Patent Description:
Aircraft wiring systems generally include a collection of different types of wires. Currently, the wires are placed in prefabricated wire bundles that are terminated into individual connectors. For some applications where the wire routes longitudinally fore/aft in the aircraft, the bundles are then installed on the racetracks. Such fabrication and installation can include many manual processes that can introduce human error, lead to quality issues, increase fabrication costs, and decrease fabrication throughput. Additionally, the connectors used in current racetrack fabrication can result in poor ergonomic working conditions within confined spaces when the racetrack is installed into the aircraft and the interfacing connectors are mated.

Furthermore, current techniques of fabricating wiring racetracks require bespoke instructions for different aircraft models. Such current techniques are not scalable and, accordingly, require reconfiguration for aircrafts of different sizes. Document <CIT> states in its abstract a cable raceway assembly having channel sections with protrusions and clamp insertable with recesses engageable with the protrusions providing a snap-fit ratchet-type engagement. Document <CIT> states in its abstract a cable duct for a vehicle, comprising a cable duct housing, which forms a receiving space for a plurality of substantially flexible conductors. At least one rail receptacle for guiding and / or holding at least one essentially dimensionally stable flat conductor rail is formed in or on the cable duct housing. The disclosure also states a line arrangement with such a cable duct. Document <CIT> states in its abstract a means for improving the electronic and electromagnetic isolation characteristics of compartments within cable trunking systems. In general, cable trunking is provided in sections having covers which enclose cables disposed in the trunking, and more specifically compartments thereof. The compartments are defined by one or more walls extending upwardly from a base section to which one or more covers is attached one or more covers, said base section having a base to complete the compartment so that cables can be safely contained therein. In general, data cables carrying low voltage signals are prone to electromagnetic interference from power cables, and these two types of cable are commonly disposed in separate compartments within the trunking. To improve the isolation of one compartment from the other, the invention proposes that a metallic plate is disposed adjacent the walls to provide a shielding effect for said data cables, at least a portion of said metallic plate being deformed out of the plane of said plate to provide a contact with which an electrical connection can be made to permit that plate to be electrically connected to an adjacent metallic plate having a similar contact and similarly disposed adjacent one of the walls. In a most preferred embodiment, the walls are provided at their free end with a flange having a depending skirt to define an upper channel, and a rib is provided on the base adjacent the wall where it joins the base to provide a lower channel so that the metallic plates in the form of strips can be slid along and retained within the channels to facilitate compartment isolation quickly and simply.

The present invention relates to an aircraft according to claim <NUM> and to a method according to claim <NUM>.

A more complete understanding of the disclosure will be afforded to those skilled in the art, as well as a realization of additional advantages thereof, by a consideration of the following detailed description of one or more implementations. Reference will be made to the appended sheets of drawings that will first be described briefly.

Examples of the disclosure and their advantages are best understood by referring to the detailed description that follows.

Various examples of aircraft wiring racetracks (raceway arrangements) are described herein. The wiring racetrack includes a first wire group, a second wire group, and a wiring pallet. The first wire group includes wires of exclusively a first category. The second wire group includes wires of exclusively a second category distinct from the first category. The wiring pallet includes a first track and a second track. The first wire group is contained exclusively within the first track. The second wire group is contained exclusively within the second track. A first connector is electrically coupled to each of the wires of the first wire group and a second connector is electrically coupled to each of the wires of the second wire group.

The systems and techniques described herein allow for modular electrical systems to be incorporated into an aircraft. Additionally, the systems and techniques allow for automated manufacturing of the electrical racetracks. As such, recurring electrical fabrication and installation costs can be reduced. Additionally, electrical racetracks can be improved in quality, maintainability, organization, space efficiency, and reliability. Furthermore, the modular nature of the systems can allow for reduced engineering costs and increase the ease of design.

<FIG> illustrates an aircraft in accordance with an example of the disclosure. The aircraft <NUM> of <FIG> can include fuselage <NUM>, wings <NUM>, horizontal stabilizers <NUM>, aircraft engines <NUM>, and vertical stabilizer <NUM>. Additionally, aircraft <NUM> can include cockpit electronics <NUM>, controller <NUM>, and wiring <NUM>.

Aircraft <NUM> described in <FIG> is exemplary and it is appreciated that in other examples, aircraft <NUM> can include more or less components or include alternate configurations. Additionally, concepts described herein can be extended to other aircraft such as helicopters, drones, missiles, etc..

Cockpit electronics <NUM> can be electronics for control or operation of various systems of the aircraft <NUM>. Cockpit electronics <NUM> can be disposed within the cockpit of the aircraft <NUM>. Cockpit electronics <NUM> can be electrically coupled (e.g., coupled so that electrical current can be communicated) to one or more other systems of the aircraft <NUM> through wiring <NUM>. Wiring <NUM> can be a wiring system that includes electrical wires disposed within one or more wiring racetracks. Wiring <NUM> can include subsystems that are electrically coupled with various connectors.

Wiring <NUM> can, thus, couple the cockpit electronics <NUM> to systems such as controller <NUM>, aircraft engines <NUM>, and various cabin systems, flight control systems, communications systems, and other systems. Additionally, wiring <NUM> can also electrically couple other electrical systems of the aircraft <NUM>, additional or alternative to the cockpit electronics <NUM>.

Controller <NUM> and cockpit electronics <NUM> can include, for example, a microprocessor, a microcontroller, a signal processing device, a memory storage device, and/or any additional devices to perform any of the various operations described herein. In various examples, controller <NUM> and/or its associated operations can be implemented as a single device or multiple connected devices (e.g., communicatively linked through wired or wireless connections such as wiring <NUM>).

Thus, cockpit electronics <NUM> and controller <NUM> can include one or more memory components or devices to store data and information. The memory can include volatile and nonvolatile memory. Examples of such memory include RAM (Random Access Memory), ROM (Read-Only Memory), EEPROM (Electrically-Erasable Read-Only Memory), flash memory, or other types of memory. In certain examples, cockpit electronics <NUM> and controller <NUM> can be adapted to execute instructions stored within the memory to perform various methods and processes described herein, including implementation and execution of control algorithms responsive to sensor and/or operator (e.g., flight crew) inputs.

Wings <NUM>, horizontal stabilizers <NUM>, and vertical stabilizers <NUM>, as well as inlets of aircraft engines <NUM> and portions of the fuselage <NUM> can be referred to herein as aerodynamic surfaces. Aerodynamic surfaces can be surfaces that generate lift, downforce, and/or otherwise affect the stability or flight of the aircraft <NUM>.

<FIG> illustrates a prior art wiring racetrack. <FIG> is a cross-sectional view of wiring racetrack <NUM>. Wiring racetrack <NUM> is an example of a conventional wiring racetrack installed on an aircraft.

Wiring racetrack <NUM> includes a raceway <NUM> with wiring bundles 204A-I coupled to wiring raceway <NUM>. Wiring bundles 204A-I can be pre-fabricated wiring bundles that each include one or more wires.

The Federal Aviation Administration (FAA), as well as other regulatory bodies, specifies different categories of wires depending on systems that the wires are associated with, their gauge, the amount of current carried, and/or due to other factors. One or more of wiring bundles 204A-I can contain a plurality of different types of wires of different categories. As such, one or more wiring bundles 204A-I can include mixed categories of wires. Furthermore, the wires of the same or a similar category can be dispersed across many different locations on wiring raceway <NUM>. Thus, design, fabrication, and maintenance of the wiring racetrack <NUM> can require a significant amount of time and manpower.

Thus, each wire of wiring bundles 204A-I is assigned a unique category based on separation and redundancy requirements (e.g., as dictated by a certification authority). For example, a wire of one category one can be assigned to control a specific aerodynamic surface on the wing. Based on this categorization, that wire should be separated from other wires that control, for example, the lights, sensors, different control surfaces, or other parts of the aircraft. Wires associated with different systems of the aircraft are thus divided into separate routing paths (groups or categories) based on certification requirements for separation and/or redundancy purposes.

<FIG> illustrates a wiring pallet in accordance with an example of the disclosure. <FIG> illustrates a wiring pallet <NUM> with tracks 306A-G. Each of tracks 306A-G can be configured to each contain a limited number of categories of wires (e.g., one or two different categories of wires). One or more of tracks 306A-G can be different sizes depending on the number and volume of wiring for each wiring category.

While <FIG> illustrates wiring pallet <NUM> with open channels, one, more than one, or all sections of other examples of wiring pallet <NUM> can include closed channels. Wiring pallet <NUM> can be divided into one or more sections. The sections can be combined to constitute wiring pallet <NUM>.

<FIG> illustrates a wiring racetrack in accordance with an example of the disclosure. <FIG> illustrates wiring racetrack <NUM> with wiring pallet <NUM> and wiring groups 308A-G. Each of wiring groups 308A-G can be accordingly disposed within tracks 306A-G of wiring pallet <NUM>. Thus, wiring group 308A can be disposed without track 306A while wiring group 308B can be disposed within track 306B.

Wiring groups 308A-G can be groups with certain specific categories of wires. Thus, for example, wiring group 308A can be a group of NN1/<NUM> wires. Wiring group 308B can be a group of RM1/<NUM> wires. Wiring group 308C can be a group of FC2 wires. Wiring group 308D can be a group of SL1/<NUM> wires. Wiring group 308E can be a group of PR1 wires. Wiring group 308F can be a group of SR2 wires. Wiring group <NUM> can be a group of LM2 wires. Such wiring categories can be in accordance with FAA specified categories (e.g., separation codes, redundancy, electromagnetic effects, etc.) or other categorization types.

In certain examples, the wiring groups 308A-G can have more than one category of wires by, for example, additionally including neutral wires (e.g., ground wires, intrinsically safe wiring, etc.) within the group that do not belong to any specific category. Nonetheless, it is appreciated that the wires of a specific category can be exclusively organized into a wiring group. Such a configuration can simplify installation of wires into any associated connectors (e.g., as only one type of wiring is in a group, the connector insert cavity utilization can be optimized).

As shown in <FIG>, the different wiring groups can be different sizes and contain different numbers of wires. Thus, for example, wiring group 308A can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inches) in diameter. Wiring group 308B can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inches) in diameter. Wiring group 308C can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inches) in diameter. Wiring group 308D can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inch) in diameter. Wiring group 308E can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inches) in diameter. Wiring group 308F can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inches) in diameter. Wiring group <NUM> can include <NUM>-<NUM> wires and be a bundle approximately <NUM> to <NUM> (<NUM> to <NUM> inches) in diameter.

The various wires of the wiring groups can be electrically coupled (e.g., can pass electrical current and/or signals to and receive such current and/or signals from) to one or more connectors. Thus, for example, wiring groups 308A-G can be coupled to connectors 310A-G, respectively, on a first end of the wires and coupled to connectors 314A-G, respectively, on a second end of the wires. Certain examples can electrically couple all the wires of a single wiring group to a single connector, but other examples can electrically couple the wires of a single wiring group to a plurality of connectors to, for example, interface with a plurality of systems.

Connectors 310A-G can be connectors disposed along one or more lateral sides (e.g., as compared to the directions that the wires run) of wiring pallet <NUM>. Connectors 310A-G can be configured to be connected to one or more wiring systems of an aircraft. Disposing connectors 310A-G along the lateral sides of wiring pallet <NUM> can allow for simplified electrical connections to electrical systems of the aircraft disposed to the lateral sides of the wiring pallet <NUM>. Wiring groups 308A-G can be connected to respective connectors 310A-G via wiring 312A-G, respectively.

In certain examples, connectors 310A-G can be integrated along the sides of wiring pallet <NUM> to allow for a solid connection. Other examples can allow for connectors 310A-G to be relatively loose (e.g., can be moved relative to wiring pallet <NUM>).

Connectors 314A-G can be connectors disposed within or at the end of tracks 306A-G, respectively. Connectors 314A-G can, thus, electrically couple with other connectors in a longitudinal direction. As such, connectors 314A-G can, for example, allow for electrical coupling to another wiring racetrack or other electrical systems. Longitudinal connectors can also allow for easy extension of the lengths of wiring racetrack <NUM>, allowing for a modular system where longer wiring racetracks can be created (e.g., for longer aircraft) through a combination of multiple racetracks. Through a combination of longitudinal and lateral connectors, wiring racetrack <NUM> can be connected to various other electrical systems of the aircraft and/or other wiring racetracks to form a modular electrical system.

<FIG> illustrates a racetrack wiring system in accordance with an example of the disclosure. <FIG> illustrates wiring racetrack <NUM> electrically coupled to connector panel <NUM> (for example panel 500A in <FIG>)A.

Connector panel <NUM> can include one or more receiver connectors (i.e., mating connectors), such as receiver connectors 510A-C, configured to mate to connectors of the wiring groups. Each receiver connector can include features (e.g., geometric features, dimensions, lead-ins, and other features) that allow for the receiver connector to only connect with a specific connector of the wiring group. Accordingly, the connectors (e.g., connectors 310A-C) of the wiring groups (e.g., of wiring groups 308A-C) can be connected to receiver connectors (e.g., receiver connectors 510A-C) of connector panel <NUM>.

Each of the receiver connectors 510A-C can, in certain examples, be configured to receive only wires of a specific category of only wires of such a category as well as any neutral or intrinsically safe wires. Thus, fabrication of the connector panel <NUM> (e.g., connection of wires to the connector) can be simplified by having only one category of wire be connected to a multiple contact connector.

As shown in <FIG>, connector panel <NUM> is disposed lateral to wiring racetrack <NUM>. Other examples can dispose connector panels longitudinally to the wiring racetrack or in other configurations. Connector panel <NUM> can allow for all wires of a wiring group of the wiring racetrack <NUM> to be easily coupled to a corresponding receiver connector, decreasing installation time. Furthermore, positioning connector panel <NUM> lateral to wiring racetrack <NUM> can allow for more direct electrical connections to systems disposed to the side of wiring racetrack <NUM>. Certain such systems are shown in <FIG>.

<FIG> illustrates an aircraft with a racetrack wiring system in accordance with an example of the disclosure. <FIG> illustrates aircraft <NUM> with wiring racetracks 300A and 300B disposed within left and right portions of the fuselage <NUM>. In certain examples, all wiring within a section of the fuselage <NUM> can be contained within the respective wiring racetracks 300A and 300B. Aircraft <NUM> also includes secondary routing pathway <NUM> with integration panel <NUM> and connector <NUM>. Aircraft <NUM> additionally includes tertiary routing pathways <NUM>.

Wiring racetrack 300A can be electrically coupled to secondary routing pathway <NUM> via connector panels 500C and 500D. Connectors panels 500C and 500D can be electrically coupled to integration panel <NUM> and connector <NUM>. Thus, electrical current and/or signals from wires of wiring racetrack 300A can be communicated to secondary routing pathway <NUM>. Wiring racetrack 300A can also be electrically coupled to tertiary routing pathways <NUM> through, for example, connector panel 500A. Wiring racetrack 300B can be electrically coupled to connector panel 500B and electrically coupled to secondary routing pathway <NUM> through other connector panels.

As shown in <FIG>, wiring racetracks 300A and 300B are substantially straight. Electrical connections to systems to the side of wiring racetracks 300A and 300B are connected through corresponding connector panels. Thus, wiring racetracks 300A and 300B can include connectors disposed on lateral sides of wiring racetracks 300A and 300B to electrically couple to such connectors. Fabricating wiring racetracks 300A and 300B to be substantially straight allows for simplified manufacturing as wires would only be required to be run substantially linearly. Bends and/or angular connections in such electrical connections can then be interfaced through corresponding connector panels and/or other connectors.

<FIG> is a flowchart detailing a method of fabricating a racetrack wiring system in accordance with an example of the disclosure. In certain examples, portions or all of the technique detailed in <FIG> can be performed by one or more robots or through automated manufacturing.

In block <NUM>, a plurality of wires can be sorted into at least a first wire group and a second wire group. In certain examples, the first wire group can include wires of exclusively a first category or include wires of the first category and neutral wires. Additionally, the second wire group can include wires of exclusively a second category distinct from the first category or include wires of the second category and neutral wires. Certain other wires can be sorted into additional wire groups of additional categories.

In block <NUM>, a wiring pallet can be fabricated. The wiring pallet can include a plurality of tracks. The wiring pallet can be, for example, a pallet with a plurality of distinct open or closed channels. The first wire group can be disposed within a first track of the wiring pallet. The second wire group can be disposed within a second track of the wiring pallet. Other wiring groups can also be disposed within their own separate tracks of the wiring pallet.

In certain examples, block <NUM> can be performed by holding the wiring pallet within a gantry. Additionally, the wiring groups can be tagged according to the separation code of the wiring group. A robot can scan the tags to determine the respective group of the wiring groups. The robot can then dispose the wiring groups within the appropriate tracks of the wiring pallet by gripping each of the wiring groups with an end effector and disposing the wiring groups within the respective tracks. An example of such a robot is described in <FIG>.

In block <NUM>, the wiring groups can be electrically coupled to corresponding connectors. Thus, the first wiring group can be electrically coupled to a first connector and the second wiring group can be coupled to a second connector. Additional operations to finish the full wiring racetrack can be performed in block <NUM>. Such additional operations can include, for example, coupling connectors to portions of the wiring racetrack, further cable management, and other processes.

In block <NUM>, the full wiring racetrack is assembled to an aircraft. The wiring racetrack can, thus, be disposed within a section of the aircraft. Certain aircraft can require a plurality of wiring racetracks. Such aircraft can be fitted accordingly.

In block <NUM>, aircraft electrical systems can be coupled to the wiring racetrack. Accordingly, one or more wiring groups can be electrically coupled to one or more aircraft systems. Such electrical coupling can include, for example, hard wiring, connectors, and/or other techniques. The wiring racetrack can thus be integrated with other electrical systems of the aircraft and, thus, provide electrical power and signal transmission to and from the systems.

<FIG> illustrates a robotic system in accordance with an example of the disclosure. <FIG> illustrates a robotic system <NUM> that includes a robot arm <NUM>, a robotic transfer unit (RTU) <NUM>, an end effector <NUM> coupled to the robot arm <NUM>, and wiring pallet <NUM>.

RTU <NUM> can move robot arm <NUM> along direction <NUM> (e.g., forwards and backwards along direction <NUM>). RTU <NUM> can include associated wire routing and components for moving robot arm <NUM>. RTU <NUM> can be configured to move robot arm <NUM> in one or more directions to wiring pallet <NUM>.

In certain examples, robot arm <NUM> can include one or more scanners configured to scan wiring groups and dispose the wiring groups within appropriate channels of wiring pallet <NUM>. Thus, for example, the wiring groups can be tagged with the separation code of the wiring group. A scanner of robot arm <NUM> can then scan the tag to determine the respective group for the wiring group. Robot arm <NUM> can then handle (e.g., pick up or otherwise) the wiring group with end effector <NUM> to dispose the wiring group within the appropriate channel of wiring pallet <NUM>.

Claim 1:
An aircraft (<NUM>) comprising:
a fuselage (<NUM>) comprising:
a wiring racetrack (<NUM>) comprising:
a first wire group (308A) comprising one or more wires of exclusively a first category;
a second wire group (308B) comprising one or more wires of exclusively a second category distinct from the first category;
a wiring pallet (<NUM>) comprising a first track (306A) and a second track (306B), wherein the one or more wires of the first category are contained exclusively within the first track, and wherein the one or more wires of the second category are contained exclusively within the second track;
a first connector (310A; 314A) electrically coupled to each of the wires of the first wire group (308A) within or at the end of the first track (306A); and
a second connector (310B; 314B) electrically coupled to each of the wires of the second wire group (308B) within or at the end of the second track (306B); and
secondary wiring (<NUM>) comprising one or more connectors electrically coupled to the first connector, the second connector, or to both the first connector and the second connector;
wherein the first wire group (308A) is electrically coupled to a first aircraft system and the second wire group (308B) is electrically coupled to a second aircraft system.