Air Data Probe Unitary Body Integrated Heater Bore
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Solution Overview
Problem
Traditional air data probes face challenges in effectively integrating heaters due to complex multi-piece assemblies, which complicates assembly, reduces repeatability, and hampers efficient heat distribution, especially in icing conditions.
Innovation Solution
The use of additively manufactured air data probes with unitary bodies featuring integrated rod heaters and enhanced conduction areas, allowing for simplified assembly, improved heat distribution, and tailored thermal resistance through varying power density along the heater.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-piece assemblies are used for heater integration, then heater installation is possible, but assembly complexity increases and repeatability decreases
Solution Approach 1:
The heater bore is integrated directly into the probe head body as a single unitary structure, eliminating the need for separate heater housing components. This merging of the heater mounting structure with the probe head body simplifies assembly to a single insertion operation and ensures consistent repeatability without complex multi-piece assemblies.
2Ease of manufacture
If complex multi-piece assemblies are used, then heater installation is achievable, but manufacturing complexity and time increase
Solution Approach 1:
The probe head body and heater bore are manufactured as a single integrated component, eliminating multiple assembly steps. This unitary construction reduces manufacturing complexity and assembly time while maintaining heater installation capability.
3Reliability
If conventional heater arrangements are used, then basic heating function is provided, but heat distribution efficiency is insufficient
Solution Approach 1:
The heater bore is positioned and configured with specific local characteristics within the probe head body to optimize heat distribution to critical areas. The unitary structure allows precise positioning of the heater relative to the probe surface, ensuring efficient heat transfer where needed most for icing protection.
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 enhances the functionality of air data probes by ensuring optimal heat distribution, simplifying manufacturing and assembly, and improving performance in icing conditions by using a single-piece structure with integrated rod heaters and enhanced conduction areas.
Implementation Method 1
heaters are positioned within air data probes to ensure the air data probes function properly in liquid water, ice crystal, and mixed phase icing conditions
Implementation Method 2
enhanced conduction areas between or extending from one or more heater bores and an exterior surface of the body to increase and further tailor the heat distribution
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A probe head of an air data probe includes a unitary body (22) extending from a first end (18) to a second end (20) of the probe head and a rod heater. The body includes an inlet (28) adjacent the first end of the probe head, an air passageway (30) extending through the body from the inlet to the second end of the probe head, a water dam (32) extending radially through the body such that the air passageway is redirected around the water dam, and a heater bore (34) extending within the body. The rod heater (24) is positioned within the heater bore.