Aircraft Power Distribution Box Busbar Integration
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Solution Overview
Problem
Current electrical distribution systems in aircraft require significant time and cost for maintenance due to the need to remove and rewire entire secondary distribution boxes to replace faulty modules, with a high number of connectors increasing mass and cost, and limitations in handling high powers through wired connectors.
Innovation Solution
The use of a power distribution bar instead of traditional connectors to connect power modules to the electrical harness, reducing the number of connections and protections needed, and allowing for higher power handling while optimizing the integration of connectors and mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired connectors are used to connect power modules to the electrical harness, then reliable electrical connection is achieved, but the number of connectors increases mass and cost significantly
Solution Approach 1:
The patent merges multiple individual wire connectors into a single busbar structure that provides multiple connection points. The busbar integrates what would otherwise require numerous separate connectors, reducing the total connector count and associated mass while maintaining reliable electrical connections to all power modules.
Solution Approach 2:
The busbar serves multiple functions simultaneously: it acts as a common electrical connection point for multiple power modules, provides structural support for module mounting, and enables both power and control signal distribution. This multi-functionality eliminates the need for separate dedicated connectors for each function.
2Reliability
If wired connectors are used to connect power modules, then electrical connections are established, but maintenance time increases due to need to remove entire distribution box
Solution Approach 1:
The patent segments the distribution box into modular units where power modules can be individually accessed and replaced. The busbar design allows modules to be connected/disconnected independently without requiring removal of the entire distribution box assembly, enabling rapid maintenance of individual faulty modules.
Solution Approach 2:
The connection system is designed to be dynamically reconfigurable, allowing power modules to be quickly connected or disconnected from the busbar. This dynamic capability enables maintenance personnel to rapidly swap modules without extensive disassembly, reducing maintenance time while maintaining connection reliability.
3Reliability
If traditional wired connectors are used, then connections are made for all wires, but protections must be multiplied in the primary distribution
Solution Approach 1:
The busbar consolidates multiple wire connections into a single integrated component, which reduces the number of separate protection devices needed. Instead of requiring individual protections for each wire connection, the busbar structure allows for fewer, more centralized protection points in the primary distribution system.
4Reliability
If wired connectors are used for high power connections, then connections are established, but cost increases significantly
Solution Approach 1:
The busbar merges multiple high-power connections into a single manufactured component, significantly reducing the total cost compared to using individual high-power connectors for each wire. The busbar can be manufactured as a single piece or pre-assembled unit, reducing assembly costs and improving manufacturing efficiency.
Data Source
Figure 1
AI summary
An electrical distribution box (1, 2) comprising first housings (4, 24) for receiving power modules and second housings (5, 25) for receiving electronic control modules, and an interface (6, 26) for making the connections between the various modules and external electrical elements. The interface (6, 26) comprises at least one input power busbar (7, 27) extending into at least a first housing (4, 24) in such a way as to be able to be connected to at least one power module, an input power busbar (7, 27) being capable of being connected to a wire of an electrical harness in such a way as to connect at least one power module to the electrical harness.