Nonconductive Support Bar in Aircraft Power Plug Assembly
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Solution Overview
Problem
Electrical distribution problems, particularly in aircraft ground power assemblies, lead to frequent electrical fires due to faulty wirings, cables, and plugs, causing overheating, sparks, and short circuits, posing significant risks to safety and infrastructure.
Innovation Solution
A plug assembly with insulated electrical conductors and a nonconductive support bar within the plug body to separate contacts and prevent misalignment, shearing, and rupturing, while a third contact acts as a voltage regulator to manage current surges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug assemblies are used without nonconductive support bars, then the device complexity is low, but the reliability deteriorates due to misalignment, shearing, and rupturing of conductors
Solution Approach 1:
A nonconductive support bar is introduced as an intermediary element between electrical conductors and contacts. This support bar prevents direct contact between conductors at different voltages, eliminating short circuits while providing mechanical support to prevent misalignment and shearing. The nonconductive material acts as a mediator that simultaneously provides electrical isolation and structural reinforcement.
Solution Approach 2:
The plug assembly combines conductive materials (for electrical contacts) with nonconductive materials (for support bars and insulation). This composite structure allows different regions of the assembly to have optimized properties: conductive regions for electrical function and nonconductive regions for isolation and mechanical support, resolving the contradiction between simplicity and reliability.
2Reliability
If insulated conductors and nonconductive support bars are added to prevent short circuits, then the reliability improves, but the ease of manufacture deteriorates
Solution Approach 1:
The support bar is integrated directly into the plug body structure, merging the support function with the existing housing. This integration eliminates the need for separate assembly steps to install support elements, as the nonconductive support bar becomes an inherent part of the molded plug body, maintaining ease of manufacture while providing enhanced reliability.
3Stability of the object's composition
If contacts are allowed to move freely without support, then the ease of operation improves, but the stability of composition deteriorates due to misalignment during engagement and disengagement
Solution Approach 1:
The nonconductive support bar provides pre-positioned mechanical support and alignment guidance for contacts before engagement occurs. This beforehand support ensures that contacts are properly aligned and cushioned against misalignment during the engagement and disengagement operations, maintaining both stability and ease of operation.
Data Source
AI summary
A method, system and assembly for transferring electrical power adapted to provide power to a grounded aircraft is provided. The assembly comprises a first and second insulated electrical conductor and a plug body, attached to ends of these conductors. A first contact and a second contact is provided within the plug body, having electrically conductive connections with the first and second conductors. A non conductive support bar disposed at least partially within the plug body separating at least portions of the first contact and the first conductor from the second contact and the second conductor.