Terminal Lead Assembly Curved Periphery Creep Resistance
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Solution Overview
Problem
Integrated drive generators in aircraft face challenges in maintaining a constant frequency of electric power generation due to varying input shaft speeds, requiring efficient speed trimming mechanisms to stabilize the output frequency.
Innovation Solution
The terminal lead assembly design includes a body with a cylindrical inner portion and a support portion with a curved outer periphery, providing improved creep resistance and lightning protection, and a method for replacing existing assemblies, ensuring secure connections and stable power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the input shaft speed varies during gas turbine engine operation, then the generator can adapt to different engine conditions, but the output frequency becomes variable instead of constant
Solution Approach 1:
A terminal lead assembly is introduced as an intermediary component between the generator windings and the external electrical connections. This assembly provides a stable, fixed reference point for electrical connections while the generator itself can vary its rotational speed. The terminal lead assembly includes a body with a cylindrical inner portion and a support portion with a curved outer periphery, creating a rigid structural intermediary that maintains electrical connection stability independent of the varying mechanical input speed.
2Device complexity
If traditional terminal lead assemblies are used, then the structure is simple, but they exhibit poor creep resistance and inadequate lightning protection
Solution Approach 1:
The terminal lead assembly employs curved surfaces throughout its structure. The support portion features a curved outer periphery, and the body includes a cylindrical inner portion. These curved geometries provide superior creep resistance compared to traditional flat or angular designs. The curvature distributes stress more evenly and prevents stress concentration points, thereby improving resistance to creep deformation while maintaining structural integrity against lightning strikes.
Solution Approach 2:
The terminal lead assembly is constructed from composite material structures combining different properties. The assembly integrates a body portion and a support portion with different geometric characteristics (cylindrical inner portion vs. curved outer periphery), creating a composite structural system that simultaneously achieves electrical conductivity, mechanical strength, creep resistance, and lightning protection without requiring overly complex multi-component assemblies.
Data Source
Figure 1A~1B
Figure 2A
Figure 2B~2C
AI summary
A terminal lead assembly for use in an integrated drive generator has a body formed of a lead portion (131L) and a support portion (131S). The lead portion (131L) is received within an aperture in the support portion (131S). The support portion (131S) has an outer periphery defined within a plane extending perpendicularly to a central axis of the lead portion (131L). The outer periphery includes two curved portions and straight side portions extending parallel to each other and connecting the curved portions. An integrated drive generator and a method are also disclosed.