Aircraft Ground Power Plug Force Tester with Positive Stop
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Solution Overview
Problem
Existing methods for testing aircraft ground power plug insertion and removal forces are inconsistent due to variable load cell mounting and the risk of overloading, leading to inaccurate measurements and potential damage during testing.
Innovation Solution
A support structure with a positive stop limits travel and includes test pins mounted on a force sensor to measure the exact forces required for seating and removing the plug, preventing excessive force application and simulating real-world conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the load cell is mounted on a bench for testing, then the insertion force can be measured, but the mounting position and method vary by location leading to inconsistent measurements
Solution Approach 1:
The patent introduces a standardized mounting plate as an intermediary component between the load cell and the testing surface. This mounting plate provides consistent alignment and attachment points, ensuring that the load cell is always positioned and oriented correctly regardless of the specific testing location or bench configuration, thereby resolving the inconsistency in measurements across different facilities
Solution Approach 2:
The testing apparatus is divided into modular components including the mounting plate, load cell, and pin assembly. This segmentation allows each component to be independently standardized and replaced, ensuring that the mounting arrangement remains consistent while allowing for easy reconfiguration or maintenance without affecting overall measurement consistency
2Measurement precision
If the operator pushes the plug onto the pins during testing, then the insertion force can be measured, but the operator may overload the load cell by pushing past full seating leading to inaccurate measurements
Solution Approach 1:
The patent incorporates a mechanical stop that prevents the plug from being pushed beyond its fully seated position. This preliminary anti-action mechanism physically blocks further movement before the load cell can be overloaded, thereby protecting the measurement device from damage and ensuring accurate measurements by eliminating the possibility of excessive force application
Solution Approach 2:
The system provides visual or mechanical feedback to the operator indicating when the plug has reached its fully seated position. This feedback mechanism allows the operator to know when to stop applying force, preventing overload conditions while ensuring complete seating of the plug for accurate insertion force measurement
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides consistent and accurate measurements of connection and removal forces, preventing damage and ensuring compliance with specifications, while allowing for testing of various aircraft ground power plug types.
Implementation Method 1
A force sensor is disposed on the support structure and configured to measure force applied to the test pins when an electrical connector plug is placed on or removed from the test pins
Data Source
AI summary
The present disclosure describes various alternative embodiments of plug force testers, in particular devices well-suited for testing aircraft ground power connection plugs. The disclosed plug force testers provide a fixed, well-supported position for test pins on which a plug is inserted, which can be positioned to correspond to a height or orientation of the pins in an actual aircraft. Embodiments described also may include means for preventing excessive force application during testing.