Integrated E-Brake Actuator Plate With Protected Wire Harness Routing
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Solution Overview
Problem
Aircraft braking systems face reliability issues due to exposed electrical harnesses that are prone to moisture ingress, damage from environmental hazards, and mechanical contact, which can impact brake performance.
Innovation Solution
The brake actuator plate assembly integrates a wire harness channel within the actuator plate, housing the electrical wiring and eliminating the need for external connectors, with a cover plate providing protection and sealing to prevent moisture ingress and physical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard connectors and exposed electrical harnesses are used in brake assemblies, then ease of installation and electrical connectivity are achieved, but reliability deteriorates due to moisture ingress and environmental damage
Solution Approach 1:
The patent integrates the electrical harness directly into the brake actuator assembly by forming wire harness channels within the actuator plate structure. This merging of the electrical system with the mechanical brake assembly eliminates exposed connectors and protects wiring from environmental hazards while maintaining electrical connectivity functionality.
Solution Approach 2:
The wire harness channels act as intermediary protective structures embedded within the actuator plate. These channels provide a protected pathway for electrical wiring, shielding it from moisture and environmental damage while allowing electrical signals to pass through to actuate the brake mechanism.
2Device complexity
If external connectors and exposed wiring are used, then electrical connectivity is established, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The electrical harness is merged with the brake actuator plate structure through integrated wire channels. This consolidation eliminates the need for separate external connectors and reduces the number of assembly steps, thereby reducing device complexity while improving reliability by protecting wiring from environmental exposure.
3Object-affected harmful factors
If wire harness channels are integrated into the actuator plate, then protection from environmental hazards is achieved, but manufacturing complexity increases
Solution Approach 1:
The wire harness channels are formed by modifying the actuator plate structure through machining, forging, or additive manufacturing processes. These manufacturing techniques alter the physical parameters of the actuator plate to create integrated channels, providing environmental protection for wiring while managing manufacturing complexity through established industrial processes.
Data Source
AI summary
A brake actuator plate assembly includes an electromechanical brake actuator, a connector configured to communicatively couple with an aircraft, a wire harness configured to terminate at the connector and conduct at least one of a voltage or a current to and from an actuator motor, and an actuator plate comprising a wire harness channel configured to house the wire harness.