Terminal Strip Adapter for Simultaneous Aircraft Electrical Testing
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Solution Overview
Problem
Existing methods for conducting power on tests on aircraft electrical power systems are labor-intensive and hazardous, requiring manual probing of multiple terminal posts, which increases the risk of errors and exposes technicians to hazards due to the need to open circuit breaker panels.
Innovation Solution
An adapter with elongated housing and pogo pins that allows for simultaneous electrical connection to terminal posts, using a wiring harness and safety fuses to ensure safe and efficient testing, enabling automated testing equipment to connect to all terminal posts simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual probing of terminal posts is used, then testing can be performed with simple equipment, but testing time and labor intensity increase significantly
Solution Approach 1:
The patent merges multiple individual probing operations into a single adapter unit that contacts multiple terminal posts simultaneously. The adapter integrates multiple pogo pins, wiring harness connections, and safety fuse elements into one unified device, allowing all terminal posts to be tested in a single operation rather than requiring sequential manual probing of each terminal.
Solution Approach 2:
The adapter is segmented into functional modules: multiple pogo pins for individual terminal contact, a wiring harness for electrical connections, safety fuses for protection, and an insulating housing for structural support. This segmentation allows each component to perform its specific function while working together as an integrated system that enables simultaneous multi-point testing.
2Ease of operation
If circuit breaker panels are opened for voltage measurements, then individual terminal posts can be accessed, but personnel safety is compromised due to exposure to electrical hazards
Solution Approach 1:
The adapter serves as an intermediary device between the testing equipment and the terminal posts. It includes safety fuses that act as protective intermediaries, automatically interrupting electrical current if abnormal conditions occur. The insulating housing material provides an intermediate barrier that protects personnel from electrical hazards while allowing the adapter to make necessary electrical contacts.
Solution Approach 2:
The adapter incorporates safety fuses and insulating materials as pre-installed protective measures. These safety elements are built into the adapter structure before use, providing automatic protection against electrical hazards. The high dielectric strength insulating material cushions against electrical shock risks, and the fuses provide advance protection against overcurrent conditions.
3Reliability
If multiple terminal posts are probed individually and repeatedly, then power state changes can be verified, but the possibility of human error increases
Solution Approach 1:
The adapter performs preliminary actions by establishing all electrical connections to multiple terminal posts simultaneously before the testing sequence begins. All pogo pins are positioned and biased into contact with their respective terminal posts in advance, and all wiring harness connections are made beforehand. This eliminates the need for repeated probing operations during the test sequence.
Solution Approach 2:
The adapter maintains continuous electrical contact with all terminal posts throughout the entire testing process. The spring-biased pogo pins ensure continuous pressure and electrical connection, and the wiring harness provides continuous signal transmission. This continuous connection allows for uninterrupted testing and verification of power state changes across all terminals simultaneously.
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 adapter significantly reduces testing time, enhances reliability, and improves safety by allowing simultaneous connection to multiple terminal posts, reducing the risk of errors and hazards during testing.
Implementation Method 1
a spring that biases the contactor outwardly from the housing
Implementation Method 2
The housing and cover are made of an electrically insulating material having a high dielectric strength, e.g., phenolic
Implementation Method 3
A printed circuit board (PCB) having a plurality of electrically conductive traces is disposed in the recess of the housing
Data Source
AI summary
An adapter enables an automated tester to make electrical contact with a plurality of terminal posts of a terminal strip of an aircraft's electrical power system simultaneously, and includes a housing, a plurality of spring-loaded contactors protruding through a floor of the housing, and a printed circuit board disposed within the housing. Conductive leads respectively couple inner ends of the contactors to conductive traces of the printed circuit board. A wiring harness having a connector at one end is coupled to the circuit board such that each of its wires is coupled to a respective contactor via a circuit trace. Fuses are mounted on the circuit board and electrically coupled between the contactors and the harness wires. The adapter detachably couples to the terminal strip such that an outer end of each of the contactors is held in biased contact with a corresponding one of the terminal posts.