Modular Mount Assembly for Cable Harnesses
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Solution Overview
Problem
The complexity and high cost of custom-designed metallic brackets and clamping devices for securing cable harnesses in gas turbine engines due to varying diameters, turning angles, and clearance requirements lead to increased part design complexity and count.
Innovation Solution
A modular mount assembly comprising a base unit, stackable extension units, and a rotatable clamp unit made from injection-molded plastic, allowing adjustable height and diameter to accommodate varying cable harness configurations without the need for custom parts, using lockable male-female connections and adhesives for secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-designed metallic brackets and clamping devices are used to accommodate varying cable harness diameters, turning angles, and clearance requirements, then the cable harness mounting meets design standards, but the part design complexity and part number count increase significantly
Solution Approach 1:
The mounting system is divided into separate modular components: a base unit with adhesive backing, multiple stackable extension units of varying lengths, and a clamp unit. These segmented modules can be combined in different configurations to accommodate various cable harness diameters, turning angles, and clearance requirements without requiring custom-designed parts for each scenario.
Solution Approach 2:
The modular mounting system serves multiple functions through a single standardized design. The same base unit, extension units, and clamp unit can be combined in various ways to mount cable harnesses with different diameters, at different heights, and with different turning angles, replacing the need for multiple custom-designed metallic brackets and clamps.
2Reliability
If custom-designed metallic brackets and clamping devices are used for each cable harness configuration, then the mounting meets specific clearance and routing requirements, but the manufacturing cost increases due to high part number count
Solution Approach 1:
Instead of creating custom parts for each configuration, the system changes parameters by selecting different combinations of standard modules. The extension units come in various lengths, and the clamp unit can be rotated to different angles, allowing the same basic design to meet different clearance and routing requirements without increasing part number count or manufacturing complexity.
Solution Approach 2:
The modular mounting system uses inexpensive plastic components that can be easily manufactured and replaced if needed. The injection-molded plastic parts are more cost-effective than custom metallic brackets, and the modular design allows for easy replacement of individual units without requiring expensive tooling for each custom part.
3Adaptability or versatility
If multiple custom metallic parts are used to accommodate different cable harness diameters and turning angles, then the mounting flexibility is achieved, but the assembly time and installation complexity increase
Solution Approach 1:
The clamp unit is designed to be rotatable, allowing it to be dynamically adjusted to different angles during installation. This dynamic capability enables the same clamp unit to accommodate various turning angles of cable harnesses without requiring multiple custom-designed clamps for different angular configurations.
Solution Approach 2:
The base unit is pre-equipped with adhesive backing that can be directly applied to the engine structure, eliminating the need for separate mounting hardware and assembly steps. The modular design allows installers to pre-select the appropriate combination of extension units needed for the specific application, simplifying the on-site assembly process.
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
Simplifies cable harness mounting by reducing part complexity and count, lowering costs, while maintaining secure and vibration-resistant cable harness routing configurations that meet aircraft engine design standards.
Implementation Method 1
The bottom surface of the base unit may be bonded to the outer surface of the support structure with an adhesive
Implementation Method 2
Each of the extension units and the clamp unit may be secured to the base unit or to one another with a lockable male-female type connection arrangement
Data Source
AI summary
A mount assembly is described. The mount assembly may comprise a base unit having a surface, an extension unit stacked on and connected to the surface, and a clamp unit stacked on and connected to the extension unit.