Air Data Probe Bulkhead With Wire Heater Channels
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Solution Overview
Problem
Air data probes on aircraft are prone to pressure sensing measurement errors and spikes due to moisture accumulation, which affects the accuracy of air data measurements, particularly around angle of attack (AOA) ports.
Innovation Solution
A bulkhead design for air data probes that incorporates a wire heater wrapped around the bulkhead, with a unique geometry that increases heating near AOA ports and includes an air gap to prevent heat loss, thereby preventing moisture entry and ensuring accurate pressure sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire heater is installed in the air data probe, then moisture prevention capability is improved, but heat loss increases and heating efficiency decreases
Solution Approach 1:
The bulkhead acts as an intermediary thermal management component between the wire heater and the probe interior. It concentrates heat at the AOA ports through its geometric design (smaller cross-section at heating zone) while the air gap serves as a thermal insulator, preventing heat loss to the probe head exterior. This mediator approach allows effective moisture prevention without excessive energy consumption.
Solution Approach 2:
The bulkhead is designed with non-uniform geometry - a smaller cross-sectional area at the heating zone near AOA ports and a larger cross-section elsewhere. This local quality variation concentrates thermal energy where it is most needed (at the AOA ports) while reducing heat dissipation in other areas, thereby improving heating efficiency and reducing overall heat loss.
2Reliability
If the bulkhead cross-sectional area is reduced to concentrate heat, then heating efficiency at AOA ports is improved, but structural strength may be compromised
Solution Approach 1:
The bulkhead features a strategically designed non-uniform cross-section: a smaller area at the heating zone to concentrate heat at AOA ports, and a larger area in other regions to maintain structural strength and rigidity. This local differentiation allows the bulkhead to simultaneously achieve high heating efficiency where needed while preserving overall structural integrity.
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 enhanced heating and insulation design effectively prevents moisture from entering AOA ports, maintaining accurate air data measurements even in harsh environmental conditions, such as precipitation and extreme cold.
Implementation Method 1
a wire heater wrapped around the bulkhead
Implementation Method 2
an air gap formed between the probe head and the middle portion of the bulkhead
Data Source
AI summary
A bulkhead for an air data probe includes an upstream end, a downstream end, and an upstream portion extending from the upstream end. The upstream portion includes an exterior surface, a first plurality of walls extending radially outward from the exterior surface of the upstream portion, a first pad extending radially outward from the exterior surface of the upstream portion, and a first plurality of channels formed between one or more of the first plurality of walls and the first pad. The first plurality of channels are configured to receive a wire heater.