Heated rigid electrical harness for a gas turbine engine
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, complex, and prone to mechanical damage, complicating assembly and maintenance, while separate heating systems add weight and cost, and are inefficient in providing heat for anti-icing and anti-condensation purposes.
Innovation Solution
A rigid electrical raft with embedded electrical conductors and heating elements, where the heating elements emit more heat per unit length than the conductors, integrated into a composite material to provide both electrical transmission and heating, reducing complexity, weight, and cost, and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring harnesses are used to transmit electrical signals, then electrical connectivity is achieved, but the harness becomes bulky, heavy, and complex
Solution Approach 1:
The patent combines multiple electrical conductors into a single rigid printed circuit board structure, eliminating the need for separate wiring harnesses. The PCB integrates numerous conductive traces that provide electrical connectivity while reducing overall complexity, weight, and volume compared to traditional bundled wire harnesses.
Solution Approach 2:
The rigid PCB serves multiple functions simultaneously: it provides electrical connectivity through conductive traces, structural support through the rigid substrate, and routing guidance through predefined trace paths. This multi-functionality replaces the separate roles previously fulfilled by individual wires, connectors, and supporting structures.
2Reliability
If conventional wiring harnesses with protective sleeves and braiding are used, then mechanical protection is provided, but the harness becomes heavier and more difficult to manipulate
Solution Approach 1:
The rigid PCB integrates mechanical protection directly into its structural substrate, eliminating the need for separate protective sleeves and braiding. The rigid material itself provides the necessary mechanical strength and protection, while the monolithic structure improves ease of installation and manipulation compared to flexible but bulky wire harnesses.
3Reliability
If separate heating components are added to prevent ice and condensation buildup, then heating function is achieved, but weight and complexity increase
Solution Approach 1:
The patent integrates heating elements directly into the rigid PCB structure, combining the electrical transmission function with the heating function in a single component. This eliminates the need for separate heating components and their associated wiring, thereby reducing overall system complexity and weight while maintaining effective anti-icing and anti-condensation capabilities.
Solution Approach 2:
The rigid PCB serves as both an electrical circuit board and a heating element. The same rigid structure that provides mechanical support and electrical connectivity also incorporates heating traces that generate thermal energy to prevent ice and condensation buildup, demonstrating multi-functionality that reduces overall system complexity.
4Reliability
If conventional wiring harnesses with multiple components are used, then electrical connectivity is achieved, but assembly and maintenance become time-consuming and error-prone
Solution Approach 1:
The rigid PCB consolidates numerous individual wires, connectors, and supporting components into a single pre-assembled unit. This integration dramatically reduces assembly time during installation and simplifies maintenance procedures, as the entire electrical connection system can be installed or replaced as one component rather than assembling multiple separate parts.
5Device complexity
If the rigid electrical raft with integrated heating elements is used, then weight and complexity are reduced, but the heating elements must emit sufficient heat per unit length
Solution Approach 1:
The heating elements on the rigid PCB are strategically positioned and dimensioned to provide concentrated heat output at specific locations where anti-icing and anti-condensation protection is most needed. This localized heating approach ensures sufficient heat emission per unit length at critical areas without requiring the entire PCB to generate excessive heat, optimizing energy efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The rigid electrical raft simplifies assembly and maintenance, reduces weight and size, and effectively prevents ice and condensation buildup, while providing efficient heating for the engine, thus improving reliability and reducing maintenance time and costs.
Implementation Method 1
electrical heating elements embedded in the rigid material and arranged to provide electrical heating
Data Source
AI summary
A rigid electrical raft has electrical conductors embedded in a rigid material. The electrical conductors transmit electrical signals through the rigid electrical raft, which may form part of an electrical system of a gas turbine engine. The rigid electrical raft also has electrical heating elements embedded therein. The electrical heating elements provide heat which may be used, for example, to prevent condensation and/or ice build-up and/or to raise the temperature of electrical components to be within a desired range.