Sensor-Integrated Cable Connectors for High-Voltage Error Detection

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Solution Overview

Problem

Existing electrical connectors and systems in aircraft are often complex, inefficient, and lack sufficient functionality for high voltage applications, particularly in monitoring electrical wiring and interconnection systems.

Innovation Solution

An electrical connector assembly with integrated circuit boards and sensors that include electrical characteristic and temperature sensors, connected to an electronic control unit (ECU) to monitor and manage electrical characteristics and temperatures, allowing for real-time error detection and prevention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional electrical connectors are used in aircraft systems, then the system structure is simple, but the functionality is insufficient for high voltage applications and lacks monitoring capabilities

Engineering Contradiction:

ImprovefunctionalityVSAvoidsystem structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple previously separate components (connectors, sensors, circuit boards, and monitoring systems) into an integrated electrical connector assembly. This merging provides high voltage monitoring capabilities, temperature sensing, and electrical characteristic measurement functions within a single unified structure, thereby improving versatility without proportionally increasing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electrical connector assembly is designed to perform multiple functions simultaneously: it provides electrical connection, monitors voltage and current, detects temperature, and communicates system status. This multi-functionality allows a single component to replace what would traditionally require multiple separate systems, enhancing adaptability while managing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate monitoring components are added to electrical systems, then monitoring capability is improved, but the system becomes heavier and larger

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The monitoring sensors and circuit board are integrated directly into the connector housing structure, eliminating the need for separate monitoring components. This combination reduces overall system weight and volume while maintaining comprehensive monitoring capabilities for voltage, current, and temperature.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The circuit board and sensors are nested within the connector assembly structure, with components arranged in a compact, space-efficient configuration. This nesting approach allows monitoring functionality to be embedded within the existing connector volume, avoiding additional weight and space requirements.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If comprehensive sensors are integrated into the connector assembly, then error detection capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveerror detection capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The electrical connector assembly is divided into modular sections: connector housing, circuit board with sensors, and communication interfaces. This segmentation allows each component to be manufactured and tested separately before final assembly, reducing overall manufacturing complexity despite the comprehensive sensor integration.

Inventive Principle:

Principle #1Segmentation

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 system provides efficient monitoring and rapid response to electrical errors, reducing the risk of failures by detecting issues such as over/under voltage, current, and leakage, and predicting potential failures, thereby enhancing system reliability and safety.

Implementation Method 1

a first temperature sensor, a second temperature sensor

Methodology Applied

Scientific EffectTemperature sensing: Thermocouple

Implementation Method 2

an electrical characteristic sensor... configured to determine a leakage current according to a difference between a first current sensed via the first electrical characteristic sensor and a second current sensed via the second electrical characteristic sensor

Methodology Applied

Scientific EffectElectrical measurement: Ohmmeter

Data Source

PatentUS20250286326A1System of cable and connectors with integrated sensors

Publication Date: 2025.09.11 EATON INTELLIGENT POWER LTD

AI summary

An electrical connector assembly includes a first connector member, a second connector member configured for connection with the first connector member, a first insulator disposed at least partially in the first connector member and/or the second connector member, a second insulator disposed at least partially in the first connector member and/or the second connector member, and a circuit board configured to be disposed at least partially between the first insulator and the second insulator in a connected configuration of the electrical connector assembly. The circuit board may include an electrical characteristic sensor and/or a temperature sensor.