Multi-part Air Data Probe Assembly Rapid Replacement
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Solution Overview
Problem
Conventional air data probe replacement procedures are time-consuming due to slow curing times of sealants, especially in adverse conditions, resulting in significant aircraft downtime, as the entire assembly needs to be detached and reattached, including removal and reapplication of sealants and electrical connections.
Innovation Solution
A multiple-part air data probe assembly with a self-sealing mount plate interface that allows for rapid removal and replacement of the sensor body without requiring frequent removal of the mount plate interface, which remains attached to the aircraft, and uses mechanical seals that do not require curing time, simplifying the replacement process by automatically disconnecting electrical and pneumatic connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the entire air data probe assembly is detached and reattached for sensor body replacement, then the sensor body can be replaced, but the replacement process becomes time-consuming due to sealant curing requirements
Solution Approach 1:
The air data probe assembly is divided into two separable parts: a permanently mounted baseplate interface that remains attached to the aircraft skin, and a removable sensor body portion. This segmentation allows the sensor body to be replaced independently without detaching the entire assembly, eliminating the need for sealant reapplication and curing time while maintaining a secure sealed connection through the baseplate's integrated sealing mechanism
Solution Approach 2:
The baseplate interface acts as an intermediary component between the aircraft skin and the sensor body. It provides a permanent sealed mounting surface that remains attached to the aircraft, allowing the sensor body to be quickly connected and disconnected without affecting the baseplate's attachment to the aircraft skin, thus enabling rapid replacement without full assembly detachment
2Reliability
If sealants are removed and reapplied during probe replacement, then the assembly can be resealed, but the curing time in adverse conditions extends the downtime
Solution Approach 1:
The sealing function is integrated into the baseplate interface as a permanent, reusable component rather than using consumable sealant material that requires curing. The baseplate's built-in sealing mechanism provides immediate seal integrity upon assembly without requiring time-dependent curing processes, eliminating the trade-off between seal reliability and curing time
Solution Approach 2:
The chemical sealing process (sealant curing) is replaced with a mechanical sealing solution integrated into the baseplate interface. The mechanical seal provides immediate and reliable sealing upon assembly, eliminating the need for chemical sealants and their associated curing times, thus resolving the contradiction between seal integrity and time consumption
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A multi-part air data probe sensor assembly facilitating rapid replacement is provided. In one embodiment, an air data probe sensor assembly comprises a mount plate interface including at least one mount plate electrical connector configured to mate with electrical lines of an aircraft and at least one mount plate pneumatic connector configured to mate with pneumatic tubes of an aircraft; and a detachable sensor body having at least one sensor electrical connector that is coupled with the at least one mount plate electrical connector and at least one sensor pneumatic connector that is coupled with the at least one mount plate pneumatic connector; and a mechanical seal provided between the mount plate interface and the detachable sensor body, wherein the mechanical seal is composed of a moisture blocking material.