Angled Electrical Connector Raft for Low-Stress Harness Routing
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Solution Overview
Problem
Conventional electrical connectors in gas turbine engines are bulky, heavy, and prone to damage due to exposure to harsh environments, leading to increased maintenance time and complexity, as well as susceptibility to mechanical stress and errors during assembly and disassembly.
Innovation Solution
The use of an electrical raft with embedded conductors in a rigid composite material, featuring a mounting angle between 20 degrees and 70 degrees, which protects the connectors from environmental exposure and reduces mechanical stress, allowing for a more reliable and compact electrical connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug or socket connector components are used for electrical connections in gas turbine engines, then electrical connectivity is achieved, but the connectors become bulky, heavy, and susceptible to damage from environmental exposure
Solution Approach 1:
The patent merges the electrical connector with the electrical harness assembly by integrating contacts directly into the harness structure. The contacts are embedded within the harness insulation and support structure, eliminating the need for separate, bulky connector housings. This integration reduces overall weight while maintaining electrical connectivity and reliability in harsh engine environments.
2Reliability
If conventional exposed connectors are used to connect electrical components, then electrical connection is established, but the connectors are exposed to high temperatures and vibrations, requiring them to be particularly robust and heavy
Solution Approach 1:
The connector structure is merged with the harness assembly, where contacts are integrated into the harness insulation and support structure. This unified design simplifies the overall structure by eliminating separate connector components, reducing complexity while maintaining durability against temperature and vibration through the integrated protective harness structure.
Solution Approach 2:
The electrical contacts are nested within the harness insulation and support structure. The contacts are positioned inside the harness assembly rather than exposed externally, allowing the harness structure itself to provide protection against environmental factors. This nested arrangement reduces the need for additional protective housing while maintaining connector durability.
3Ease of operation
If conventional harnesses with multitude of insulated wires and cables are used, then electrical signal transmission is achieved, but the harness becomes bulky, heavy, and difficult to manipulate
Solution Approach 1:
Multiple electrical conductors are merged into a single integrated raft structure where conductors are embedded within a rigid material matrix. This consolidation transforms numerous separate wires and cables into one unified assembly, dramatically reducing weight and improving manipulability while maintaining all necessary electrical signal transmission paths.
4Reliability
If conventional harnesses with protective sleeves and braiding are used to prevent mechanical damage, then conductor protection is improved, but the harness becomes even bulkier and heavier
Solution Approach 1:
The protective function traditionally provided by separate sleeves and braiding is merged into the rigid material matrix itself. The rigid material serves as both the structural support and the protective enclosure for embedded conductors, eliminating the need for additional protective layers and reducing overall harness volume while maintaining conductor protection.
Data Source
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AI summary
An electrical raft (200) is provided that has electrical conductors (252) embedded in a rigid material (220). The electrical raft is provided with an electrical connector (700). The electrical connector (700) is mounted in the electrical raft (200) at a mounting angle (730). The mounting angle is set such that the electrical conductors (252) can be connected to the electrical connector without having to turn through an angle or a radius of curvature that would subject them to excessive bending stress. Similarly, the mounting angle means that any conductors (766) that may be connected to the electrical connector (700) do not have to turn through an angle or a radius of curvature that would subject them to excessive bending stress. Furthermore, mounting the electrical connector (700) at the mounting angle (730) may allow the assembled electrical raft (200) to be more compact.