Angled Electrical Raft Connectors 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 high temperatures and vibrations, complicating assembly and maintenance, and increasing maintenance time and costs.
Innovation Solution
An electrical raft with embedded conductors in a rigid composite material, featuring a mounting angle between 20 degrees and 70 degrees for the connector, providing protection and reducing mechanical stress on conductors, and allowing for a compact and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug or socket connector components are used to connect wires and cables to electrical components, then electrical connection functionality is achieved, but the connectors add weight and complexity to the electrical harnesses
Solution Approach 1:
The patent merges the electrical connector with the electrical harness by integrating the connector components directly into the harness structure. The connector housing is formed as an integral part of the harness assembly, eliminating separate connector components and reducing overall complexity while maintaining electrical connection functionality.
Solution Approach 2:
The electrical harness is designed to perform multiple functions: it provides electrical connection through integrated connectors, mechanical support for wires and cables, and structural organization. This multi-functionality reduces the need for separate components and simplifies the overall system.
2Reliability
If conventional plug or socket connector components are exposed to engine environment, then electrical connection is maintained, but the connectors are susceptible to damage from high temperatures and vibrations
Solution Approach 1:
The connector housing is designed with vibration-resistant features and thermal protection before exposure to harsh engine conditions. The integrated structure provides inherent protection against vibrations and temperature extremes, preventing damage before it occurs rather than relying on post-damage repairs.
Solution Approach 2:
The electrical harness uses high-temperature resistant materials and vibration-dampening structures to protect connectors from engine environment. The composite construction combines materials with different properties to resist both thermal and mechanical stresses simultaneously.
3Reliability
If conventional harnesses are made robust to survive engine environment, then connector durability is improved, but the connectors become bulky and heavy
Solution Approach 1:
Instead of making the entire connector bulky for uniform protection, the patent applies protection only where needed. The integrated harness structure provides localized reinforcement at connector points while maintaining lightweight construction in other areas, optimizing the weight-strength ratio.
4Reliability
If conventional harnesses are made robust with reinforced protective sleeves, then conductor protection is improved, but the harnesses become bulky and heavy and harder to manipulate
Solution Approach 1:
The protective sleeves and braiding are integrated into the harness structure as unified components rather than separate add-ons. This merging provides adequate protection while maintaining flexibility and ease of manipulation, as the protection is built into the harness design rather than added as bulky external reinforcement.
Data Source
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.