Low-Current Electrical Contact Cleaning via Wetting Current

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Solution Overview

Problem

Low current electrical contacts in vehicles, such as aircraft, suffer from degradation due to residue buildup, leading to increased contact resistance and intermittent operation, which is difficult to detect and address with existing methods, resulting in unreliable performance and unnecessary component replacements.

Innovation Solution

A system and method using a control unit to determine contact resistance and remove residue via a wetting current, analyzing resistance and stabilization time relative to electromagnetic interference levels, and performing a final conductivity test to ensure circuit integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contact pressure is increased to improve contact resistance, then contact resistance decreases, but component life is shortened due to increased wear

Engineering Contradiction:

Improvecontact resistanceVSAvoidcomponent life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The system performs preliminary detection of contact resistance and applies cleaning current to remove residue buildup before it significantly degrades performance. By addressing contamination early through regular monitoring and cleaning cycles, the need for excessive contact pressure is eliminated, thereby preventing premature wear while maintaining reliable electrical connection.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If special contact materials are used to improve performance, then contact resistance decreases, but cost increases

Engineering Contradiction:

Improvecontact resistanceVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system enables self-service maintenance by automatically detecting contact resistance levels and applying cleaning current to remove residue buildup. This self-maintaining capability allows standard contact materials to perform optimally over extended periods without degradation, eliminating the need for expensive special materials while maintaining reliable electrical connection.

Inventive Principle:

Principle #25Self-service

3Ease of repair

If conventional testing methods are used, then component replacement is simplified, but intermittent in-flight operation continues due to undetectable high resistance connections

Engineering Contradiction:

Improvecomponent replacementVSAvoidintermittent operation detection

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

The system replaces mechanical/component-based testing approaches with electrical field-based detection. By measuring contact resistance through electrical measurements and analyzing stabilization time characteristics, the system can detect high resistance connections and residue buildup that conventional mechanical testing methods miss, enabling identification of intermittent faults without physical component replacement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Use of energy by moving object

If low current is used in the circuit, then power consumption decreases, but cleaning capability is insufficient leading to residue buildup

Engineering Contradiction:

Improvepower consumptionVSAvoidresidue removal capability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The system employs periodic action by applying cleaning current in controlled pulses rather than continuously. The control unit monitors contact resistance and applies higher current pulses only when residue buildup is detected, then returns to low-current normal operation. This periodic cleaning approach maintains adequate residue removal capability while preserving low power consumption during normal circuit operation.

Inventive Principle:

Principle #19Periodic action

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

Effectively detects and removes residue from low current electrical contacts, improving circuit conductivity and reducing the need for arbitrary component replacements, thereby enhancing reliability and extending component life.

Implementation Method 1

remove, via a wetting current, residue on the one or more electrical contacts

Methodology Applied

Scientific EffectWetting current: Electrolysis

Implementation Method 2

determine contact resistance of one or more electrical contacts of one or more circuits

Methodology Applied

Scientific EffectElectrical resistance measurement: Electrical Resistance

Data Source

PatentUS12198872B2Systems and methods for detecting and removing residue from low current electrical contacts

Publication Date: 2025.01.14 THE BOEING CO

AI summary

A system, a method, a device, and an apparatus include a control unit configured to determine contact resistance of one or more electrical contacts of one or more circuits, and remove, via a wetting current, residue on the one or more electrical contacts.