Modular Cable Outlet Element for Aircraft Raceway Integration
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Solution Overview
Problem
Current methods for routing cables in aircraft, such as passenger entertainment systems, require complex and costly manual processes for creating cable outlets, leading to inefficiencies, design errors, and increased production time, with exposed sharp edges posing safety risks and aesthetic concerns.
Innovation Solution
A modular cable outlet element with a cable lead-in section, raceway arrangement connection, and cable lead-out section, designed for easy connection and production using injection-molded polyamide components, eliminating the need for manual milling and deburring, and allowing for efficient routing of cables while maintaining aesthetic concealment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual milling and notching is used to create cable outlets in raceways, then cable routing is achieved, but production time increases and production costs increase
Solution Approach 1:
The cable outlets are pre-formed in the raceway during the extrusion process itself, rather than being created afterward through manual milling. This preliminary action eliminates the need for subsequent manual operations and significantly reduces production time
Solution Approach 2:
The manual mechanical milling process is replaced by an automated extrusion process that forms cable outlets directly during raceway manufacturing. This substitution of mechanical systems with automated forming processes increases productivity and reduces labor-intensive operations
2Productivity
If manual milling is used to create cable outlets, then cable routing is achieved, but production costs increase due to manual labor
Solution Approach 1:
Manual milling operations are replaced by automated extrusion technology that forms cable outlets during the raceway manufacturing process. This eliminates manual labor costs and reduces overall manufacturing expenses
Solution Approach 2:
The cable outlet formation process is merged with the raceway extrusion process, allowing both components to be manufactured simultaneously in one operation. This consolidation eliminates separate manufacturing steps and reduces overall production costs
3Productivity
If sharp edges are left at milled cable outlets, then production time is reduced, but safety hazards increase and aesthetic quality deteriorates
Solution Approach 1:
The cable outlets are pre-formed with smooth, rounded edges during the extrusion process, eliminating the need for subsequent deburring operations. This preliminary formation of safe edges prevents safety hazards while maintaining production efficiency
Solution Approach 2:
The extrusion process naturally forms smooth, rounded cable outlet edges as a beneficial byproduct of the molding process, converting what would traditionally be a harmful sharp edge into a safe, aesthetically pleasing feature without requiring additional processing steps
Data Source
AI summary
A cable outlet element (101) for leading out a cable (106) that can be muted through a raceway arrangement (105) comprises a cable lead-in section (101), a raceway arrangement connection (102), a cable lead-out section (103) and a cable outlet connection (104). The raceway arrangement connection (102) can be connected to a raceway arrangement (105) such that a cable (106) that can be routed through the raceway arrangement (105) can be fed into the cable lead-in section (101). To jointly form a cable outlet aperture the cable outlet connection (104) can be connected to a cable outlet connection (111) of another cable outlet element (107) such that at the connected cable outlet connections (104,111) a cable (106) fed into the cable lead-in section (101) can be led out through the jointly formed cable outlet aperture.