CCA-15 Aircraft Ground Power Cable Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Flexible electric cables used for powering planes on the ground face high mechanical and thermal stress due to their weight and friction, making manual handling difficult and inefficient, especially when spooling and unspooling, and existing cables do not adequately address the need for weight reduction while maintaining load capacity.
Innovation Solution
The cable design incorporates CCA-15 wires with a copper cross-section portion of 15% for phase and neutral conductors, a non-metallic central support element, and a synthetic fiber torsion-resistant sheath, along with slippery foils and high-strength insulation to reduce weight and enhance mechanical resistance, achieving a 20% weight reduction compared to copper conductor cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If copper conductors are used in the cable, then high electrical conductivity is achieved, but the cable weight increases significantly
Solution Approach 1:
The patent uses CCA-15 (copper-clad aluminum) composite wires where the core is aluminum and the outer layer is copper. This composite structure provides electrical conductivity comparable to pure copper while reducing weight by approximately 20%, as aluminum has lower density than copper. The copper cladding ensures good electrical contact and corrosion resistance while the aluminum core provides lightweight structural support.
Solution Approach 2:
The patent changes the material composition parameter from 100% copper to CCA-15 (15% copper content). This parameter change maintains sufficient electrical conductivity for the application while achieving the desired weight reduction. The conductor cross-section is optimized to compensate for the lower conductivity of CCA compared to pure copper, ensuring the overall electrical performance meets requirements.
2Length of moving object
If the cable length is increased to reach distant planes, then coverage area is improved, but the tension force required to pull the cable increases
Solution Approach 1:
The patent introduces a central tension element running through the cable core that is specifically designed to counteract the cable's own weight. This element provides internal support that reduces the effective weight bearing load, making it easier to pull and position long cables (up to 35 meters) without requiring excessive tension force from airport workers.
Solution Approach 2:
The cable employs a composite structure combining CCA conductors with a central tension element made of high-strength, low-weight material. This composite design optimizes the strength-to-weight ratio, allowing the cable to maintain structural integrity over long lengths while reducing the force needed for manual handling and spooling operations.
3Ease of operation
If the cable is made flexible for easy handling, then ease of operation is improved, but mechanical strength and load capacity may be reduced
Solution Approach 1:
The cable employs stranded conductors composed of multiple individual wires twisted together, rather than solid conductors. This segmentation provides flexibility allowing the cable to bend and move easily during spooling and handling operations, while the combined strength of multiple strands maintains adequate mechanical load capacity and resistance to fatigue from repeated flexing.
Solution Approach 2:
The cable uses a composite construction combining flexible stranded CCA conductors with a central tension element and protective sheathing. This composite structure achieves the desired flexibility for manual handling while the tension element and sheath provide the necessary mechanical strength to support electrical loads and resist damage during operation.
Data Source
AI summary
A flexible electric cable for the electric power supply of planes on the ground is subjected to an unspooling and spooling process, the cable having a conductor layout including a plurality of insulated energy supply conductors which are arranged concentrically with respect to a longitudinal central axis of the generally circular in cross-section cable, several insulated neutral conductors which are arranged concentrically with respect to the central axis, and several insulated control conductors which are arranged concentrically with respect to the central axis. A non-metallic, tension- and compression-resistant support member is disposed at the center of the cable, which support member extends over the length of the cable. At least the energy supply conductors include CCA wires having a copper content of at least 15%.