Contactless Electrical Connector for Induction Sensor

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Solution Overview

Problem

Existing electrical connectors for induction sensors in gas turbine engines are complex, bulky, fragile, and prone to interference and maintenance challenges due to multiple contacts and connections, making them difficult to repair and replace.

Innovation Solution

A current transformer-based electrical connector with a primary coil attached to the sensor and a secondary coil connected to the cable, held together by a removable attachment means such as a washer on a stem core, allowing easy disconnection by separating the coils.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a sealed socket with movable plug and multiple contacts is used to connect the sensor to the electrical harness, then electrical connection continuity is ensured, but the connector becomes complex, bulky, heavy, and fragile

Engineering Contradiction:

Improveelectrical connection continuityVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical contact-based connection system (socket with movable plug and multiple contacts) with an electromagnetic induction system. The primary coil on the sensor and secondary coil on the connector create electrical connection through electromagnetic coupling, eliminating the need for direct mechanical contacts while ensuring electrical continuity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces magnetic coupling as an intermediary between the sensor and electrical harness. The magnetic field acts as a mediator to transfer electrical energy and signals without requiring direct physical contact between the sensor connector and harness, thus simplifying the connection structure while maintaining reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If multiple contacts and threads are used in the connector assembly, then electrical ground and HF shielding continuity is ensured, but the connector becomes fragile and prone to interference

Engineering Contradiction:

Improveelectrical ground and HF shielding continuityVSAvoidconnector durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces multiple mechanical contacts and threads with a single robust mechanical attachment (such as a bayonet or screw connection) that holds the primary and secondary coils in close proximity. The electromagnetic coupling maintains electrical ground and HF shielding continuity without requiring multiple separate contact points, thus improving durability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a complex connector assembly with multiple connections is used, then electrical connection is ensured, but repair and replacement operations become awkward

Engineering Contradiction:

Improveelectrical connectionVSAvoidsensor replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent segments the connection system into two independent parts: the primary coil attached to the sensor and the secondary coil attached to the electrical harness. This segmentation allows the sensor to be easily removed and replaced by simply detaching the primary coil from the secondary coil, without requiring disconnection of multiple contacts or threads.

Inventive Principle:

Principle #1Segmentation

4Reliability

If four mechanical connections are used to ensure electrical ground and HF shielding continuity, then connection reliability is improved, but weight and space requirements increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnector weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges the functions of electrical ground connection, HF shielding, and signal transmission into a single integrated electromagnetic coupling system. The magnetic field coupling simultaneously handles all these functions that previously required four separate mechanical connections, thus reducing connector weight and space requirements.

Inventive Principle:

Principle #5Merging (Combining)

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

Simplifies maintenance by eliminating the need to remove electrical contacts, reduces weight and space requirements, and enhances reliability against thermal and vibrational stresses, while maintaining electromagnetic integrity.

Implementation Method 1

an electrical connector between an induction sensor and an electrical cable for transmitting the signal supplied by the sensor, is characterized in that it comprises a current transformer with a primary coil and a means for electrical connection to the sensor and a secondary coil with a means for connecting to said cable

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS8710833B2Contactless electrical connector for an induction sensor, and sensor including such a connector

Publication Date: 2014.04.29 SAFRAN AIRCRAFT ENGINES SAS

AI summary

An electrical connector between an induction sensor and a cable for transmitting a signal provided by the sensor, including a current transformer with a primary coil and a mechanism for electrically coupling to the sensor, and a secondary coil with a mechanism for electrically coupling to the cable, the primary and secondary coils being attached together by a removable attachment mechanism.