Aircraft Sensor Joining System Isolating Structural Deformations

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Solution Overview

Problem

Aircraft structures with embedded sensors face malfunctions due to large deformations from external stresses, as the sensor's rigid matrix and the structure's materials respond differently, leading to potential ruptures at the binder and cable connections.

Innovation Solution

A joining system comprising an enclosure with flexible connections and a rapid curing binder that houses the sensor, allowing it to maintain operation by isolating deformations and providing structural integrity without disrupting signal transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the sensor is fixed directly on the aircraft structure, then the sensor maintains good electrical connection and structural support, but the sensor is vulnerable to deformations and material incompatibility causing binder rupture and cable connection failure

Engineering Contradiction:

Improvesensor operation reliabilityVSAvoiddeformation impact on sensor

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The sensor system is segmented into distinct functional components: the sensing element, the enclosure, the flexible connection, and the binder. This segmentation allows each component to perform its specific function optimally while isolating the sensitive transducer from harmful deformations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The enclosure acts as an intermediary between the structure and the transducer, while the flexible connection serves as a mediator that transmits signals but isolates mechanical deformations. This intermediary approach protects the transducer from direct exposure to structure deformations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If a rigid matrix is used to embed the coil, then the sensor maintains structural integrity, but the rigid matrix and structure have different material behaviors leading to binder rupture under deformation

Engineering Contradiction:

Improvesensor structural integrityVSAvoidbinder connection reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The flexible connection acts as a flexible shell that connects the transducer to the enclosure while accommodating structural deformations. This flexible element prevents stress concentration and binder rupture that would occur with rigid connections under deformation conditions.

Inventive Principle:

Principle #30Flexible shells and thin films

3Measurement precision

If the transducer is directly exposed to the structure surface, then the sensor responds accurately to structural deformations, but the transducer is vulnerable to damage from large deformations reaching approximately 5 mm per metre

Engineering Contradiction:

Improvedeformation measurement accuracyVSAvoidlarge deformation damage risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The transducer is extracted from direct exposure to the structure surface and placed inside a protective enclosure. This extraction removes the transducer from the harmful deformation environment while the flexible connection maintains the ability to transmit measurement signals.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The enclosure and flexible connection provide beforehand cushioning protection for the transducer against large deformations. This protective arrangement is built into the sensor design before deployment, preventing damage from anticipated deformation conditions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Ease of operation

If cables are connected to the structure at the exit from the rigid matrix, then electrical connection is established, but the connection point becomes a vulnerability for rupture under differential material behavior

Engineering Contradiction:

Improveelectrical connection establishmentVSAvoidcable connection reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The enclosure serves as an intermediary that houses the cable connections internally, isolating them from direct exposure to structure deformations. This intermediary approach maintains electrical connectivity while protecting the connection points from mechanical failure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11214348B2Aircraft structure comprising a sensor with an improved joining system and aircraft comprising said structure

Publication Date: 2022.01.04 AIRBUS OPERATIONS (SAS)

AI summary

A sensor is fixed on an aircraft structure by a joining system which includes at least one enclosure in which is positioned at least one transducer, at least one passage configured to allow at least one conducting element to pass through the enclosure, at least one flexible connection connecting each transducer present in the enclosure to said enclosure and at least one binder joining together the enclosure and the structure. This joining system makes it possible to limit the spread of the deformations of the structure toward the transducer or transducers and ultimately the risks of malfunction.