Aircraft Wire Track Assembly With Replaceable Snap-Fit Cover
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Solution Overview
Problem
Existing wire routing solutions in aircraft require the entire raceway and wires to be removed and replaced when the top surface becomes damaged, which is costly, time-consuming, and inefficient for repair and manufacturing.
Innovation Solution
A track assembly with a removably attached cover and retainer system, where the cover can be replaced independently of the retainer and wires, using a snap fit or similar mechanism, allowing for easier and less costly repair and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a single-piece raceway is used to route wires in aircraft, then the wiring is protected and routed securely, but the entire raceway and wires must be removed and replaced when the top surface becomes damaged, increasing repair costs and time
Solution Approach 1:
The raceway is divided into modular segments with interchangeable tops and bases. The top portion can be removed and replaced independently from the base portion that contains the wires, allowing partial replacement rather than complete replacement. This segmentation enables the top surface to be swapped without disturbing the wired base structure.
Solution Approach 2:
The top surface component is extracted as a separate replaceable element from the raceway assembly. This extracted top can be removed and replaced independently when damaged, while the base portion with embedded wires remains in place. This extraction principle allows the harmful damaged top to be removed without removing the functional base and wires.
2Ease of manufacture
If a single-piece raceway is used to route wires in aircraft, then the wiring is protected and routed securely, but manufacturing costs and time increase due to complete replacement requirements
Solution Approach 1:
The raceway is divided into modular segments with interchangeable tops and bases. The top portion can be removed and replaced independently from the base portion that contains the wires, allowing partial replacement rather than complete replacement. This segmentation enables the top surface to be swapped without disturbing the wired base structure.
Solution Approach 2:
The damaged top surface is discarded and replaced with a new or refurbished top, while the base portion containing the wires is recovered and retained in place. This selective replacement reduces material waste and manufacturing time compared to replacing the entire raceway assembly.
3Ease of repair
If a removably attached cover system is used in the track assembly, then the cover can be replaced independently to reduce repair costs and time, but the attachment mechanism adds structural complexity
Solution Approach 1:
The attachment mechanism uses snap-fit features that provide a dynamic balance between secure attachment and easy release. The snaps engage firmly during normal operation to maintain structural integrity, but can be easily disengaged by applying force to release tabs or by flexing the cover, enabling quick replacement without tools.
Solution Approach 2:
The snap-fit attachment mechanism is designed to be self-locking during assembly, where the cover automatically engages with the base when installed. For disassembly, simple manual manipulation of release tabs or flexing the cover suffices, eliminating the need for specialized tools or complex fastening procedures.
Data Source
AI summary
A track assembly for routing wires in an aircraft is provided including a retainer configured to be coupled to a track or frame in the aircraft, the retainer having a first wall, a second wall, a first flange projecting inward from the first wall, a second flange projecting inward from the second wall, a first catch extending outward from a first side, and a second catch extending outward from a second side, wherein the retainer define a passageway for wires, and a cover having a first arm projecting from a bottom surface and having a first hook for engaging the first catch, and a second arm projecting from the bottom surface and having a second hook for engaging the second catch, wherein the cover is configured to be removably coupled to the retainer.