Direct-Coupled Generator Terminal for Compact Aircraft Power Transfer
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Solution Overview
Problem
Existing power systems in aircraft, comprising alternating current (AC) generators, are bulky, heavy, and require significant space, making them cost-prohibitive for smaller aircraft and impacting navigation efficiency in larger ones.
Innovation Solution
A direct coupling scheme for generator terminals using a stud and nut configuration, where the stud is inserted into a coaxial hole of a nut, with an electrical conductor and end member to provide power to a bus bar, reducing the need for separate components and minimizing space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separated terminal with connecting leads is used to electrically couple the generator to the bus bar, then the system is functional and reliable, but the space, weight, and size requirements increase significantly
Solution Approach 1:
The patent combines the terminal components (stud, nut, electrical conductor, end member) into a single integrated assembly that directly couples to the generator. This merging eliminates the need for separate connecting leads and multiple discrete components, thereby reducing overall weight while maintaining functional reliability through direct electrical coupling.
Solution Approach 2:
The integrated terminal assembly serves multiple functions simultaneously: the stud provides mechanical attachment, the nut secures the connection, the electrical conductor transfers power, and the end member interfaces with the generator. This multi-functionality reduces the need for separate specialized components, decreasing overall system weight while ensuring reliable electrical coupling.
2Reliability
If a separated terminal with connecting leads is used to electrically couple the generator to the bus bar, then the system is functional, but the space and size requirements increase significantly
Solution Approach 1:
By merging all terminal components into one compact integrated assembly, the patent eliminates the spatial separation required for discrete components and connecting leads. This consolidation dramatically reduces the area occupied by the terminal system while maintaining reliable electrical coupling through direct connection to the generator.
3Reliability
If traditional generator systems with thick exterior housing are used, then the generator is protected and functional, but the system becomes heavy and bulky
Solution Approach 1:
The patent employs a thin-walled housing design that provides necessary protection for the generator components while significantly reducing weight compared to traditional thick exterior housing. The thin film structure maintains structural integrity and protective function while eliminating excess material weight.
4Reliability
If traditional generator systems with thick exterior housing are used, then the generator is protected, but the system occupies a sizable amount of space
Solution Approach 1:
The thin-walled housing design reduces the volume occupied by the generator by eliminating the bulk associated with thick exterior housing. The thin film structure provides necessary protection while minimizing the space required, allowing for more efficient use of aircraft cabin or cargo space.
Data Source
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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.