Additive Pitot Probe with Encapsulated Heating Cable
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Solution Overview
Problem
Existing pitot probe manufacturing methods, such as brazing, face challenges with irregular braze filler application, leading to inefficiencies in heat conduction and increased costs due to the need for reapplication, which can affect the accuracy of air velocity measurements by allowing ice buildup at high altitudes.
Innovation Solution
The use of additive manufacturing techniques, including directed energy deposition and cold spray processes, to fabricate a pitot probe around an endoskeleton mandrel with a coaxial heating cable encapsulated in a thermally conductive additive coating, ensuring even heat distribution and preventing ice buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brazing is used to join the heating coil to the pitot tube, then the heating coil can be attached to the probe, but the braze filler is irregularly applied leading to poor heat conduction and increased manufacturing costs
Solution Approach 1:
The patent replaces the mechanical brazing process with an additive manufacturing process. The heating cable is embedded directly into the probe body through additive deposition of thermally conductive material, eliminating the need for separate brazing operations and irregular filler application. This substitution resolves the contradiction by providing both ease of manufacture (single integrated process) and manufacturing precision (controlled material deposition).
Solution Approach 2:
The patent merges the heating coil attachment and probe body formation into a single additive manufacturing process. The thermally conductive material is deposited to simultaneously form the probe body structure and embed the heating cable, combining multiple manufacturing steps into one operation. This resolves the contradiction by eliminating the separate brazing step that caused irregular filler application while maintaining secure thermal coupling.
2Reliability
If brazing is used to join the heating coil to the pitot tube, then the heating coil can be attached to the probe, but reapplication costs increase due to irregular braze application
Solution Approach 1:
The additive manufacturing process replaces the multi-step brazing operation with a single deposition process. The heating cable is embedded during probe body formation without requiring separate brazing, inspection, and reapplication steps. This substitution resolves the contradiction by ensuring reliable attachment in one operation, eliminating time losses associated with irregular braze application and rework.
3Productivity
If traditional manufacturing methods are used, then the probe can be manufactured, but ice buildup interferes with fluid flow into the probe opening at high altitudes
Solution Approach 1:
The patent changes the thermal conduction parameter by using additive deposition of highly thermally conductive material to embed the heating cable. This creates superior thermal coupling compared to traditional brazing, ensuring more effective heat transfer to prevent ice buildup. The parameter change in thermal conductivity resolves the contradiction by maintaining manufacturing efficiency while eliminating ice interference through improved heating performance.
Solution Approach 2:
The patent uses composite material deposition combining the probe body material with thermally conductive material in the additive manufacturing process. This composite approach creates an integrated structure with optimized thermal properties for preventing ice buildup while maintaining manufacturing efficiency. The composite material solution resolves the contradiction by providing both productivity and protection against harmful ice formation.
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
This approach reduces manufacturing time and costs, improves product yield, and ensures accurate air velocity measurements by effectively coupling heat to the probe body, preventing ice interference and maintaining fluid flow integrity.
Implementation Method 1
additive manufacturing techniques, including directed energy deposition
Implementation Method 2
heating cable encircling an external surface of the endoskeleton mandrel
Implementation Method 3
thermally conductive additive coating, ensuring even heat distribution
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
Systems and methods for additive manufacturing for air data probes are provided. In at least one embodiment a probe comprises a support structure comprising one or more ports for receiving one or more fluids, the support structure comprising an endoskeleton mandrel having an opening for receiving a fluid; and a heating cable encircling an external surface of the endoskeleton mandrel. The probe also comprises an additive coating fused to the external surface of the endoskeleton mandrel and an extemal surface of the heating cable; and an internal assembly inside the support structure for carrying pressures from the one or more ports to one or more instruments that respond to the one or more fluids to provide a measurement.