Patent Grant
10044128
The present invention generally relates to the field of aircraft ground power devices. In particular, the present invention is directed to a modular, repairable aircraft ground power receptacle, method of repair and repair kit.
Commercial aircraft, in general, while on the ground, are powered by ground power units that connect to the aircraft through a flexible rubber plug that is either molded to the power cable or manually attached to the same cable. The rubber plug is then attached to a ground power receptacle located in an accessible location on the aircraft fuselage. In the standard connection type, the receptacle has protruding pins that are received in sockets on the plug. The receptacle is also mounted through the fuselage of the aircraft in a manner that maintains the pressure seal for the aircraft. Repair or replacement of a conventional receptacle thus typically requires breaking and then resealing the pressure seal around the receptacle.
Embodiments disclosed herein include a modular, repairable, aircraft ground power receptacle, which comprises receptacle base member, plural pin bases, plural connection pins and a pin cover plate. The receptacle base member has an inner side and an outer side. The plural pin bases extend at least in part through the receptacle base member, each with an electrical connector extending from the inner side and a socket opening extending to the outer side. The plural connection pins are each associated with a pin base, and the connection pins have an attachment end configured and dimensioned to be received in and mate with the socket of its associated pin base to form an electrical connection there between. The connection pins also have prong ends configured and dimensioned to mate with a ground power plug. The connection pins are removable from the pin bases without disconnecting internal aircraft power cables attached to the electrical connectors of the pin bases and without breaking the pressure seal between the receptacle and surrounding fuselage. The pin cover plate defines plural pin openings, with each opening corresponding in size and position to one of the connection pins. The pin cover plate is attachable to the base member outer side with the connection pins extending there through.
In another embodiment, a method of repairing an aircraft ground power receptacle with said receptacle mounted to an aircraft, includes removing a pin cover plate from an outer side of the receptacle, removing at least one connection pin from an associated socket of a pin base mounted in the receptacle, inserting a new connection pin into the associated socket in place of the removed connection pin, and replacing the pin retaining plate on the outer side of the receptacle and over the new connection pin. With such a method, the pin bases, which are connected to aircraft power cables within the aircraft, need not be disconnected to accomplish the removing and inserting of the connection pins.
Other disclosed embodiments include a repair kit for an aircraft ground power receptacle, in which the repair kit contains at least one replacement pin having a pin prong end configured and dimensioned to be received through an opening in a pin cover plate of the receptacle and to mate with an aircraft ground power plug. The replacement pin also has a pin attachment end configured and dimensioned to be received in, mate with and form an electrical connection with a socket of a pin base mounted in the receptacle.
For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:
Embodiments described herein relate to receptacles mounted on aircraft to receive ground power from a ground power unit via a standard ground power cable and plug. Dimensions and connection force for aircraft ground power connectors have been standardized under various specifications depending on aircraft type and power requirements. Examples of such specifications include Military Specification MS25486H for “Connector, Plug, Attachable, External Electric Power, Aircraft, 115/200 Volt, 400 Hertz” and SAE Aerospace Standard AS21378 for “Plugs and Cable Assemblies, External Power, Aircraft, 230-400 Volt, 400 Hertz,” each of which is incorporated by reference herein.
Depending on the type of plug used with the ground power unit, it can be heavy and somewhat unwieldy when attached to the fairly large and stiff power cable. Some plugs may weigh in the range of 15 pounds and be over a foot long. Further, a relatively high force can be required to properly seat the plug in the receptacle. These factors can lead to damage of both the ground power cable/plug and/or receptacles. If a cable or plug is damaged, it can be readily swapped out for a new cable/plug without significant delay. The damaged cable or plug can later be repaired or replaced without immediate effect on ground operations of the aircraft. However, if the receptacle is damaged, because it is generally integrated into both the aircraft fuselage, forming part of the pressure seal of the aircraft, and the aircraft power system, replacement or repair can require significant time because the receptacle typically must be removed, including work in the avionics bay disconnecting aircraft power cables from the receptacle and breaking the pressure seal, and then reattaching the cables and plugs and reconfirming the pressure seal, all of which must be done in careful, quality controlled manner. Such a process can significantly impact ground operations. Embodiments described herein provide a receptacle that can be easily repaired with minimum of tools and without requiring disconnection from internal aircraft power cables or removal of the receptacle from the aircraft.
Referring to
Base 22 may be formed of a hard molded, non-conductive rubber or plastic with suitable insulating properties. In one alternative, pin bases 30, 32 and captive base fasteners 34 may be properly positioned in a mold and then the mold filed with the material for base 22. In this manner, the components are securely captured in the insulating material of the base. If desired, captive nuts 38 also may be molded into base 22 to provide threads to receive fasteners 36. While molding in this manner provides a convenient and efficient way to produce base 22 with captured components as described, embodiments described herein may be produced by other means and the description is not limited to a particular method of manufacture.
In some embodiments, the pin assembly for power pins and relay pins may have substantially the same configuration with the primary difference being only relative size. One example of such a configuration is shown in
Pin bases 30, 32 may include socket body 48, which defines socket 50. The outer surface of socket body 48 may be formed with a roughened surface 52 (such as a knurled surface) and necked portion 54, features which may help to secure the pin bases in the molded base 22. For example, the roughened surface may help resist rotational forces and the necked portion may help to resist longitudinally applied forces such as when pins are pushed in or pulled out. Extending from socket body 48, opposite socket 50, connector 56 is configured to extend out of the inner side of base 22 and provide for connection to aircraft internal electrical cables. In the illustrated example, connector 56 is shown with threads to receive a threaded clamp type connector element. Other suitable electrical connection types also may be employed as connector 56. Captive base fasteners 34 also may be provided with features to help secure them in a molded base 22, including, for example, body 60 with a knurled surface (for example like knurled surface 52) and necked portion 62. Threaded ends 58 are positioned to extend out of base 22 on the inner and outer sides.
An alternative pin assembly 16a is illustrated in
When receptacles are damaged in service, the most common component damaged are the extending prongs of the pins that are received in the plug sockets. Referring again to
As indicated above, one advantage of embodiments disclosed herein is the ability to repair or replace pins of the receptacle without disturbing the pressure seal of the aircraft. Ordinarily with a typical, conventional receptacle, maintenance people would have to go inside the avionics bay of the aircraft, disconnect the cable between the aircraft bus and the receptacle, and then break the pressure seal and remove and replace the conventional receptacle. In contrast, receptacle embodiments described herein can be serviced entirely from outside the aircraft and do not require entrance into the avionics bay to effect repair or replacement of pins as described above.
As will be appreciated, the replacement procedure is modified appropriately to accommodate screw threaded attachment ends 42a when alternative pin assembly 16a is used with alternative pin cover plate 14a as shown in
For aircraft utilizing modular, repairable ground power receptacles as described herein, receptacle repair kits may be provided. Such a receptacle repair kit may include, at a minimum, replacement pins 39, but also may include replacement pin cover plates 14, cover plate fasteners 36 and, optionally, an appropriate tool for driving fasteners 36. When alternative pin assembly 16a is used with alternative cover plate 14a, an additional tool configured to engage collar 46a also may be included in the kit.
The foregoing has been a detailed description of illustrative embodiments of the invention. It is noted that in the present specification and claims appended hereto, conjunctive language such as is used in the phrases “at least one of X, Y and Z” and “one or more of X, Y, and Z,” unless specifically stated or indicated otherwise, shall be taken to mean that each item in the conjunctive list can be present in any number exclusive of every other item in the list or in any number in combination with any or all other item(s) in the conjunctive list, each of which may also be present in any number. Applying this general rule, the conjunctive phrases in the foregoing examples in which the conjunctive list consists of X, Y, and Z shall each encompass: one or more of X; one or more of Y; one or more of Z; one or more of X and one or more of Y; one or more of Y and one or more of Z; one or more of X and one or more of Z; and one or more of X, one or more of Y and one or more of Z.
Various modifications and additions can be made without departing from the spirit and scope of this invention. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments. Furthermore, while the foregoing describes a number of separate embodiments, what has been described herein is merely illustrative of the application of the principles of the present invention. Additionally, although particular methods herein may be illustrated and/or described as being performed in a specific order, the ordering is highly variable within ordinary skill to achieve aspects of the present disclosure. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.
Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.
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