Angled Face Cap Probe Anti-Rotation Design
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Solution Overview
Problem
Conventional angled face cap probes in gas turbine engines are prone to damage, causing the sensor to rotate and extend into the path of rotating airfoils, leading to undesirable damage to the airfoil due to the lack of effective rotation resistance.
Innovation Solution
An angled face cap probe design featuring a housing with a sensor body angled to match the airfoil, an outer cap with radially inward cap legs to resist sensor rotation, and ceramic components to provide structural support and electrical insulation, along with a lead channel and tack strap for secure electrical connections, preventing sensor rotation and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional angled face cap probes are used without rotation resistance features, then the sensor can freely rotate to match the airfoil angle, but the sensor may rotate into the path of the airfoil causing damage
Solution Approach 1:
The patent introduces an intermediary structure (the housing with cap legs and ceramics) between the sensor and the rotating airfoil. The cap legs extend into the cavity to physically restrict sensor rotation, while the angled sensing face allows the sensor to remain aligned with the airfoil for accurate measurement without freely rotating into the airfoil's path.
Solution Approach 2:
The sensor housing is designed to self-align with the airfoil through its angled geometry while the cap legs automatically engage with the sensor body to prevent rotation. The structure provides its own rotation resistance without requiring external control mechanisms, ensuring the sensor maintains proper alignment while preventing harmful rotation.
2Measurement precision
If the sensor is allowed to rotate freely for alignment, then measurement accuracy is improved, but the reliability of the probe decreases due to potential sensor damage
Solution Approach 1:
The housing and cap legs are pre-configured during manufacturing to provide rotation resistance before the probe is installed. The cap legs are positioned to engage with the sensor body in advance, creating a predetermined rotation barrier that allows initial alignment but prevents excessive rotation that would cause damage during operation.
Solution Approach 2:
The patent changes the physical parameters of the sensor mounting structure by adding cap legs with specific dimensions and angles. These geometric parameters are designed to provide just enough rotation resistance to prevent damage while allowing sufficient movement for proper alignment with the airfoil surface.
3Strength
If ceramic components are added for structural support and insulation, then the probe's structural integrity is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple functions into the ceramic components: they provide structural support for the sensor, electrical insulation between the sensor and housing, and mechanical positioning within the cavity. By combining these functions into single components rather than separate elements, the design reduces overall complexity while maintaining structural integrity and insulation properties.
Data Source
AI summary
An angled face cap probe includes a housing having a radially inner end and a radially outer end, defining a cavity, and configured to be located radially outward from an airfoil. The angled face cap probe further includes a sensor located in the cavity at the radially inner end of the housing, having a sensor body with a sensing face that is angled to match or substantially match an angle of a radially outward face the airfoil, and having a sensor flat that is elongated in a first direction. The angled face cap probe further includes an outer cap located in the cavity, coupled to the housing, and having an outer cap main body and cap legs that extend radially inward from the outer cap main body to interface with the sensor flat to resist rotation of the sensor relative to the housing.