Rotary Contactor Cam Actuation for Aircraft Modular Maintenance
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Solution Overview
Problem
Current aircraft power distribution systems rely on large, complex linear contactors that are difficult to maintain and replace, due to their cylindrical form factor and extensive wiring harnesses, which complicates maintenance and reduces reliability.
Innovation Solution
A rotary actuation system for contactors that uses a cam mechanism with lobes to actuate switching devices radially, allowing for a flatter form factor and reduced wire harness connections, enabling easier maintenance and integration into modular line replaceable units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a linear actuator with cylindrical form factor is used for the contactor, then the contactor can achieve reliable switching operation, but the contactor size becomes large and difficult to implement in quick line replaceable modules
Solution Approach 1:
The patent inverts the traditional linear actuator design by using a rotary actuator that rotates in a plane perpendicular to the bus bar. This inversion changes the actuation direction from axial (linear) to radial (rotary), enabling a compact form factor that fits within line replaceable module constraints while maintaining reliable switching operation through the cam mechanism's lobes that actuate contacts radially outward.
2Stability of the object's composition
If a linear actuator with cylindrical form factor is used for the contactor, then the contactor can achieve stable operation, but the installation depth increases and maintenance becomes complicated
Solution Approach 1:
The patent segments the contactor into modular components: a rotary actuator assembly, a cam mechanism with lobes, contact assemblies, and a bus bar interface. This segmentation allows the entire contactor to be designed as a compact line replaceable module that can be quickly installed and maintained as a single unit, reducing installation depth and simplifying maintenance procedures while maintaining operational stability.
3Adaptability or versatility
If extensive wiring harnesses and individual chassis are used for each contactor, then the contactor can provide complete electrical interfaces, but the device complexity increases and reliability reduces
Solution Approach 1:
The patent merges multiple electrical interfaces and functions into a single integrated contactor design. The rotary actuator with cam lobes simultaneously actuates multiple contacts in a radial arrangement, eliminating the need for separate chassis and extensive wiring harnesses. This consolidation reduces device complexity and potential failure points while maintaining complete electrical interfacing capabilities for control and power circuits.
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 rotary actuation system simplifies maintenance by providing a compact, modular contactor design that reduces installation depth and facilitates heat dissipation, improving reliability and ease of replacement within aircraft environments.
Implementation Method 1
an actuator responds to a control current and operable to rotate the cam
Data Source
AI summary
A contactor with a rotary actuation system, the contactor including a plurality of switching devices configured to switch a plurality of electrical circuits, a plurality of cam followers each operably coupled to one of the switching devices, wherein each cam follower is configured to actuate a switching device, and a cam mechanism, the cam pivotally attached to a point rotation, the cam having plurality of lobes about its perimeter, the cam in operable communication with each cam follower such that upon rotation of the cam mechanism, each cam follower engages a lobe of the plurality of lobes, it causes each cam follower to actuate the respective switching device. The contactor also includes an actuator connected to the cam, the actuator responsive to a control current and operable to rotate the cam and a controller, the controller operable to supply a control current the actuator.