Aperture Location via Thermal Signature of Embedded Conductive Elements
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Solution Overview
Problem
Existing methods for forming apertures in aircraft propulsion system nacelle components with embedded heater elements often result in damage to these elements, leading to operational failures and the need for entire component replacement.
Innovation Solution
A manufacturing method that uses thermal sensors, such as infrared cameras, to locate embedded conductive heater elements and form apertures without interfering with them, ensuring the apertures are positioned between or outside the elements to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heater elements are embedded within the outer skin, then the heater elements are not visible and aesthetically integrated, but apertures may inadvertently damage the heater elements
Solution Approach 1:
The patent applies preliminary action by detecting the location of embedded heater elements before forming apertures. Thermal sensors or other detection methods are used to map the positions of conductive heater elements within the outer skin, and this information is stored for guiding subsequent aperture formation operations, preventing damage before it occurs
Solution Approach 2:
The patent implements feedback by using the detected heater element locations to control the aperture formation process. The system continuously monitors heater element positions and adjusts aperture drilling operations in real-time, ensuring that apertures are formed only in safe locations that do not coincide with heater elements
2Ease of operation
If apertures are formed in the outer skin, then access to underlying components is enabled, but heater elements may be pierced or severed
Solution Approach 1:
Before forming apertures, the patent performs preliminary detection of heater element locations using thermal sensors or other detection systems. This advance knowledge allows the aperture formation process to be planned and executed in a way that avoids heater elements entirely, enabling safe access to underlying components
Solution Approach 2:
The patent introduces an intermediary information layer - a digital map or model of heater element locations - that mediates between the aperture formation process and the physical heater elements. This intermediary guide layer allows apertures to be formed safely by referencing the stored location data rather than directly interacting with the embedded heater elements
3Reliability
If the entire nose lip is replaced due to heater element damage, then operational reliability is restored, but manufacturing time and material waste increase
Solution Approach 1:
The patent applies preliminary action by detecting and mapping heater element locations before aperture formation, preventing damage that would otherwise require complete nose lip replacement. This preventive approach maintains productivity by avoiding rework and material waste
Solution Approach 2:
The patent converts the potential harm of heater element damage into benefit by using thermal detection methods to identify heater element locations. This information, which could have been used to locate problems, is instead used proactively to prevent problems, transforming a detection capability into a protective measure that maintains manufacturing efficiency
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 method allows for precise aperture formation in components like acoustic panels for aircraft propulsion systems, preventing heater element damage and reducing the need for component replacement, thereby enhancing operational reliability and reducing maintenance costs.
Implementation Method 1
An electric current is applied to the first conductive element such that the first conductive element produces a signature
Implementation Method 2
A location of the first conductive element in the panel is determined based on the signature using an infrared camera
Data Source
AI summary
A manufacturing method is provided. During this method, a panel is provided that includes non-conductive material and a plurality of conductive elements at least partially embedded within the non-conductive material. The conductive elements include a first conductive element. An electric current is applied to the first conductive element such that the first conductive element produces a signature. A location of the first conductive element in the panel is determined based on the signature. An aperture is formed in the panel based on the determined location of the first conductive element.