Closed-Loop Cable Carriage for Vibration-Resistant Thrust Reversers
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Solution Overview
Problem
Existing electrical connections between stationary and movable parts of aircraft structures, such as thrust reversers, are unreliable due to vibrations during flight, leading to frequent failures and increased testing costs and inefficiencies.
Innovation Solution
A closed loop electrical cable system with guide wheels and spring dampers that allows the cable to rotate freely and maintain tension, reducing in-service fatigue and providing a robust connection that withstands vibrations, enabling reliable power transmission between fixed and movable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electrical cable runs through a track system to connect the fixed structure and the transcowl, then power and data transmission is enabled, but the connection becomes unreliable due to vibrations during aircraft operation
Solution Approach 1:
A carriage assembly acts as an intermediary between the fixed structure and the movable transcowl. The carriage includes a closed-loop cable management system with guide wheels that redirect the electrical cable, preventing direct stress transmission from the transcowl's movement and vibrations to the cable connection points. This intermediary mechanism isolates the cable from harmful vibrational forces while maintaining continuous electrical connectivity.
Solution Approach 2:
The electrical cable connection system transitions from a rigid, fixed track system to a dynamic, flexible arrangement. The cable is allowed to flex and move within the closed-loop configuration, with guide wheels that can rotate to accommodate changes in cable tension and position. This dynamic adaptation enables the system to absorb vibrations and movement without compromising connection reliability.
2Length of moving object
If the transcowl moves a large distance (around 1 metre stroke length) for thrust reverser operation, then the reverser functionality is achieved, but the electrical cable experiences increased stress and fatigue
Solution Approach 1:
The cable management system is segmented into multiple sections with guide wheels positioned at intervals along the cable path. This segmentation divides the total cable length into smaller, supported spans, reducing the stress and fatigue on any single section of the cable during the 1-metre stroke length movement of the transcowl.
Solution Approach 2:
The closed-loop cable configuration and guide wheel arrangement provide beforehand cushioning by distributing mechanical stress throughout the entire cable loop rather than concentrating it at connection points. The system is designed in advance to accommodate the full range of motion, preventing cable damage before it occurs during operation.
3Adaptability or versatility
If sensors and electronic devices are mounted on the transcowl for extended periods, then monitoring and control functionality is improved, but the electrical connection must withstand prolonged vibration exposure
Solution Approach 1:
The carriage assembly serves as a stable intermediary platform that moves with the transcowl while maintaining protected electrical connections. Sensors and electronic devices can be mounted on the carriage or transcowl, and the closed-loop cable system provides a reliable communication pathway that is isolated from the full impact of vibrations, enabling long-term sensor deployment.
4Device complexity
If a traditional electrical cable connection is used, then the setup is simple, but the connection fails during flight testing due to vibrations
Solution Approach 1:
The carriage assembly with its closed-loop cable management system acts as an intermediary that adds complexity to the connection mechanism but dramatically improves reliability. The guide wheels and cable routing arrangement protect the electrical connection from vibrations while maintaining functionality, making the additional complexity worthwhile for preventing connection failures during flight testing.
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 ensures a reliable electrical connection during movement, reducing the likelihood of cable breakage and enabling efficient flight testing and extended use of sensors and electronic devices on movable parts, such as transcowl, by minimizing unsupported cable lengths and using tensioned ribbon cables.
Implementation Method 1
spring dampers that allows the cable to rotate freely and maintain tension, reducing in-service fatigue
Implementation Method 2
spring dampers that allows the cable to rotate freely and maintain tension, reducing in-service fatigue
Implementation Method 3
guide wheels and spring dampers that allows the cable to rotate freely
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A structure comprising a nacelle or a thrust reverser, the structure comprising a stationary part and a movable part, the structure comprising: a first guide provided on or in the stationary part of the structure or the movable part of the structure; a first electrical connector attached to the stationary part of the structure; a second electrical connector attached to the movable part of the structure; and a carriage movable along the first guide; wherein the carriage comprises a closed loop electrical cable mounted in or on a carriage body such that the closed loop cable can rotate, wherein the first electrical connector is electrically connected to the closed loop electrical cable and the closed loop electrical cable is electrically connected to the second electrical connector, thereby providing an electrical connection from the stationary part of the structure to the movable part of the structure.