Electrical Power Contactor Local Ground Plane Wiring Reduction

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Solution Overview

Problem

In vehicle power distribution networks, especially in aircraft, the complexity and weight of wiring increase due to separate conductors for current return, and there's a risk of electromagnetic coupling, which is critical in aeronautics and can lead to system malfunctions.

Innovation Solution

An electrical power contactor with a local electrical ground plane connected to the reference potential of the power supply, using a common conductor for current returns from coils and auxiliary contacts, and a controller, housed in a mechanical enclosure with low resistance connections to minimize wiring and electromagnetic interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate conductors are used for current return in vehicle power distribution networks, then electrical continuity and safety are improved, but wiring complexity and weight increase

Engineering Contradiction:

Improveelectrical continuityVSAvoidwiring weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines multiple separate current return conductors into a single common conductor that serves as the return path for multiple circuits (power contactor coil, auxiliary contacts, and controller). This merging reduces the total number of conductors required, thereby reducing wiring complexity and weight while maintaining electrical continuity through the shared ground connection to the vehicle chassis.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common conductor performs multiple functions by serving as the current return path for different components (coil, auxiliary contacts, controller) simultaneously. This multi-functional conductor replaces what would traditionally require separate dedicated return conductors for each component, reducing overall wiring while ensuring electrical continuity for all circuits.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate conductors are used for current return, then electrical safety is improved, but device complexity increases

Engineering Contradiction:

Improveelectrical safetyVSAvoidwiring complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple separate return conductors are merged into a single common conductor that safely returns current from multiple components to the vehicle chassis ground. This consolidation reduces wiring complexity while maintaining electrical safety through proper grounding and isolation of the common conductor from other circuit elements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The common conductor acts as an intermediary element that safely channels return currents from multiple isolated circuits to the vehicle ground. This intermediary approach maintains electrical safety by providing a dedicated, controlled return path while simplifying the overall wiring architecture.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If separate conductors are used for current return, then electrical isolation is improved, but electromagnetic coupling risk increases

Engineering Contradiction:

Improveelectrical isolationVSAvoidelectromagnetic coupling

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Multiple isolated return conductors are merged into a single common conductor, reducing the number of separate current loops in the system. This reduction in loops minimizes the potential for electromagnetic coupling between adjacent conductors while maintaining electrical isolation between different circuit functions through their shared connection to the vehicle ground.

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

This configuration reduces wiring complexity and weight by up to 30%, minimizing electromagnetic coupling and enhancing reliability by using a local electrical ground plane with low resistance connections.

Implementation Method 1

at least one coil arranged to actuate at least one power contact; and at least one controller supplying the at least one coil with a voltage +Vdc

Methodology Applied

Scientific EffectMagnetic field generation: Electromagnet

Data Source

PatentUS11251006B2Electrical power contactor and vehicle including such a contactor

Publication Date: 2022.02.15 AIRBUS (SAS)

AI summary

An electrical power contactor including a local electrical ground plane configured to be electrically connected to a reference potential 0Vdc of an electrical power supply of the power contactor. Current returns from at least one coil and from at least one auxiliary contact of the electrical power contactor are formed by a common conductor that is connected to the local electrical ground plane. A current return from a controller of the electrical power contactor is also connected to the local electrical ground plane.