Terminal Block Cover Assembly for De-Icing Fluid Arc Mitigation
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Solution Overview
Problem
Conventional terminal block and cover designs for electric generators in aircraft experience electrical arcing issues due to contamination buildup from de-icing fluid, leading to potential damage.
Innovation Solution
A terminal block cover assembly with extended insulation features, including increased extension lengths and phase divider walls, to electrically isolate terminal block studs and feeder cables, creating a sawtooth path that mitigates arcing by increasing dielectric distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional terminal block and cover designs are used, then the structure is simple and easy to manufacture, but electrical arcing events occur due to contamination buildup from de-icing fluid
Solution Approach 1:
The terminal block cover extends in the longitudinal direction beyond the terminal block, creating an extended insulation region that projects beyond the lateral margins of the terminal block. This dimensional extension provides additional electrical isolation without adding complex internal structures, effectively increasing dielectric distance in the critical arc path direction.
Solution Approach 2:
The terminal block is divided into multiple insulation regions by transverse divider walls that extend from the front face toward the rear face. These divider walls create separate insulated compartments for different electrical conductors, preventing arcing between adjacent phases while maintaining a relatively simple overall structure.
2Reliability
If extended insulation features are added to electrically isolate terminal block studs, then arcing events are eliminated, but manufacturing complexity increases
Solution Approach 1:
The terminal block cover is integrated with the terminal block assembly, with the cover extending longitudinally beyond the block and featuring built-in insulation regions. This merging of functions into a single integrated component provides enhanced arc mitigation while maintaining ease of manufacture through conventional molding and assembly processes.
Solution Approach 2:
The extension length of the terminal block cover and the positioning of transverse divider walls are optimized to provide sufficient dielectric distance for arc mitigation in de-icing fluid environments. These parameter changes are implemented within standard manufacturing tolerances and processes, avoiding excessive complexity while achieving reliable arc prevention.
3Reliability
If dielectric distance is increased to prevent arcing, then electrical isolation is improved, but the device dimensions increase
Solution Approach 1:
Instead of increasing dielectric distance uniformly in all directions, the terminal block cover extends longitudinally beyond the terminal block, concentrating the additional insulation where it is most effective for arc mitigation. This targeted dimensional change provides improved electrical isolation without proportionally increasing overall device volume.
Solution Approach 2:
The transverse divider walls are positioned at specific locations within the terminal block to create localized insulation regions between adjacent electrical conductors. This local quality approach provides enhanced electrical isolation at critical points where arcing is most likely to occur, rather than uniformly increasing dimensions throughout the entire device.
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
Substantially eliminates arcing events by providing enhanced electrical isolation, protecting generator components from damage and ensuring reliable operation in environments with de-icing fluid.
Implementation Method 1
an extension length section of the mounted terminal block cover extends a pre-determined distance from the first mounting hole of the terminal block cover and toward the second side to electrically isolate the first terminal block stud
Data Source
AI summary
The present disclosure provides for terminal block cover assemblies for electric generators, and related methods of fabrication and use. More particularly, the present disclosure provides for terminal block cover assemblies for generators for aircraft or the like, with the terminal block cover assemblies having electrical arcing mitigation features and structures, and related methods of fabrication and use. The terminal block cover assemblies of the present disclosure can be utilized to reduce electrical arcing events in environments where de-icing fluid is used in the engine cowl.