High Altitude Generator Terminal Block Arc Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Gas turbine engine generator terminal block assemblies face challenges in protecting phase terminals from arcing, foreign object debris, and maintaining electrical integrity during lightning strikes at high altitudes, particularly in withstanding significant voltages.
Innovation Solution
A terminal block assembly with a base and integral protrusions, terminal leads, and pads, along with a cover design that includes recesses and holes for secure mounting, providing a non-conductive and debris-tolerant connection between phase leads and the generator stator, while preventing arcing and electrical shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a terminal block assembly is used to protect phase terminals from arcing and foreign object debris, then protection reliability is improved, but the device complexity increases due to the need for cover structures, protrusions, and integral components
Solution Approach 1:
The patent merges multiple protective functions into a single integrated terminal block assembly. The cover, terminal block, protrusions, and sealing elements are combined into one unified structure that simultaneously provides arc protection, debris protection, and electrical insulation, thereby improving reliability without proportionally increasing complexity.
Solution Approach 2:
The terminal block assembly is segmented into distinct functional components: the cover structure for arc protection, the terminal block for electrical connections, protrusions for positioning, and integral seals for debris protection. This segmentation allows each component to be optimized for its specific function while maintaining overall system reliability.
2Reliability
If the terminal block assembly is designed to withstand significant voltages during lightning strikes at high altitude, then electrical integrity is improved, but the manufacturing complexity increases due to specialized non-conductive materials and precise structural requirements
Solution Approach 1:
The terminal block assembly utilizes composite material structures combining non-conductive materials with conductive elements. The terminal block itself appears to be a composite structure providing both electrical insulation and mechanical strength, enabling it to withstand high voltage lightning strikes while maintaining manufacturability through standardized material selections.
Solution Approach 2:
Different regions of the terminal block assembly have different material properties optimized for their specific functions: non-conductive materials in areas requiring electrical insulation, conductive materials for electrical connections, and reinforced structures for mechanical support. This local quality approach allows the assembly to withstand high voltages without requiring uniformly complex manufacturing throughout the entire structure.
3Manufacturing precision
If protrusions are made integral with the terminal block to provide precise positioning, then positioning precision is improved, but the manufacturing complexity increases due to integral forming requirements
Solution Approach 1:
The protrusions are formed as integral parts of the terminal block during the initial manufacturing process, establishing precise positioning features before final assembly. This preliminary action ensures that the protrusions are already precisely positioned and oriented, eliminating the need for separate positioning operations and reducing overall manufacturing complexity despite the integral forming requirement.
Data Source
AI summary
A method of installing the terminal block assembly onto a generator includes the step of providing a terminal block with multiple terminal studs. Protrusions that are integral with the terminal block are aligned with corresponding bores in a generator housing. The terminal block is mounted on the generator housing with the protrusions received in the bores. A terminal lead assembly is inserted through the protrusion, and a terminal pad of the terminal lead assembly is arranged over the terminal stud. A terminal lug is fastened to the terminal stud. A terminal cover is secured to the terminal block over the terminal with a boss of the terminal block received in a corresponding recess of the terminal cover.