Coil Temperature Measurement Using Paired Gauge Wire Turns
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Solution Overview
Problem
Current temperature monitoring solutions for coiled electrical components in aircraft are costly, difficult to integrate, and provide localized temperature readings that may not guarantee compliance with safety thresholds, as they require additional equipment and can lead to false alarms or excessive component sizing.
Innovation Solution
A method involving a gauge wire made from resistive material, such as copper, wound inside the coil with a diameter of 0.05 mm to 0.25 mm, which measures the potential difference between its terminals to calculate the mean temperature, compensating for magnetic field disturbances and providing precise temperature measurements by using 'outbound' and 'inbound' turns in pairs, and connections to external equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature probe is integrated on the outside of the coil, then temperature monitoring is achieved, but the cost increases and integration becomes difficult
Solution Approach 1:
The temperature sensing function is merged with the coil structure itself by winding a gauge wire around the core. The gauge wire serves dual purposes: as part of the coil assembly and as the temperature sensor. This eliminates the need for separate temperature probes and their associated mounting hardware, thereby reducing integration complexity while maintaining temperature monitoring capability.
Solution Approach 2:
The gauge wire performs multiple functions: it forms part of the coil's electrical structure and simultaneously acts as a temperature sensor. This multi-functionality reduces the total component count and simplifies the overall device architecture, addressing the integration complexity issue while ensuring reliable temperature monitoring.
2Reliability
If a temperature probe is used, then temperature detection is provided, but additional specific equipment is required increasing cost
Solution Approach 1:
The temperature sensing function is integrated into the coil assembly through the gauge wire, eliminating the need for separate temperature probe equipment. This merging of functions reduces the bill of materials and manufacturing costs while maintaining reliable temperature detection capability.
Solution Approach 2:
The coil assembly itself provides the temperature sensing function through its gauge wire construction. The system uses its own structural components (the gauge wire) to perform the measurement function, rather than requiring external specialized equipment, thereby reducing manufacturing costs.
3Measurement precision
If a temperature probe measures local surface temperature, then a temperature reading is obtained, but it does not guarantee that the critical temperature has not been exceeded elsewhere on the component
Solution Approach 1:
The temperature measurement is segmented into multiple measurement points along the gauge wire's length. By measuring temperature at multiple locations (start, middle, end sections) rather than a single point, the system obtains a more comprehensive temperature distribution profile, ensuring that critical temperature limits are not exceeded anywhere along the coil.
Solution Approach 2:
The measurement approach transitions from a single-point surface measurement to a distributed multi-point measurement along the length of the gauge wire. This dimensional expansion of measurement coverage ensures comprehensive temperature monitoring throughout the component, not just at one location, thereby improving safety compliance reliability.
4Reliability
If the coil is oversized to limit spontaneous heating, then safety margin is increased, but mass and cost increase
Solution Approach 1:
The system implements continuous temperature feedback through the gauge wire measurements. By monitoring the actual temperature in real-time and comparing it against critical thresholds, the system can operate the coil at higher power levels with confidence, knowing that temperature excursions will be detected immediately. This eliminates the need for conservative oversizing and reduces the required safety margin, thereby reducing mass.
5Measurement precision
If the resistance of the gauge wire is increased to improve temperature measurement sensitivity, then measurement precision improves, but the wire diameter must be decreased
Solution Approach 1:
The system optimizes the gauge wire parameters (diameter, length, resistance) to achieve the desired measurement precision while maintaining mechanical integrity. By carefully selecting the resistance value and wire dimensions, the system achieves sufficient temperature measurement sensitivity without requiring excessively thin wires that would be mechanically weak or difficult to manufacture.
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 solution provides precise temperature measurements that ensure safety compliance without excessive safety margins, integrates seamlessly with the component, and reduces manufacturing costs while offering improved precision and reliability compared to conventional methods.
Implementation Method 1
the resistance of the gauge wire varying with the temperature in accordance with a known law
Implementation Method 2
the measurement must compensate for any disturbances caused by the presence of magnetic fields, the gradients of which create an electromotive force in the windings that they pass through
Data Source
AI summary
The invention relates to a method of measuring the temperature of a coiled component comprising the injection of a known DC current into a gauge wire (1) made of resistive material, the resistance of the gauge wire varying with temperature according to a known law, the measurement of potential difference between the terminals (7a, 7b) of said gauge wire, and a step of calculation transforming the potential difference into a mean temperature of the gauge wire, said gauge wire (1) being wound inside the coil, and arranged as a series of “outbound” turns (5) and a series of “inbound” turns (6) associated pairwise with a geometry and a position that are substantially equal. It also relates to a component made in order to be able to implement this method and the measurement device as a whole.