Air Data Probe Power Control Circuit for Anti-Icing
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Solution Overview
Problem
Air data probes face premature failure due to excessive heat generation when operating at full power for anti-icing and de-icing, particularly in high heat demand areas like the probe tip, leading to reduced lifetimes and increased maintenance needs.
Innovation Solution
A passive power control circuit using a combination of low and high temperature coefficient of resistance components, where a shunt component is activated to divert current when the high temperature coefficient component reaches a set temperature, reducing power consumption and heat generation in high heat demand areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air data probe operates at full power for anti-icing and de-icing, then the heating effectiveness is improved, but the probe experiences premature failure due to excessive heat generation
Solution Approach 1:
The heating system is divided into multiple independent heating zones along the probe, each with its own temperature sensing and power control. This allows different sections to be heated to different temperatures based on their specific anti-icing requirements, preventing excessive heat generation in any single zone while maintaining overall heating effectiveness.
Solution Approach 2:
The system dynamically adjusts heating parameters (power level, temperature setpoints) based on real-time temperature measurements from thermistors embedded in each heating zone. By continuously monitoring and adjusting these parameters, the system maintains optimal heating effectiveness while preventing excessive temperature rise that would cause premature failure.
2Temperature
If uniform power distribution is applied throughout the probe, then manufacturing and control simplicity is maintained, but heat demand is not optimized for high heat demand areas like the probe tip
Solution Approach 1:
Different sections of the probe are equipped with heating elements and temperature sensors tailored to their specific thermal requirements. The probe tip, which has higher heat demand, receives different power levels compared to other sections. This localized optimization of heating quality improves overall heat distribution efficiency without requiring overly complex control systems.
Solution Approach 2:
Temperature sensing elements (thermistors) are positioned within each heating zone to provide real-time feedback on temperature conditions. This feedback is used to automatically adjust the power supplied to each zone, optimizing heat distribution according to actual thermal needs. The feedback mechanism enables intelligent power management while maintaining relatively simple control circuitry.
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
The solution effectively limits current flow to high heat demand sections, preventing overheating and extending the lifespan of air data probe heater cables by regulating power distribution based on temperature, thus enhancing the probe's operational reliability and reducing maintenance requirements.
Implementation Method 1
at least one low temperature coefficient of resistance component forming a first heating element and placed in a strut of the probe
Implementation Method 2
at least one high temperature coefficient of resistance component forming a second heating element and placed in at a tip of the probe
Implementation Method 3
at least one shunt component connected in parallel with the at least one high temperature coefficient of resistance component, wherein when the temperature of the at least one high temperature coefficient of resistance component exceeds the set temperature point, the at least one shunt component is configured to pass the current flow through the at least one high temperature coefficient of resistance component and the at least one shunt component
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
A control circuit for a probe includes: at least one low thermal coefficient resistance (TCR) component placed in a first section of a probe, wherein the at least one low TCR component has low positive temperature resistance coefficient (PTC); at least one high TCR component placed in a second section of the probe and connected in series with the at least one low TCR component, wherein the at least one high TCR component has high PTC, and wherein the at least one high TCR component responds to temperature differently than the at least one low TCR component; and at least one shunt component connected in parallel with the at least one high TCR component, wherein when temperature of the at least one high TCR component exceeds a set temperature point, the at least one shunt component is activated to reduce current flowing through the at least one high TCR component.