceding clause, wherein each connector further comprises at least one sealing element disposed between an interface of the receptacle and the plug.

[0053] The system of any preceding clause, wherein the receptacle and plug each include at least one radially extending portion, the at least one radially extending portion of the receptacle and plug defining at least one flange portion that facilitates a mechanical connection between a lead end of one of the electric machine and the electric component and a corresponding power distribution cable.

[0054] 10. The system of any preceding clause, further comprising at least one fastener for securing a mechanical connection between a lead end of one of the electric machine and the electric component and a corresponding power distribution cable via the at least one flange.

[0055] 10. The system of any preceding clause, wherein each connector further comprises at least one flange extension disposed between one of the electric machine and the electric component and the corresponding power distribution cable, the at least one flange extension surrounding the at least one flange portion.

[0056] 10. The system of any preceding clause, further comprising at least one fastener for securing a mechanical connection between one of the electric machine and the electric component and a corresponding power distribution cable via the at least one flange extension.

[0057] 10. The system of any preceding clause, wherein the connector head comprises an interface region defining a flange that facilitates a mechanical connection between the electric machine and one lead end of the electric component.

[0058] 10. The system of any preceding clause, further comprising at least one fastener for securing a mechanical connection between one of the electric machine and the electric component and a corresponding power distribution cable via the flange.

[0059] 10. The system of any preceding clause, further comprising at least one sealing element disposed within the flange for sealing a mechanical connection between one of the electric machine and the electric component and a corresponding power distribution cable via the flange.

[0060] 10. The system of any preceding clause, wherein the quick connect / disconnect electrical connector comprises a spring loaded electrical connector having one or more louvered spring contacts.

[0061] 10. The system of claim 9, wherein the receptacle is disposed on one lead end of the electric machine and the electric component, the plug is disposed on a corresponding power distribution cable, and the spring-loaded electrical connector having one or more louvered spring contacts is disposed on the plug with the one or more louvered spring contacts protruding outward from the corresponding power distribution cable toward the receptacle.

[0062] 10. The system of claim 1, wherein the receptacle is disposed on one lead end of the electric machine and the electric component, the plug is disposed on a corresponding power distribution cable, and the spring-loaded electrical connector having one or more louvered spring contacts is disposed on the plug, and the one or more louvered spring contacts are disposed on the receptacle with the one or more louvered spring contacts protruding inwardly toward the corresponding power distribution cable.

[0063] 10. The system of claim 1, wherein the receptacle is disposed within a corresponding power distribution cable and the plug is disposed at one lead end of the electrical machine and electrical component, and the spring-loaded electrical connector having one or more louvered spring contacts is disposed on the plug with the one or more louvered spring contacts projecting outwardly toward the receptacle in the corresponding power distribution cable.

[0064] 10. The system of any preceding clause, wherein the receptacle is disposed within a corresponding power distribution cable, the plug is disposed at one lead end of the electric machine and the electric component, and the spring-loaded electrical connector having one or more louvered spring contacts is disposed in the receptacle with the one or more louvered spring contacts protruding inwardly toward the plug disposed at the one lead end of the electric machine and the electric component.

[0065] A system comprising a plurality of electric machines and electric components, each electric machine and electric component having a lead end with a main phase lead thereon, the main phase lead having an internal cavity defining a hollow coolant passage formed therethrough; a plurality of power distribution cables for distributing electrical power among the plurality of electric machines and electric components, each power distribution cable including a hollow coolant passage therethrough; and a plurality of connectors for facilitating mechanical and electrical connection between the plurality of electric machines and electric components and the plurality of power distribution cables, each connector being disposed between one of the electric machines and electric components and a corresponding power distribution cable operative to supply electrical power thereto, each connector extending over a portion of the corresponding power distribution cable facilitating mechanical connection between the electric machine and electric component and the corresponding power distribution cable. a plurality of connectors including a connector head; a receptacle disposed on one of the main phase leads of the electric machine and the electric component and the corresponding power distribution cable; a plug disposed on the other of the main phase leads of the electric machine and the electric component and the corresponding power distribution cable; a spring-loaded electrical connector disposed on one of the receptacle and the plug, the spring-loaded electrical connector facilitating an electrical connection between one of the electric machine and the electric component and the corresponding power distribution cable, the spring-loaded electrical connector including a protruding spring contact; and a cooling device having a cooling fluid operably coupled to the plurality of electric machines and the plurality of power distribution cables, the cooling device being configured to supply cooling fluid to the plurality of electric machines and the electric components through hollow coolant passages in each of the electric machines and the electric components and to supply cooling fluid to the plurality of power distribution cables through hollow coolant passages in each of the power distribution cables.

[0066] The system of the preceding paragraph, wherein the hollow coolant passages in each power distribution cable are in fluid communication with hollow coolant passages in an adjacent electrical machine or electrical component.

[0067] 10. The system of any preceding clause, wherein the plurality of electric machines comprises one or more of a generator having a stator with stator windings, and an electric motor having a stator with stator windings.

[0068] 10. The system of any preceding clause, wherein the cooling device is configured to directly cool a stator winding of each of the plurality of electric machines via hollow coolant passages in main phase leads of the electric machines and hollow coolant passages in corresponding power distribution cables adjacent the electric machines. [Explanation of symbols]

[0069] 10 Electrical System 12 Connectors 14 Power Distribution Cables 16 Electrical Machinery 18 Electrical Components 20 Cooling device 22 Pump 24 Heat exchanger 26 Piping 28 Shared Coolant Network 30 Main Phase Lead 32 Lead End 34 End 36 Connector head 38 first end region 40 second end region 42 Intermediate area 44 Interface 46 flange 48 Fasteners 50 sealing elements 51 Insulator 52 Female part 53 Inner wall 54 Male 56 Spring-loaded electrical connector 57 Louvered spring contact 58 Internal Cavity 60 hollow coolant passage 62 Internal Cavity 64 hollow coolant passage 66 Radially extending portion 68 Radially extending portion 70 flange 72 flange extension

Claims

1. A system (10), comprising: a plurality of electric machines (16) and electric components (18), each having a lead end (32); a plurality of power distribution cables (14) for distributing power between the plurality of electric machines (16) and the electric components (18); a plurality of connectors (12) for facilitating mechanical and electrical connection between the plurality of electric machines (16) and electric components (18) and the plurality of power distribution cables (14), each connector (12) being disposed between one of the electric machines (16) and the electric components (18) and a corresponding power distribution cable (14) operative to supply power thereto, each connector (12) comprising: a connector head (36) extending over a portion of the corresponding power distribution cable (14) to facilitate the mechanical connection between the one of the electric machine (16) and the electrical component (18) and the corresponding power distribution cable (14); a receptacle disposed on one of the lead ends (32) of the electric machine (16) and the electric component (18) and the corresponding power distribution cable (14); a plug disposed on the other of the lead ends (32) of the electric machine (16) and the electric component (18); and a plurality of connectors (12) including a quick connect / disconnect electrical connector disposed on one of the receptacle and the plug, the quick connect / disconnect electrical connector facilitating the electrical connection between the one of the electric machine (16) and the electric component (18) and the corresponding power distribution cable (14).

2. 2. The system of claim 1, wherein the lead end (32) of the one of the electric machine (16) and the electrical component (18) and the corresponding power distribution cable (14) include an internal cavity (58) defining a hollow coolant passage (60) formed therein, the hollow coolant passage (64) in the lead end (32) of the one of the electric machine (16) and the electrical component (18) being in fluid communication with the hollow coolant passage (60) of the corresponding power distribution cable (14).

3. 3. The system (10) of claim 2, further comprising a cooling device (20) having a cooling fluid operably coupled to the plurality of electric machines (16) and electrical components (18) and the plurality of power distribution cables (14), the cooling device (20) being configured to supply the cooling fluid to the plurality of electric machines (16) and electrical components (18) via the plurality of power distribution cables (14).

4. The system (10) of claim 2, wherein each connector (12) further comprises at least one sealing element (50) disposed between the receptacle interface (44) and the plug.

5. 5. The system (10) of claim 4, wherein the receptacle and the plug each include at least one radially extending portion (66, 68), the at least one radially extending portion (66, 68) of the receptacle and the plug defining at least one flange portion (70) that facilitates a mechanical connection between the lead end (32) of the one of the electric machine (16) and the electric component (18) and the corresponding power distribution cable (14).

6. 6. The system (10) of claim 5, further comprising at least one fastener (48) for securing the mechanical connection between the lead end (32) of one of the electric machine (16) and the electric component (18) and the corresponding power distribution cable (14) via the at least one flange (46).

7. 6. The system (10) of claim 5, wherein each connector (12) further comprises at least one flange extension (72) disposed between the one of the electric machine (16) and the electrical component (18) and the corresponding power distribution cable (14), the at least one flange extension (72) surrounding the at least one flange portion (70).

8. 8. The system (10) of claim 7, further comprising at least one fastener (48) for securing the mechanical connection between the one of the electric machine (16) and the electrical component (18) and the corresponding power distribution cable (14) via the at least one flange extension (72).

9. 2. The system (10) of claim 1, wherein the connector head (36) includes an interface region defining a flange (46) that facilitates the mechanical connection between the lead end (32) of the one of the electric machine (16) and the electrical component (18).

10. 10. The system (10) of claim 9, further comprising at least one fastener (48) for securing the mechanical connection between the one of the electric machine (16) and the electric component (18) and the corresponding power distribution cable (14) via the flange (46).

11. 10. The system (10) of claim 9, further comprising at least one sealing element (50) disposed within the flange (46) for sealing the mechanical connection between the one of the electric machine (16) and the electrical component (18) and the corresponding power distribution cable (14) via the flange (46).

12. The system (10) of claim 1, wherein the quick connect / disconnect electrical connector comprises a spring loaded electrical connector (56) having one or more louvered spring contacts.

13. 13. The system (10) of claim 12, wherein the receptacle is disposed on the lead end (32) of one of the electric machine (16) and the electric component (18), the plug is disposed on the corresponding power distribution cable (14), and the spring-loaded electrical connector (56) having one or more louvered spring contacts is disposed on the plug with the one or more louvered spring contacts protruding outward from the corresponding power distribution cable (14) toward the receptacle.

14. 13. The system (10) of claim 12, wherein the receptacle is disposed on the lead end (32) of the one of the electric machine (16) and the electric component (18), the plug is disposed on the corresponding power distribution cable (14), and the spring-loaded electrical connector (56) having one or more louvered spring contacts is disposed in the receptacle with the one or more louvered spring contacts projecting inwardly toward the corresponding power distribution cable (14).

15. 13. The system (10) of claim 12, wherein the receptacle is disposed within the corresponding power distribution cable (14), the plug is disposed at the lead end (32) of the one of the electric machine (16) and the electric component (18), and the spring-loaded electrical connector (56) having one or more louvered spring contacts is disposed on the plug with the one or more louvered spring contacts projecting outwardly toward the receptacle in the corresponding power distribution cable (14).

16. 13. The system (10) of claim 12, wherein the receptacle is disposed within the corresponding power distribution cable (14), the plug is disposed at the lead end (32) of the one of the electric machine (16) and the electrical component (18), and the spring-loaded electrical connector (56) having one or more louvered spring contacts is disposed in the receptacle with the one or more louvered spring contacts projecting inwardly toward the plug disposed at the lead end (32) of the one of the electric machine (16) and the electrical component (18).

17. A system (10), comprising: a plurality of electric machines (16) and electric components (18), each having a lead end (32) with a main phase lead (30) thereon, said main phase lead (30) having an interior cavity (62) defining a hollow coolant passage (64) formed therethrough; a plurality of power distribution cables (14) for distributing electrical power between the plurality of electric machines (16) and electrical components (18), each of the power distribution cables (14) including a hollow coolant passage (60) therethrough; a plurality of connectors (12) for facilitating mechanical and electrical connection between the plurality of electric machines (16) and the electric components (18) and the plurality of power distribution cables (14), each connector (12) being disposed between one of the electric machines (16) and the electric components (18) and a corresponding power distribution cable (14) operative to supply power thereto, each connector (12) comprising: a connector head (36) extending over a portion of the corresponding power distribution cable (14) to facilitate the mechanical connection between the electric machine (16) and the electrical component (18) and the corresponding power distribution cable (14); a receptacle disposed on one of the main phase leads (30) of the electric machine (16) and the electric component (18) and the corresponding power distribution cable (14); a plug disposed on the other of the main phase leads (30) of the electric machine (16) and the electric component (18) and on the corresponding power distribution cable (14); a spring-loaded electrical connector (56) disposed in one of the receptacle and the plug, the spring-loaded electrical connector (56) facilitating the electrical connection between the one of the electrical machine (16) and the electrical component (18) and the corresponding power distribution cable (14), the spring-loaded electrical connector (56) including a protruding spring contact; a cooling device (20) having a cooling fluid operably coupled to the plurality of electric machines (16) and electric components (18) and the plurality of power distribution cables (14), the cooling device (20) being configured to supply cooling fluid to the plurality of electric machines (16) and electric components (18) via the hollow coolant passages (64) in each of the electric machines (16) and electric components (18) and to supply cooling fluid to the plurality of power distribution cables (14) via the hollow coolant passages (60) in each of the power distribution cables (14).

18. 20. The system (10) of claim 17, wherein the hollow coolant passages (60) in each power distribution cable (14) are in fluid communication with the hollow coolant passages (64) of an adjacent electric machine (16) or electrical component (18).

19. 20. The system (10) of claim 17, wherein the plurality of electric machines (16) comprises one or more of a generator having a stator with stator windings and an electric motor having a stator with stator windings.

20. 20. The system of claim 19, wherein the cooling device is configured to directly cool the stator windings of each of the plurality of electric machines via the hollow coolant passages in the main phase leads of the electric machines and the hollow coolant passages in corresponding power distribution cables adjacent the electric machines.

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