Integrated E-Brake Actuator Plate With Sealed Harness Channel
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Solution Overview
Problem
Aircraft braking systems face reliability issues due to exposure of electrical harnesses to harsh environments, including moisture ingress and physical damage from operators or machinery, which can lead to failures.
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 connector configured to communicatively couple with the aircraft and a sensor contact for temperature monitoring, enhancing protection and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical harness is exposed externally for connectivity, then ease of operation is improved, but reliability deteriorates due to moisture ingress and physical damage
Solution Approach 1:
The patent merges the electrical harness with the actuator plate by integrating the wire harness channel directly into the actuator plate structure. This consolidation eliminates separate external harness routing, protecting wires within the sealed actuator plate environment while maintaining electrical connectivity through integrated contacts.
Solution Approach 2:
The wire harness is nested within the actuator plate through the wire harness channel, which is formed as an internal cavity or recessed channel within the actuator plate structure. This nesting protects the electrical harness from external environmental hazards while keeping it functionally connected.
2Ease of manufacture
If standard connectors are used for electrical connection, then ease of manufacture is improved, but reliability deteriorates due to moisture ingress at connector interfaces
Solution Approach 1:
The patent extracts the vulnerable external connector interface from the system by integrating the electrical connection points directly into the actuator plate. The wire harness terminates at contacts formed on the actuator plate itself, eliminating the need for separate external connectors that are prone to moisture ingress.
Solution Approach 2:
The connector function is merged with the actuator plate structure by forming contacts directly on the plate. This integration eliminates the separate connector component and its vulnerable interface, creating a sealed, unified structure that prevents moisture ingress while maintaining electrical connectivity.
3Ease of repair
If wire harness is routed externally, then ease of repair is improved, but reliability deteriorates due to exposure to environmental hazards and physical damage
Solution Approach 1:
The wire harness is nested within the actuator plate structure through the wire harness channel, protecting it from external environmental hazards and physical damage. The channel is formed via machining, forging, or additive manufacturing, creating a protected pathway for the electrical connections.
Solution Approach 2:
The wire harness channel acts as a protective enclosure or shell within the actuator plate, shielding the electrical harness from external hazards. This protective channel maintains the flexibility of electrical connection while providing robust environmental protection.
Data Source
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AI summary
A brake actuator plate assembly includes an electromechanical brake actuator (104), a connector (304) configured to communicatively couple with an aircraft, a wire harness (302) 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 (304) comprising a wire harness channel (308) configured to house the wire harness.