Electronic unit mounting
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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, with exposed connectors susceptible to damage and vibration, and requiring time-consuming access through dedicated panels, which complicates maintenance and increases weight and fuel consumption.
Innovation Solution
An electrical raft with embedded conductors is mechanically fixed to the engine, allowing the electronic unit to form part of the gas-washed surface, enabling direct access and simplifying maintenance by eliminating the need for access panels, and using flexible printed circuits for compact and resilient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical harnesses with exposed connectors are used, then electrical connections can be established, but the connectors are susceptible to damage and vibration, adding weight and complexity
Solution Approach 1:
The patent merges the electrical connectors with the ECU housing into a single integrated unit. The connectors are permanently attached to the ECU and positioned to engage with mating connectors on the engine control system, eliminating the need for separate harness assemblies and reducing overall system complexity while improving reliability through integrated design
Solution Approach 2:
The patent extracts the electrical connectors from the conventional flexible harness and integrates them directly into the ECU structure. This extraction eliminates the vulnerable portion of the harness that is exposed to vibration and damage, while the remaining harness becomes a simpler, more protected component
2Reliability
If conventional electrical harnesses are used, then electrical connections are established, but the harnesses are bulky and heavy, occupying significant space
Solution Approach 1:
The electrical connectors are merged with the ECU housing, creating a compact integrated assembly. This eliminates the need for separate heavy harness components and reduces overall weight while maintaining reliable electrical connections through the integrated connector design
Solution Approach 2:
The patent uses a flexible printed circuit board (FPC) as the electrical connection medium instead of conventional bulky wire harnesses. The FPC provides necessary flexibility for connection while being significantly thinner and lighter, reducing weight and space occupation while maintaining electrical reliability
3Ease of repair
If dedicated access panels are provided for ECU maintenance, then the ECU can be accessed, but the design is complicated and fuel consumption increases
Solution Approach 1:
The ECU is designed with its connectors and maintenance access points positioned on externally accessible surfaces. The ECU can be serviced directly through the engine casing without requiring dedicated access panels, as the connectors are positioned to engage from the outside, allowing maintenance personnel to access and service the ECU through normal engine openings
Solution Approach 2:
Instead of providing dedicated access panels to reach the ECU, the patent inverts the approach by positioning the ECU connectors and access points on externally accessible surfaces. The connectors are arranged to engage with the engine control system from the outside, eliminating the need for internal access panels and simplifying the overall engine design
4Reliability
If exposed connectors are used, then electrical connections can be made, but the connectors need to be particularly robust, making them bulky and heavy
Solution Approach 1:
The connectors are merged with the ECU housing structure, creating a unified component that eliminates the need for oversized protective housings. The integrated design allows the connector to be positioned within the ECU structure where it is naturally protected, reducing weight while maintaining durability through structural integration rather than additive protection
Data Source
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.