Wire support member for an environmental control system

A wire support member for an environmental control system includes a bracket having an inner surface, an outer surface, and a thickness. A first arm projects from the bracket, a first flange projects from a first end of the first arm. The first flange includes a first harness support opening therethrough. A second arm also projects from the bracket parallel to the first arm, and a second flange projects from a second end of the second arm. The second flange has a second harness support opening therethrough. A ratio of a diameter of the first harness support opening and of the second harness support opening to the thickness of the bracket optimizes the routing and support for the wiring.

BACKGROUND

The present disclosure relates to aircraft environmental control systems (ECS), and more specifically to mounting systems for components of an ECS. An ECS utilizes cabin air compressors to condition air for delivery to an aircraft cabin. The pressure and temperature of the aircraft cabin must be maintained throughout a wide variety of flight conditions. A pack control unit (PCU) communicates with and receives feedback from cabin air compressor modules to ensure that the temperature and pressure of the aircraft cabin remains at sufficient levels. The PCU communicates with the cabin air compressor modules through wiring that is routed from the PCU to each module. The wiring must be routed and supported such that the wiring will not interfere with other parts of the ECS and will not wear through.

SUMMARY

According to an embodiment of the present invention, a wire support member for an environmental control system includes a bracket having an inner surface, an outer surface, and a thickness T1, a first arm projecting from the bracket, a first flange projecting from a first end of the first arm, the first flange having a first harness support opening therethrough, the first harness support opening having a diameter D1, a second arm projecting from the bracket and oriented in a plane with the first arm, and a second flange projecting from a second end of the second arm, the second flange having a second harness support opening therethrough, the second harness support opening having a diameter D2.

According to another embodiment of the present invention, a wire support assembly for an environmental control system includes a wiring for the environmental control system having a first wire bundle extending from a pack control unit and branching into a second wire bundle and a third wire bundle, the second wire bundle extending from the first wire bundle to an outboard module, and the third wire bundle extending from the first wire bundle to an inboard module, a first wire support member mounted to a first backbone support structure, the first wire support member supporting the first wire bundle, the second wire bundle, and the third wire bundle, the first wire support member including a bracket having an inner surface, an outer surface, and a thickness T1, a first arm projecting from the bracket, a first flange projecting from a first free end of the first arm, the first flange having a first harness support opening therethrough, the first harness support opening having a diameter D1, a second arm projecting from the bracket and oriented in a plane with the first arm, and a second flange projecting from a second end of the second arm, the second flange having a second harness support opening therethrough, the second harness support opening having a diameter D2, a second wire support member mounted to an outboard support structure of the outboard module, the second wire support member supporting the second wire bundle between the first wire support member and the outboard module, and a third wire support member mounted to a first compressor casing of the inboard module, the third wire support member supporting the third wire bundle between the first wire support member and the inboard module.

DETAILED DESCRIPTION

FIG. 1is a perspective view of a wire harness support system for an aircraft environmental control system (ECS)10. ECS10includes pack control unit12(PCU), inboard module14, and outboard module16. Inboard module14includes inboard cabin air compressor18and module support structure20. Outboard module16includes outboard cabin air compressor22and module support structure24. ECS10also includes wiring26extending from PCU12to inboard module14and outboard module16. Wiring26includes first wire harness28, second wire harness30, and third wire harness32. Wiring26is supported by first wire support member34, second wire support member36, and third wire support member38. ECS10further includes backbone support structure39for supporting ECS10and various other modules of ECS10.

First wire harness28is connected to PCU and supported by first wire support member34. First wire harness28splits to form second wire harness30and third wire harness32. Both second wire harness30and third wire harness32are supported by first wire support member34. Second wire harness30is connected to, and extends from, first wire harness28, and second wire harness30is also connected to outboard module16. As second wire harness30proceeds from first wire support member34to outboard module16, second wire harness30is supported by second wire support member36. First wire support member34is mounted to backbone support structure39and optimizes the routing of first wire harness28, second wire harness30, and third wire harness32. Second wire support member36is mounted to module support structure24and optimizes the routing of second wire harness30. Third wire support member38is mounted to a housing of inboard module14and optimizes the routing of third wire harness32.

Similar to second wire harness30, third wire harness32is connected to and extends from first wire harness28. Third wire harness32extends from first wire harness28to inboard module14. Third wire harness32is supported by third wire support member38as third wire harness32proceeds from first wire support member34to inboard module14. As third wire harness32proceeds along third wire support member38, third wire harness32splits to include a main bundle and a secondary bundle. Both the main bundle and the secondary bundle are supported by and routed by third wire support member38.

First wire support member34is mounted to a backbone support structure39. Fasteners extend through fastener openings (best seen inFIG. 2) of first wire support member34and into the backbone support structure39to secure first wire support member34. First wire support member34supports first wire harness28. First wire support member34also supports second wire harness30and third wire harness32after second wire harness30and third wire harness32split from first wire harness28. First wire support member34optimizes the routing of first wire harness28to PCU12. First wire support member34also optimizes the routing of second wire harness30from first wire harness28to second wire support member36, and of third wire harness32from first wire harness28to third wire support member38, which prevents second wire harness30and third wire harness32from becoming entangled. Optimizing the routing of first wire harness28, second wire harness30, and third wire harness32also prevents inadvertent contact with various components of ECS10that may have an effect on the operation of the wire harnesses.

FIG. 2is a perspective view of first wire support member34. First wire support member34includes inner surface40, outer surface42, thickness T1, first arm44, and second arm46. First wire support member34further includes aperture48, first fastener opening50, second fastener opening52, third fastener opening54and fourth fastener opening56. First arm44includes first flange58projecting from a first end of first arm44. First arm44further includes fifth fastener opening60and sixth fastener opening62. First flange58includes wire harness support64a, fastener openings66, first free end68, first outer edge70, first inner edge72, first flange inner surface74, and first flange outer surface76. Wire harness support64aincludes diameter D1and center C1. Second arm46includes second flange78projecting from a first end of second arm46. Second flange78includes wire harness support64b, fastener openings80, second free end82, second outer edge84, second inner edge86, second flange inner surface88, and second flange outer surface90. Wire harness support64bincludes diameter D2and center C2. Notch92is formed between first arm44and second arm46. First wire support member34also includes clamp94projecting from inner surface40at an end of first wire support member34opposite first arm44and second arm46.

First wire harness28proceeds from PCU12to first wire support member34. First wire support member34supports first wire harness28and routs first wire harness28to ensure that first wire harness28does not experience excessive wear due to contact with various components of ECS10. After first wire harness28is secured by first wire support member34, first wire harness28splits to form second wire harness30and third wire harness32. Second wire harness30passes through and is supported by wire harness support64abetween first wire harness28and second wire support member36(best seen inFIG. 1). Similarly, third wire harness32passes through and is supported by wire harness support64bbetween first wire harness28and third wire support member38(best seen inFIG. 1).

First wire support member34is secured to backbone support structure39by fasteners extending through first fastener opening50, second fastener opening52, third fastener opening54, fifth fastener opening60, and sixth fastener opening62. First arm44and wire harness support64aguide second wire harness30and prevent second wire harness30from becoming entangled with third wire harness32between first wire harness28and third wire support member38. Similarly, second arm46and wire harness support64bguide third wire harness32and prevent third wire harness32from becoming entangled with second wire harness30between first wire harness28and second wire support member36.

First wire support member34is made from a lightweight material to reduce the weight impact on the aircraft caused by first wire support member34, the lightweight material being sufficiently rigid to support the wiring throughout the flight envelope of the aircraft. First wire support member34may be coated or uncoated. In the present embodiment, first wire support member34is made from aluminum or an aluminum alloy. It is understood, however, that first wire support member34may be made of any suitable material for supporting and routing the wiring throughout the flight envelope of the aircraft without having a significant weight impact on the aircraft, such as titanium, titanium alloys, or carbon fiber.

Clamp94is secured to inner surface42by a fastener extending through fourth fastener opening56and engaging clamp94. While first wire support member34is described as including clamp94, it is understood that any suitable retaining mechanism for routing and retaining first wire harness28may be utilized. Clamp94may also include a cushion, such as a cushion made from an elastomer material, disposed between clamp94and first wire bundle28to prevent clamp94from having an effect on the operation of first wire harness28.

Aperture48through first wire support member34reduces the weight of first wire support member34. While aperture48is shown as an egg-shaped opening, it is understood that aperture48may take any suitable shape for enhancing the weight reduction of first wire support member34without reducing the structural integrity of first wire support member34. For example, aperture48may be circular, square, polygonal, or may take any other suitable shape.

FIG. 3Ais a front elevation view of first wire support member34.FIG. 3Bis a side elevation view of first wire support member34.FIG. 3Cis a bottom plan view of first wire support member34.FIGS. 3A-3Cwill be discussed together. First wire support member34includes inner surface40, outer surface42, thickness T1, first arm44, and second arm46. First wire support member34further includes aperture48, first fastener opening50, second fastener opening52, third fastener opening54and fourth fastener opening56. First arm44includes first flange58projecting from a first end of first arm44. First arm44further includes fifth fastener opening60and sixth fastener opening62. First flange58includes wire harness support64a, fastener openings66, first free end68, first outer edge70, first inner edge72, first flange inner surface74, and first flange outer surface76. Second arm46includes second flange78projecting from a first end of second arm46. Second flange78includes wire harness support64b, fastener openings80, second free end82, second outer edge84, second inner edge86, second flange inner surface88, and second flange outer surface90. Notch92is formed between first arm44and second arm46. First wire support member34also includes clamp94projecting from inner surface40at an end of first wire support member34opposite first arm44and second arm46.

Referring specifically toFIG. 3A, length L1is a distance between first free end68and center C1. Similarly, length L2is a distance between second free end82and center C2. Length L3is a distance between first outer edge70and center C1. Length L4is a distance between second outer edge84and center C2.

Referring specifically toFIG. 3C, Length L6is a distance between center C3and second flange inner surface86. L7is a distance between center C3and an apex of notch92. Second fastener opening52, third fastener opening54, fifth fastener opening60, and sixth fastener opening62may be located with reference to first fastener opening50. Length L5is a distance between center C3and first flange inner surface74. Length L8is a horizontal distance between C3and C4, and length L9is a vertical distance between C3and C4. Thus, second fastener opening52is horizontally displaced length L6from first fastener opening50and is vertically displaced length L9from first fastener opening50. Length L10is a horizontal distance between C3and C5, and length L11is a vertical distance between C3and C5. Length L12is a horizontal distance between C3and C7, and length L9is a vertical distance from C3to C7. As length L9is the vertical distance from center C3to center C7and from center C3to center C4in the present embodiment, both second fastener opening52and fifth fastener opening60are located on the same vertical plane. Length L13is a horizontal distance from center C3and center C8. In the present embodiment first fastener opening50and sixth fastener opening62lie in the same plane.

Similarly length L14is a distance between center C3and a vertical edge of first wire support member34. Length L15is a distance between center C3and a horizontal edge of first wire support member34. Length L16is a distance between center C6and the vertical edge of first wire support member34, and length L17is a distance between center C6and the horizontal edge of first wire support member34.

In the present embodiment, length L1is about 0.750 inches (1.905 centimeters). Length L2is also about 0.750 inches (1.905 centimeters). Length L3is about 0.750 inches (1.905 centimeters). Length L4is also about 0.750 inches (1.905 centimeters). Length L5is about 4.030 inches (10.236 centimeters). Length L6is about 2.505 inches (6.363 centimeters). Length L7is about 1.588 inches (4.034 centimeters). Length L8is about 1.150 inches (2.921 centimeters). Length L9is about 0.960 inches (2.438 centimeters). Length L10is about 2.510 inches (6.375 centimeters). Length L11is about 0.800 inches (2.032 centimeters). Length L12is about 3.870 inches (9.830 centimeters). Length L13is about 5.020 inches (12.751 centimeters). Length L14is about 1.025 inches (2.604 centimeters). Length L15is about 5.140 inches (13.056 centimeters). Length L16is about 1.450 inches (3.683 centimeters). Length L17is about 0.500 inches (1.270 centimeters). While lengths have been described, it is understood that the lengths may vary within acceptable engineering tolerances, plus or minus 0.060 inches (0.152 centimeters) for example. Additionally, it is to be understood that the relationships between the various lengths are within the scope of the present invention. For example, first wire support member34may be scaled to twice the preferred size and a ratio of L8to L9would remain at about 1.2.

The ratio of diameter D1to thickness T1, and the ratio of diameter D2to thickness T1ensure that first wire support member34has adequate structural integrity to support first wire harness28, second wire harness30, and third wire harness32. The ratios are also configured such that first wire support member34routes second wire harness30to second wire support member36and third wire harness32to third wire support member38in such a way that both second wire harness30and third wire harness32do not become entangled and avoid various components of ECS10that may have an adverse effect on either second wire harness30or third wire harness32. Similarly, the ratio of diameter D1or D2to thickness T1ensures adequate routing and support for first wire harness28to PCU12. Furthermore, while first wire support member34has sufficient structural integrity, the ratios also ensure that first wire support member34is sufficiently lightweight that first wire support member34does not have an adverse weight impact on the aircraft.

First wire support member34is mounted to backbone support structure39(shown inFIG. 1). Backbone support structure39locates first wire support structure34near a centerline of the ECS10. This location reduces the amount of strain imparted on first wire support member34by wiring26by reducing the total length of wiring26needed to allow PCU12to communicate with inboard module14and outboard module16. This also allows first wire support member34to remain lightweight as first wire support member34does not have to carry as heavy of a load.

First wire support member34must be able to support the weight of first wire harness28, second wire harness30, and third wire harness32throughout the envelope of flight conditions experienced by the aircraft. First wire support member28must also maintain the routing of first wire harness28to ensure that constant communication from and to PCU12is maintained. First wire support member36retains first wire harness28in a floating position away from other components of environmental control system10to prevent first wire harness28from rubbing against or interfering with the other components of environmental control system10. Additionally, first wire support member28must maintain the routing of second wire harness30between first wire harness28and second wire support member36and of third wire harness32between first wire harness28and third wire support member38in such a way that second wire harness32and third wire harness34do not interfere with each other. The ratio of thickness T1to diameter D1and to diameter D2ensures that first wire harness28, second wire harness30, and third wire harness32are maintained in positions that ensure the integrity of the wiring system. The ratio of thickness T1to diameter D1and diameter D2also ensures that first wire support member34is sufficiently lightweight and compact, while also maintaining sufficient structural integrity to allow first wire support member34to support first wire harness28, second wire harness30, and third wire harness32.

Discussion of Possible Embodiments

A wire support member for an environmental control system, the wire support member including a bracket having an inner surface, an outer surface, and a thickness T1, a first arm projecting from the bracket, a first flange projecting from a first end of the first arm, the first flange having a first harness support opening therethrough, the first harness support opening having a diameter D1, a second arm projecting from the bracket and oriented in a plane with the first arm, and a second flange projecting from a second end of the second arm, the second flange having a second harness support opening therethrough, the second harness support opening having a diameter D2.

The wire support member of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:

A further embodiment of the foregoing wire support member, wherein a ratio of D1to T1is between 9.0 and 10.5.

A further embodiment of any of the foregoing wire support members, wherein a ratio of D2to T1is between 9.0 and 10.5.

A further embodiment of any of the foregoing wire support members, wherein T1is between 0.119 inches (0.302 centimeters) and 0.131 inches (0.333 centimeters).

A further embodiment of any of the foregoing wire support members, wherein a length of the first arm is greater than a length of the second arm.

A further embodiment of any of the foregoing wire support members, wherein D1is between 1.209 inches (3.070 centimeters) and 1.229 inches (3.122 centimeters) and D2is between 1.209 inches (3.070 centimeters) and 1.229 inches (3.122 centimeters).

A further embodiment of any of the foregoing wire support members, wherein a weight reduction aperture extends through the bracket from the inner surface to the outer surface.

A wire support assembly for an environmental control system, the wire support assembly including a wiring for the environmental control system including a first wire bundle extending from a pack control unit and branching into a second wire bundle and a third wire bundle, the second wire bundle extending from the first wire bundle to an outboard module, and the third wire bundle extending from the first wire bundle to an inboard module, a first wire support member mounted to a first backbone support structure, the first wire support member supporting the first wire bundle, the second wire bundle, and the third wire bundle, the first wire support member including a bracket having an inner surface, an outer surface, and a thickness T1, a first arm projecting from the bracket, a first flange projecting from a first free end of the first arm, the first flange having a first harness support opening therethrough, the first harness support opening having a diameter D1, a second arm projecting from the bracket and oriented in a plane with the first arm, and a second flange projecting from a second end of the second arm, the second flange having a second harness support opening therethrough, the second harness support opening having a diameter D2, a second wire support member mounted to an outboard support structure of the outboard module, the second wire support member supporting the second wire bundle between the first wire support member and the outboard module, and a third wire support member mounted to a first compressor casing of the inboard module, the third wire support member supporting the third wire bundle between the first wire support member and the inboard module.

A further embodiment of the foregoing wire support assembly, wherein a ratio of D1to T1is between 9.0 and 10.5.

A further embodiment of any of the foregoing wire support assemblies, wherein a ratio of D2to T1is between 9.0 and 10.5.

A further embodiment of any of the foregoing wire support assemblies, wherein T1is between 0.119 inches (0.302 centimeters) and 0.131 inches (0.333 centimeters).

A further embodiment of any of the foregoing wire support assemblies, wherein a length of the first arm is greater than a length of the second arm.

A further embodiment of any of the foregoing wire support assemblies, wherein D1is between 1.209 inches (3.070 centimeters) and 1.229 inches (3.122 centimeters) and D2is between 1.209 inches (3.070 centimeters) and 1.229 inches (3.122 centimeters).

A further embodiment of any of the foregoing wire support assemblies, wherein a clamp is mounted to the inner surface of the bracket and the first wire harness is supported by the clamp.

A further embodiment of any of the foregoing wire support assemblies, wherein the clamp includes an elastomer cushion secured between the clamp and the second wire bundle.