Annular Bus Ring Assembly for Generator Rectifier Connections
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Solution Overview
Problem
Existing brushless generators in aerospace power systems face challenges with high centrifugal loading, which damages complex connections between rectifier assemblies and rotor leads, leading to potential shorting and maintenance issues, especially at high speeds.
Innovation Solution
An annular bus ring assembly with bent tabs forming pads, mounted on a dielectric hub with castellations, and connected by braided wire rope leads to diodes, allowing for secure and insulated connections that can withstand high centrifugal forces and be assembled outside the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex set of connections with six stranded leads is used to connect diodes to rotor leads, then electrical connectivity is achieved, but the connection becomes susceptible to damage from high centrifugal loading
Solution Approach 1:
The patent divides the complex six-lead connection into two separate annular bus rings, each handling three connections. This segmentation reduces the complexity of individual connection assemblies while maintaining all necessary electrical connections, making each segment more manageable and less susceptible to centrifugal damage.
Solution Approach 2:
The patent combines multiple electrical connections into integrated annular bus ring structures with embedded pads. By merging the functions of multiple leads into a single rigid annular structure, the connection becomes more robust against centrifugal forces while maintaining all required electrical pathways.
2Reliability
If multiple separate leads are used for connecting rectifier assemblies, then electrical connections are established, but the risk of shorting increases requiring additional insulation
Solution Approach 1:
The patent combines multiple electrical connections into integrated annular bus ring structures with embedded pads. By merging the functions of multiple leads into a single rigid annular structure, the connection becomes more robust against centrifugal forces while maintaining all required electrical pathways.
3Reliability
If rectifier assembly connections are made inside the rotor, then brushless operation is achieved, but maintenance and repair become difficult
Solution Approach 1:
The patent creates a modular rectifier assembly with annular bus rings that can be independently handled and installed. This segmentation allows the rectifier assembly to be pre-assembled and tested outside the rotor, then installed as a complete unit, greatly facilitating future maintenance and repair while maintaining brushless operation.
4Strength
If conventional wiring methods are used in high-speed rotors, then assembly is simple, but the connections cannot withstand high centrifugal forces
Solution Approach 1:
The patent uses a rigid annular bus ring structure with embedded pads that provides structural strength to withstand centrifugal forces. The annular configuration distributes mechanical stresses evenly around the rotor perimeter, while the rigid structure prevents the connection degradation that would occur with flexible wiring in high-speed rotation.
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
The solution provides a robust and reliable connection that prevents shorting and withstands high centrifugal loads, enabling the generator to operate effectively without the need for frequent maintenance or reworking, and can be tested before installation.
Implementation Method 1
a plurality of annular bus rings with tabs bent over forming a plurality of pads
Implementation Method 2
a dielectric hub having castellations to support the plurality of annular bus rings
Implementation Method 3
a plurality of wire rope leads connecting the pads of the annular bus ring assembly to the diodes
Implementation Method 4
This results in a complex set of connections linking six diodes to two main rotor leads of the generator, which is susceptible to damage from the high centrifugal loading present on a rotor
Data Source
AI summary
An annular bus ring assembly for connecting main rotor windings of a generator to the exciter diodes includes a plurality of annular bus rings with tabs bent over forming plurality of pads mounted on either side of a dielectric hub. The pads of annular bus rings clocked at an angle to each other to generate a pattern of plurality of pads on a equal angle spacing on a diameter to connect to the diodes by wire rope leads and a pattern of two connection at 90° spacing to connect to main generator leads.