Retaining Harness Assembly for Aircraft Galley Connectors

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Solution Overview

Problem

The existing systems for connecting and disconnecting electrical connectors in aircraft galleys, such as shipside and test connectors, require high forces and awkward positions, leading to discomfort, injuries, and potential damage due to the use of torque rings and strap wrenches, making the process unsafe and inefficient.

Innovation Solution

A retaining harness assembly that securely connects electrical connectors in a linear, non-rotational manner without the need for threaded interfaces, using a biasing mechanism to maintain the connection and a spring override ring to facilitate easy disconnection, reducing the force required and minimizing the risk of injury.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a torque ring is used to secure the connection between electrical connectors, then the connection strength is improved, but the force required for disconnection increases significantly

Engineering Contradiction:

Improveconnection strengthVSAvoiddisconnection force

Core Design Contradiction:

StrengthVSForce

Solution Approach 1:

The torque ring is divided into two functional parts: a locking mechanism that secures the connector during operation, and a release mechanism that allows easy disconnection. The biasing mechanism provides continuous locking force while the spring override ring enables sudden release when needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The torque ring transitions from a static high-force connection to a dynamic release system. The biasing mechanism maintains constant locking pressure, while the spring override ring allows rapid disengagement by overcoming the biasing force temporarily, converting the static strong connection into a dynamically controllable one.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If strap wrenches are used to disconnect the connectors, then the connection can be broken, but the operational safety deteriorates due to awkward positions and high forces

Engineering Contradiction:

Improvedisconnection capabilityVSAvoidoperational safety

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The torque ring system is self-servicing through the spring override ring mechanism. The operator simply needs to activate the spring override ring, which automatically engages the biasing mechanism to release the locking force, eliminating the need for external strap wrenches and awkward manual force application.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The spring override ring acts as an intermediary between the operator and the torque ring locking mechanism. Instead of directly applying high force to break the connection, the operator activates the spring override ring, which mediates the force application through the biasing mechanism to safely release the lock.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If high force is applied to rotate the torque ring for disconnection, then the connectors can be separated, but the risk of damage increases

Engineering Contradiction:

Improvedisconnection speedVSAvoidrisk of damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The biasing mechanism is pre-loaded during the connection process, storing elastic potential energy in the biasing element. This preliminary action prepares the system for easy release, as the stored energy automatically pushes the torque ring to disengage when the spring override ring is activated, eliminating the need for high-force manual separation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The high force that was previously harmful during disconnection is converted into a beneficial pre-loaded biasing force during connection. The biasing mechanism stores energy that becomes useful for automatic release, transforming the harmful high-force requirement into a beneficial stored energy source that facilitates safe and quick disconnection.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution allows for safe, efficient, and simple connection and disconnection of electrical connectors, reducing the risk of injury and damage, and eliminating the need for high-force disconnection methods, thereby improving the safety and efficiency of the process.

Implementation Method 1

a biasing mechanism that exerts a retaining force into the second electrical connector and the torque ring of the first electrical connector

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a spring override ring that is configured to compress the biasing mechanism to disconnect the first and second electrical connectors

Methodology Applied

Scientific EffectSpring compression: Spring

Data Source

PatentEP3133703B1Test connector retaining harness assembly

Publication Date: 2019.10.09 THE BOEING CO

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AI summary

An electrical system may include a first electrical connector (100) configured to be coupled to an electrical panel, a second electrical connector (102) configured to be coupled to a testing device that is configured to test components coupled to the electrical panel, and a retaining harness assembly (200) that removably connects to the first and second electrical connectors (100, 102) to maintain a secure mating relationship between the first and second electrical connectors (100, 102).