Integrated Generator Terminal for Direct Bus Bar Power Transfer
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Solution Overview
Problem
Existing aircraft power systems, particularly those using alternating current (AC) generators, are bulky, heavy, and require significant space, making them cost-prohibitive for smaller aircraft and impacting navigation efficiency for larger ones.
Innovation Solution
A compact generator terminal system comprising a stud, nut, and electrical conductor that is directly coupled to the generator, allowing for direct power transfer to a bus bar without separate terminals and connectors, reducing space and weight requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separated terminal with connecting leads is used to transfer power from the generator, then the power transfer is functional, but the space, weight, and size requirements increase
Solution Approach 1:
The patent combines the terminal and connecting leads into an integrated unit that directly couples to the generator. The terminal housing incorporates the electrical conductor and connection elements, eliminating the need for separate terminal components and reducing overall system weight while maintaining functional power transfer capability.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components from the power transfer system. By removing separate terminals and connecting leads, the design achieves direct coupling between the generator and bus bar, reducing weight and simplifying the power transfer path while maintaining reliability.
2Reliability
If a separated terminal with connecting leads is used to transfer power from the generator, then the power transfer is functional, but the space and size requirements increase
Solution Approach 1:
The patent merges the terminal housing, electrical conductor, and connection elements into a single integrated assembly. This consolidation reduces the spatial footprint by eliminating gaps and mounting requirements for separate terminal components, allowing more compact installation on aircraft while maintaining full power transfer functionality.
Solution Approach 2:
The electrical conductor is nested within the terminal housing, and the entire terminal assembly is designed to fit compactly within the generator structure. This nested arrangement minimizes the external dimensions and space requirements while preserving the functional integrity of the power transfer system.
3Weight of stationary object
If a compact terminal design is used to reduce space and weight, then the space and weight requirements are reduced, but the device complexity increases
Solution Approach 1:
The terminal housing serves multiple functions simultaneously: it provides structural support, houses the electrical conductor, provides electrical insulation, and facilitates mounting to the generator. This multi-functionality reduces the need for separate specialized components, thereby reducing overall complexity despite the compact design.
Solution Approach 2:
The patent uses uniform materials and standardized connection elements throughout the terminal assembly. The housing, conductor, and mounting features are designed with consistent dimensional tolerances and material properties, simplifying manufacturing and assembly processes while achieving a compact, integrated structure.
Data Source
AI summary
A terminal for a power generator includes an electrical conductor comprising a cavity and end member. The end member is configured to be disposed inside the power generator and receive electrical power from the power generator. A stud is disposed into the cavity of the electrical conductor. Accordingly, the terminal can be directly coupled into the power generator without straps or other intermediate equipment to provide electrical power to the terminal.