Plug-In Interconnection Unit for Aircraft Winding Connections

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Solution Overview

Problem

The existing electrical machine winding systems for aircraft and similar applications require complex and time-consuming cable connections, which are prone to damage and increase the overall weight and complexity of the device, especially for high-pole pair machines.

Innovation Solution

An interconnection unit with plug-in connectors that electrically connects stator or rotor windings without soldering or welding, featuring multiple contact points and connection sections to facilitate series or parallel connections, reducing mechanical work and enhancing reproducibility and simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cable connections with soldering or welding are used to connect individual windings, then reliable electrical connection is achieved, but the production time increases significantly and the device complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The connection system is segmented into modular plug-in connectors that can be independently assembled and connected. Each connector handles specific winding connections, allowing parallel assembly and reducing overall production time while maintaining connection reliability through standardized interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connectors and cable assemblies are pre-assembled and pre-tested before final installation in the winding system. This preliminary preparation eliminates time-consuming on-site soldering or welding operations during final assembly, significantly reducing production time while ensuring connection quality.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If conventional cable connections with soldering or welding are used to connect individual windings, then reliable electrical connection is achieved, but the device complexity and weight increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple individual cable connections are merged into integrated plug-in connector assemblies that combine multiple electrical contacts and mechanical fastening elements into single modular units. This reduces the total number of separate components and simplifies the overall connection system architecture while maintaining reliable electrical connections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plug-in connectors are designed as universal components that can accommodate different winding configurations and connection requirements through standardized interfaces. This multi-functionality reduces the need for multiple specialized connection types, thereby reducing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional cable connections with soldering or welding are used to connect individual windings, then electrical connection is established, but the risk of damage during production and operation increases

Engineering Contradiction:

Improveconnection durabilityVSAvoiddamage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The thermal processes of soldering or welding are replaced with mechanical plug-in connector assemblies that establish electrical connections through contact pressure and elastic deformation. This substitution eliminates thermal damage risks to surrounding components and reduces the risk of connection damage during assembly and disassembly operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Power

If the number of pole pairs and individual windings is increased to achieve higher power density, then the machine performance improves, but the number of cable connections and production complexity increase

Engineering Contradiction:

Improvepower densityVSAvoidconnection establishment time

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The winding connection system is segmented into modular plug-in connectors that can be independently assembled and connected. Each connector handles specific winding connections, allowing parallel assembly and reducing overall production time while maintaining connection reliability through standardized interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11777358B2Interconnection unit and method for producing a winding system

Publication Date: 2023.10.03 ROLLS ROYCE DEUT LTD & CO KG

AI summary

The disclosure relates to an electrical machine for a drive system of an electrically driven aircraft and its winding system. In particular, the disclosure relates to an interconnection unit for interconnecting the windings of the winding system. For electrically connecting winding arrangements of the winding system, the interconnection unit has a connection arrangement with large number of contact points which are configured and arranged on the interconnection unit such that these contact points of the interconnection unit may be connected to contact points of the winding arrangements to be contact-connected. The connection arrangement furthermore has a large number of electrical connection sections, wherein a respective connection section connects two of the contact points to one another. This interconnection unit may be contact-connected by way of its contact points to corresponding contact points of the winding arrangements, so that a desired winding system may be constructed in a simple manner.