Electrical Raft ECU Mounting for Lightweight Engine Wiring
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, and complex, making them difficult to install and maintain, and are susceptible to damage and vibration, which increases maintenance time and risk to personnel, while also adding weight and complexity to the engine.
Innovation Solution
The use of an electrical raft with embedded conductors, where the electronic control unit forms part of the engine's gas-washed surface, allowing for direct access and simplifying maintenance by eliminating the need for access panels and providing a robust, lightweight solution for electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical harnesses with multiple wires and connectors are used, then electrical connections can be established, but the system becomes bulky, heavy, and complex
Solution Approach 1:
Multiple individual electrical wires and connectors are merged into a single integrated electrical raft structure. The raft consolidates numerous conductors, insulating material, and connector elements into one unified component that attaches directly to the ECU, eliminating the need for separate wire management and multiple discrete connectors.
Solution Approach 2:
The electrical raft serves multiple functions simultaneously: it provides electrical conductors for power and signals, incorporates insulating material for electrical isolation, provides structural support for mounting the ECU, and creates a streamlined external surface. This multi-functional design replaces what would traditionally require separate components.
2Reliability
If conventional electrical harnesses are used, then electrical connections are provided, but weight increases significantly
Solution Approach 1:
The electrical raft combines multiple heavy components (individual wires, insulating sleeves, connectors, and mounting brackets) into a single lightweight integrated structure, significantly reducing overall weight while maintaining electrical connection stability.
Solution Approach 2:
The electrical raft utilizes composite construction with conductors embedded in insulating material, creating a lightweight yet structurally sound component that provides both electrical functionality and mechanical strength without the weight of traditional separate components.
3Ease of operation
If exposed connectors are used to connect ECUs to harnesses, then electrical connections are established, but the connectors become susceptible to damage from vibration and environmental factors
Solution Approach 1:
The electrical connectors are extracted from their traditional exposed position and integrated directly into the electrical raft structure that attaches to the ECU. This eliminates the exposed connector portion that would be susceptible to vibration and environmental damage while maintaining electrical connectivity.
Solution Approach 2:
The connectors are nested within the protected structure of the electrical raft and ECU mounting assembly, rather than being exposed externally. This nesting protects vulnerable connector elements from vibration and environmental factors while maintaining functional accessibility.
4Reliability
If conventional harnesses with multiple wires are used, then electrical connections are provided, but the harness occupies significant space within the engine
Solution Approach 1:
Numerous individual wires and their associated insulating and support structures are merged into a single compact electrical raft that attaches directly to the ECU, dramatically reducing the volume occupied by electrical components within the engine assembly.
Solution Approach 2:
The electrical connections transition from a three-dimensional sprawling harness configuration to a two-dimensional planar raft structure that attaches flatly to the ECU surface, minimizing volumetric occupation while maintaining all necessary electrical pathways.
5Reliability
If conventional electrical harnesses are used, then electrical connections are established, but installation and maintenance become time-consuming and complex
Solution Approach 1:
The electrical system is segmented into a modular electrical raft unit that can be installed and maintained as a single component rather than dealing with numerous individual wires and connectors, significantly reducing installation and maintenance time while maintaining connection stability.
Solution Approach 2:
The electrical raft is pre-assembled with all conductors, insulating material, and connector elements integrated before installation on the engine, eliminating the need for complex on-site wiring and connection procedures during installation or maintenance.
Data Source
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AI summary
An electrical assembly 600 comprising an electrical raft 200 and an electronic unit 300 is provided to a gas turbine engine 10. The electrical raft 200 has electrical conductors 252 embedded in a rigid material 220, which may be a rigid composite material. The electrical conductors 252 are in electrical contact with the electronic unit 300. When the electronic unit 300 is installed, at least a part 310 of it forms a part of a gas-washed surface of the engine 10. The electronic unit 300 is then easily accessible from the engine 10, and potentially complex and/or heavy access doors/panels may not be required.