Aircraft Modular Connector Alignment via Centring Pins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connection systems for aircraft distribution systems face challenges with connector height and mechanical design due to positioning tolerances, which complicates the installation and reduces the cost advantage of plug-in protection boards.
Innovation Solution
A modular connector system is introduced, featuring integral input, output, and service connection modules on protection boards and additional modular connectors on the rack, with centring pins for precise alignment, allowing for optimized connector height and controlled positioning tolerances, and incorporating power slots connected via busbars to the primary power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional printed circuit board connectors are used, then the connectors are compact, standard and inexpensive, but a power motherboard with additional external connectors is required, which cancels out the cost advantage
Solution Approach 1:
The patent combines the power connector and signal connector into a single integrated modular connector assembly. This merging eliminates the need for a separate power motherboard, as the modular connector directly provides both power and signal connections when plugged into the rack, thereby reducing overall system complexity while maintaining cost efficiency.
Solution Approach 2:
The modular connector is designed to perform multiple functions simultaneously - it provides both power transmission and signal communication through its integrated structure. This multi-functionality allows a single connector to replace what would traditionally require separate power and signal connectors, simplifying the overall system architecture.
2Ease of operation
If connectors compatible with aircraft electrical harnesses are directly connected, then direct connection to aircraft wiring is achieved, but the connectors have significant height and mechanical design is tricky due to positioning tolerances
Solution Approach 1:
The patent employs a nested structure where the aircraft-compatible connector is integrated within the modular connector assembly. The aircraft connector is positioned inside or alongside the modular connector housing, allowing direct connection to aircraft wiring while the outer modular structure provides mechanical support and alignment features, thereby reducing the overall height and simplifying mechanical design.
Solution Approach 2:
The modular connector structure acts as an intermediary between the aircraft wiring connector and the protection board. It provides alignment features and positioning mechanisms that facilitate easy connection while maintaining direct electrical connection to aircraft wiring, thus resolving the mechanical design challenges without compromising connection directness.
3Manufacturing precision
If modular connector system with centring pins is used, then alignment and connection accuracy is enhanced, but the connector height increases
Solution Approach 1:
The patent introduces centring pins that extend in a direction perpendicular to the main connector face, utilizing the vertical dimension for alignment purposes. These pins protrude slightly to provide precise positioning in the horizontal plane during insertion, while their minimal height ensures they do not significantly increase the overall connector profile, thus achieving high alignment accuracy without substantial height increase.
Data Source
AI summary
Connection system arranged in a rack, for connecting at least one protection board (13a, 13b) of an electrical distribution system of an aircraft with a primary power supply, to at least one powered device (8a, 8b) and to a motherboard arranged in the rack.The connection system includes at least one modular connector on each protection board and, for each protection board capable of being inserted in the rack, at least one additional modular connector attached at least partly on the rack and at least one additional connector connected to the motherboard.