Dual-Channel Harness Sleeve for Folding Wing Tip Cable Separation

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Solution Overview

Problem

The challenge of providing a wiring harness for a folding wing tip in aircraft that can withstand harsh environmental conditions, movement, and changes in tensional loads, while ensuring segregation of high voltage wiring and minimizing the risk of arcing and abrasion, is exacerbated by limited space and the need for redundancy.

Innovation Solution

A protective sleeve made of fluorosilicone polymer is used to encase the wiring harness, which includes features such as slits for easy installation and removal, clamps for secure attachment, and sleeve guides for controlled movement, ensuring separation of high and low voltage conductors and protection against wear and arcing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a wiring harness is extended across the folding wing tip joint to provide power and data, then the wing tip device can be controlled during flight, but the wiring harness is exposed to harsh environmental conditions, repeated movement, and changes in tensional loads that can damage the cables

Engineering Contradiction:

Improvewiring harness flexibilityVSAvoidcable durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The wiring harness is nested within a protective sleeve that extends across the folding joint. The sleeve acts as a protective channel that moves with the joint, allowing the wiring to be contained and protected while maintaining the necessary flexibility for wing tip movement between flight and ground configurations

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A flexible protective sleeve is used to encase the wiring harness. The sleeve is designed to be resilient and flexible enough to accommodate the repeated bending and movement at the folding joint while providing protection against environmental conditions and mechanical damage to the cables within

Inventive Principle:

Principle #30Flexible shells and thin films

2Power

If high voltage wiring is provided to the folding wing tip for high voltage feed, then power can be supplied to the wing tip device, but the risk of arcing and damage to adjacent structure increases

Engineering Contradiction:

Improvehigh voltage feed capabilityVSAvoidarcing risk

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The protective sleeve acts as an intermediary barrier between the high voltage wiring and the surrounding environment. The sleeve material provides electrical insulation properties that prevent arcing to adjacent structure while still allowing the high voltage power to be transmitted to the wing tip device

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protective sleeve is made from a composite material that combines electrical insulation properties with flexibility and resilience. This composite material provides both the necessary electrical protection against arcing and the mechanical flexibility to accommodate joint movement

Inventive Principle:

Principle #40Composite materials

3Length of moving object

If the wing tip device is made movable to reduce span for ground operations, then airport gate and taxiway clearance is improved, but the wiring harness must cope with repeated movement and environmental exposure

Engineering Contradiction:

Improvewing spanVSAvoidenvironmental exposure

Core Design Contradiction:

Length of moving objectVSObject-affected harmful factors

Solution Approach 1:

The wiring harness is nested within a protective sleeve that is itself nested within or protected by the wing structure. This multi-layer nesting arrangement allows the wiring to be protected from environmental exposure while the wing tip maintains its movability for span reduction during ground operations

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

A flexible protective sleeve encases the wiring harness, providing a protective barrier against environmental conditions such as moisture, temperature extremes, and mechanical abrasion that the wiring would otherwise be exposed to during repeated wing tip movement

Inventive Principle:

Principle #30Flexible shells and thin films

4Reliability

If sufficient segregation of high voltage wiring from adjacent structure is provided to prevent arcing, then safety is improved, but the available volume within the aircraft structure towards the wing tip is limited

Engineering Contradiction:

Improvearcing preventionVSAvoidavailable volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The protective sleeve provides a thin but effective barrier that segregates the high voltage wiring from adjacent structure. The sleeve material provides sufficient electrical insulation to prevent arcing while occupying minimal volume, allowing the wiring to be positioned within the limited space available towards the wing tip

Inventive Principle:

Principle #30Flexible shells and thin films

Data Source

PatentUS20250276783A1Sleeve for a pair of wiring harnesses

Publication Date: 2025.09.04 AIRBUS OPERATIONS LTD

AI summary

An aircraft with a folding wing tip arrangement and first and second wiring harnesses extending between a fixed wing and a wing tip device is disclosed. It is desirable to transfer power and/or data into a folding wing tip, which presents challenges such as repeated exposure to potentially harsh environmental conditions, with movement, and/or with changes in tensional loads. The wiring harnesses include a plurality of conductors and are arranged to transmit electrical power and/or data to the wing tip device. The sleeve includes two channels to receive the harnesses, the position of the channels being fixed, relative to one another, such that the harnesses are held apart.