Electrical Coupling Unit with Cam-Driven Rotational Alignment
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Solution Overview
Problem
The existing methods for testing aircraft engine electronic controllers (EECs) face challenges in reliably and securely connecting/disconnecting cables, particularly in confined spaces, leading to potential damage and manual errors during environmental testing.
Innovation Solution
An electrical coupling unit with a push-fit connector system that ensures rotational alignment before connection, utilizing a coaxial actuation sleeve and cam formations to automate the connection process, reducing the risk of damage and facilitating rapid reconfiguration for different platforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual connection/disconnection of cables is performed, then flexibility in testing different EECs is achieved, but connection reliability decreases and damage risk increases
Solution Approach 1:
The coupling unit performs self-alignment through the cam formation mechanism. When the actuation sleeve is moved axially, the cam formation automatically converts this linear motion into rotational motion of the backshell, which in turn rotates the electrical connector to achieve precise rotational alignment with the mating connector. This self-aligning mechanism eliminates the need for manual alignment operations while ensuring reliable connection.
Solution Approach 2:
The cam formation acts as an intermediary mechanism between the actuation sleeve and the electrical connector. It translates the simple axial movement of the actuation sleeve into the complex rotational alignment required for reliable connection, mediating between the operator's simple action and the precise alignment requirement.
2Ease of operation
If manual connection tools are used to aid the connection process, then ease of operation improves, but harmful factors increase due to potential damage to the EEC
Solution Approach 1:
The coupling unit is designed to be self-aligning through the cam formation mechanism, eliminating the need for external manual tools. The operator simply needs to move the actuation sleeve axially, and the system automatically performs the rotational alignment and connection, reducing the risk of tool-induced damage to the EEC.
Solution Approach 2:
The invention replaces complex manual manipulation and tool-based assistance with a controlled mechanical conversion system. The cam formation provides a deterministic mechanical path that converts linear actuation into rotational alignment, replacing the need for manual positioning tools and reducing the risk of accidental damage.
3Reliability
If rotational alignment is required before push-fit connection, then connection reliability improves, but device complexity increases
Solution Approach 1:
The cam formation mechanism adds a dimensional transformation to the connection process. It converts motion from one dimension (axial movement of the actuation sleeve) to another dimension (rotational movement of the backshell and electrical connector). This dimensional conversion achieves precise rotational alignment through a relatively simple mechanical structure.
Solution Approach 2:
The coupling unit is segmented into distinct functional components: the actuation sleeve for axial movement, the cam formation for motion conversion, and the backshell for rotational movement. This segmentation allows each component to perform its specific function efficiently, managing complexity through functional decomposition.
4Productivity
If automated connection is implemented, then productivity improves, but ease of operation may worsen due to automation complexity
Solution Approach 1:
The coupling unit is designed as a self-aligning system that automatically performs rotational alignment when the actuation sleeve is moved axially. This self-service mechanism enables automated operation without requiring complex control systems, maintaining ease of operation while significantly improving productivity through rapid, repeatable connections.
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
The solution provides a low connection failure rate, enables automated and secure cable management, and prevents damage to the EEC and connectors, allowing for efficient testing under various environmental conditions.
Implementation Method 1
the backshell and the actuation sleeve are operatively connected by one or more cam formations which, on contact of the electrical connector with the mating electrical connector, convert forward axial movement of the actuation sleeve into the rotation of the backshell
Data Source
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AI summary
An electrical coupling unit (19) comprising an electrical connector (20) for push-fit electrical connection in an axial direction of the coupling unit to a mating electrical connector (20') of a receiving unit (12). The electrical connector (20) and the mating electrical connector (20') have respective keying elements (22, 22'). The electrical coupling unit (19) further comprises a backshell (21) fixed on the electrical connector (20) and extending on the rear therefrom to house electrical leads extending from the electrical connector (20). The electrical coupling unit (19) further has a coaxial actuation sleeve (23) surrounding the backshell (21). The actuation sleeve (23) is axially movable to effect the push-fit connection. The backshell (21) and the actuation sleeve (23) are operatively connected by a cam (29) and a cam surface (31a, 31b, 31c) such that movement of the actuation sleeve (23) in a forward axial direction towards the receiving unit (12) is resisted by contact between both connectors (20, 20'') to produce rotation of the backshell (21), thereby rotationally aligning both keying elements (22, 22') and allowing mating of both connectors (20, 20').