Disconnect plunger for integrated drive generator

An integrated drive generator comprising:

• an input shaft;
• a disconnect shaft having a gear interface with said input shaft, said disconnect shaft including a shaft cam surface, the disconnect shaft being biased toward contact with said input shaft;
• and
• a disconnect plunger having a plunger cam surface for mating with said shaft cam surface on said disconnect shaft, and for causing said disconnect shaft to be selectively moved against said bias, and away from said input shaft, said disconnect shaft having a plunger body extending between a first end and a second end, said plunger cam surface formed on said second end, said plunger cam surface having a cylindrical cam portion extending across said second end, and said cylindrical cam portion including a location formed at a first radius about a point spaced beyond said second end relative to said first end, and a first distance being defined from a second end facing surface of a cylindrical guide portion positioned intermediate the first and second end, and a ratio of said first radius to said first distance being between 0.15 and 0.30;
• and
• said point being spaced in a direction perpendicular to a center axis of said plunger body, and measured from said center axis by a second distance, and a ratio of said second distance to said first radius being between 0.25 and 0.40.

A method of replacing a disconnect shaft in an integrated drive generator comprising the steps of:

• removing an existing disconnect plunger from an integrated drive generator, the integrated drive generator including an input shaft having a gear interface with a disconnect shaft, said disconnect shaft for driving gears to rotate a generator, said disconnect shaft including a shaft cam surface, the disconnect shaft having a spring biasing said disconnect shaft to be in contact with said input shaft, and said existing disconnect plunger having a plunger cam surface for mating with said shaft cam surface on said disconnect shaft, and for causing said disconnect shaft to be selectively moved against said spring force, and away from said input shaft;
• and
• replacing said existing disconnect plunger with a replacement disconnect plunger, said replacement disconnect plunger includes a plunger body extending between a first end and a second end, there being a replacement plunger cam surface formed on said second end, said replacement plunger cam surface having a cylindrical cam portion extending across said second end, and said cylindrical cam portion including a location formed at a first radius about a point spaced beyond said second end relative to said first end, and a first distance being defined from a second end facing surface of a cylindrical guide portion positioned intermediate the first and second end, and a ratio of said first radius to said first distance being between 0.15 and 0.30;
• and
• said point being spaced in a direction perpendicular to a center axis of said plunger body, and measured from said center axis by a second distance, and a ratio of said second distance to said first radius being between 0.25 and 0.40.