Aircraft Bulkhead Connector Tool for Single-Side Fuel Tank Installation
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Solution Overview
Problem
The installation of bulkhead connectors in aircraft fuel systems requires access to both sides of the bulkhead, which can damage the fuel tank and poses health and safety risks, and is inconvenient.
Innovation Solution
A bulkhead connector and installation tool combination that allows single-side access installation, where the installation tool protrudes through an aperture in the bulkhead to manipulate the connector without direct access, using a tapered design and removable fasteners or biased latches for engagement and disengagement, and is made of plastic to minimize damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If access to both sides of the bulkhead is required for installation, then the bulkhead connector can be properly installed, but the fuel tank may be damaged and health and safety risks increase
Solution Approach 1:
The installation tool acts as an intermediary device that enables manipulation of the bulkhead connector from a single side. The tool includes a manipulation portion that engages with the connector and a protrusion that extends through the bulkhead aperture, allowing engineers to install connectors without accessing the fuel tank interior, thus eliminating damage risks while maintaining installation reliability
2Reliability
If access to both sides of the bulkhead is required for installation, then the bulkhead connector can be properly installed, but the installation process becomes inconvenient and costly
Solution Approach 1:
The installation tool serves as a mediator that transforms a two-sided installation process into a single-sided operation. By incorporating a manipulation portion for connector engagement and a protrusion for through-bulkhead extension, the tool allows complete installation from one side, significantly improving operational convenience while maintaining installation reliability
Solution Approach 2:
The installation tool extends the manipulation capability into the third dimension by protruding through the bulkhead aperture. This dimensional extension allows engineers to access and manipulate the connector from the exterior side only, converting a constrained two-sided process into an unrestricted single-sided operation
3Manufacturing precision
If the installation tool is made rigid for precise positioning, then positioning accuracy improves, but the risk of damage to the bulkhead connector or bulkhead increases
Solution Approach 1:
The installation tool employs material parameter changes by using plastic instead of rigid metal. This material selection maintains sufficient positioning precision while inherently reducing damage risk through the material's flexibility and compliance, allowing accurate connector positioning without compromising structural components
Data Source
AI summary
An apparatus and method for installing an aircraft bulkhead connector with a bulkhead is disclosed where access to only one side of the bulkhead is required. The disclosure is also applicable to installation of bulkhead connectors in aircraft fuel tanks. An aircraft bulkhead connector and installation tool is also disclosed. The bulkhead connector includes a female end portion and the installation tool includes a male end portion. The male end portion of the installation tool is removably engaged with the female end portion of the bulkhead connector, such that the installation tool protrudes beyond the female end portion of the bulkhead connector. The installation tool may be inserted through an aperture in a bulkhead and used to both position and hold the bulkhead connector during the installation process.