Rotor Blade Conductor Assembly With Movable Outboard Support
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Solution Overview
Problem
Conventional electrical conductors in rotary wing aircraft rotor blades experience high failure rates due to centrifugal forces, radial accelerations, and bending displacements, leading to reduced reliability, shortened lifespan, and increased installation time, with external placement affecting aerodynamic performance and being difficult to repair or replace without damaging the rotor blade.
Innovation Solution
An electrical conductor assembly with a substrate and attached conductors, where the inboard end is securely attached to the rotor blade and the outboard end is movable, providing structural support and allowing easy repair or replacement, and an anchor assembly with a clamshell mechanism for secure attachment without invasive techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electrical conductors are bonded to the rotor blade along their length, then the electrical conductors are securely attached, but the electrical conductors experience high strains due to centrifugal force and bending displacements, leading to high failure rates and shortened wire life
Solution Approach 1:
The electrical conductor system is divided into two functional segments: an inboard portion that is bonded to the rotor blade for secure attachment, and an outboard portion that remains unbonded and free-moving to accommodate centrifugal forces and bending displacements. This segmentation allows each portion to perform its specific function optimally without compromising the other.
Solution Approach 2:
A flexible connector or transition zone is introduced between the bonded inboard portion and the unbonded outboard portion. This intermediary element allows relative movement and strain accommodation while maintaining electrical continuity and mechanical connection, protecting the conductor from high strains.
2Strength
If electrical conductors are bonded to the rotor blade along their length, then the electrical conductors are securely attached, but the installation time is substantial and the conductors are not easily repairable or replaceable
Solution Approach 1:
By segmenting the conductor into bonded and unbonded portions, the system enables modular installation and replacement. The unbonded outboard portion can be independently accessed, removed, and replaced without requiring invasive techniques or extensive bonding operations, significantly reducing installation and maintenance time.
Solution Approach 2:
The design facilitates easy replacement of the outboard conductor portion when worn or damaged. Instead of replacing the entire bonded conductor system, only the unbonded outboard portion needs to be replaced, saving time and resources while maintaining the secure inboard attachment.
3Ease of operation
If electrical conductors are placed along the outside of the rotor blade, then the conductors are accessible, but the aerodynamic performance of the rotor blade decreases due to change in airfoil contours
Solution Approach 1:
The electrical conductor system is nested within the rotor blade structure, with the inboard portion positioned inside the blade and the outboard portion extending outward only where necessary. This nested configuration eliminates external conductors that would disrupt airfoil contours, preserving aerodynamic performance while maintaining conductor functionality.
Solution Approach 2:
The conductor routing is moved from a purely external configuration to a three-dimensional path that utilizes the internal volume of the rotor blade. By routing conductors through the blade's internal structure and emerging only at necessary points, the design eliminates aerodynamic interference while maintaining electrical connectivity.
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 enhances reliability, extends the lifespan of electrical conductors, reduces weight, and maintains aerodynamic performance by internal placement, allowing for easy maintenance and repair without damaging the rotor blade.
Implementation Method 1
the outboard end portion is configured to provide structural support to and carry a weight of the at least one electrical conductor under centrifugal force created when the rotor blade is rotated
Data Source
AI summary
An electrical conductor assembly for a rotor blade includes a substrate and at least one electrical conductor. The substrate includes an inboard end portion and an outboard end portion. The at least one electrical conductor is attached to the substrate and extends between the inboard end portion and the outboard end portion. The at least one electrical conductor is configured to transmit electricity along a length of the rotor blade. The inboard end portion and the outboard end portion are structured such that when the electrical conductor assembly is installed within the rotor blade, the inboard end portion is securable relative to the rotor blade and the outboard end portion is movable relative to the rotor blade.