Annular Wire Barrel for Rotating Turbomachine Cables
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Solution Overview
Problem
Conventional systems for routing wire bundles from turbomachines are cumbersome, non-serviceable, and limit the number of sensors due to manual fixation on a single printed circuit board, with g-loads compromising connection integrity.
Innovation Solution
An annular wire barrel with circumferentially spaced thru-holes is coupled to the rotor shaft, allowing individual wire bundles to extend through, providing radial support and facilitating connection to a slip ring or data processor, enabling greater instrumentation and maintenance capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bundles are manually fixed to a single printed circuit board, then connection reliability is high, but the system becomes tedious, non-serviceable, non-repairable, and limits the number of sensors
Solution Approach 1:
The patent divides the wire bundle routing into multiple segments by creating multiple separate thru-holes in the rotor shaft instead of using a single common printed circuit board. Each wire bundle can be individually routed through its own thru-hole, allowing for modular assembly, easier maintenance, and the ability to service or replace individual wire bundles without affecting the entire system.
2Measurement precision
If multiple sensors are installed to enhance monitoring capabilities, then measurement precision improves, but the complexity of routing and managing the wire bundles increases
Solution Approach 1:
The patent resolves the routing complexity by transitioning from a two-dimensional planar arrangement (single printed circuit board) to a three-dimensional radial arrangement (multiple thru-holes distributed circumferentially around the rotor shaft). This dimensional change allows wire bundles to be routed in different spatial directions, reducing interference and simplifying management as the number of sensors increases.
3Reliability
If wire bundles are subjected to g-loads during rotation, then the system operates under realistic conditions, but the integrity of connections and individual wires is compromised
Solution Approach 1:
The patent applies local quality by providing individual thru-holes for each wire bundle, allowing each routing path to be optimized and supported independently. This localized approach enables better stress distribution and connection support at specific points along the wire bundle path, reducing the overall impact of g-loads on connection integrity compared to a centralized routing system.
Data Source
AI summary
A system for routing rotatable wire bundles which extend from a rotor shaft of a turbomachine includes a plurality of wire bundles which extend outwardly from an inner passage of the rotor shaft of the turbomachine. An annular wire barrel is coupled to an end of the rotor shaft. A plurality of thru-holes is defined within and/or by the wire barrel. The plurality of thru-holes is annularly arranged therein. Each thru-hole extends through an aft wall of the wire barrel and is circumferentially spaced from adjacent thru-holes. Each wire bundle extends individually through a corresponding thru-hole of the plurality of thru-holes.