Conformal Air-Data Probe Structure With Heated Pneumatic Chambers
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Solution Overview
Problem
Air-data probes experience pressure sensing measurement errors and inaccuracies due to atmospheric moisture accumulation, leading to inaccuracies in airspeed, altitude, and other fluid dynamic characteristics during ground operation and flight.
Innovation Solution
An additively manufactured air-data probe with integrally formed pneumatic chambers and tubes, incorporating heater wire coils and labyrinthine paths for moisture and ice damming, along with a non-integrally formed outer cover tip for conformality, to enhance moisture management and data accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If atmospheric moisture accumulates in pressure sensing chambers and conduits, then moisture management becomes problematic, but measurement precision deteriorates due to pressure sensing errors and spikes
Solution Approach 1:
The patent applies preliminary action by incorporating heater wire coils that pre-heat the pneumatic chambers and conduits before moisture can accumulate to problematic levels. The heater wires are wrapped around the chambers and conduits to proactively prevent moisture condensation and ice formation, thereby maintaining measurement precision while managing moisture reliability issues
Solution Approach 2:
The patent uses heater wire coils as an intermediary element between the moisture problem and the pressure sensing system. The heater wires act as a mediating thermal field that prevents moisture from directly contacting and interfering with the pressure sensing chambers and conduits, thus protecting measurement accuracy while addressing moisture management
2Ease of manufacture
If conventional air-data probes are used, then basic functionality is provided, but manufacturing complexity increases and functionality is limited
Solution Approach 1:
The patent merges multiple pneumatic chambers (pitot chamber, static pressure chambers, angle of attack chambers, angle of sideslip chambers) and their associated conduits into a single additively manufactured component. This integration simplifies manufacturing by reducing the number of separate parts and assembly steps while maintaining all necessary sensing functions for multi-functionality
Solution Approach 2:
The additively manufactured inner member serves multiple functions simultaneously: it houses pitot pressure sensing, static pressure sensing, angle of attack measurement, and angle of sideslip measurement. This universal design provides comprehensive air-data probe functionality within a single manufactured component, enhancing versatility without increasing manufacturing complexity
3Ease of manufacture
If moisture accumulates in pressure sensing ports and conduits, then production costs and maintenance requirements increase, but device complexity remains constrained
Solution Approach 1:
The heater wire coils are integrated into the additively manufactured inner member structure during the manufacturing process itself, rather than being added as a separate complex subsystem. This preliminary integration of moisture management capability simplifies the overall device structure while preventing moisture-related production and maintenance issues
Solution Approach 2:
The heating function is merged directly into the structural design of the inner member by embedding heater wire coils within channels of the additively manufactured component. This combination eliminates the need for separate heating assemblies and reduces overall device complexity while addressing moisture management needs
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 solution provides improved moisture management and data accuracy, enabling conformal integration with aircraft surfaces while simplifying production and enhancing performance.
Implementation Method 1
The outer surface of the mandrel bulkhead can include a channel defined therein configured to receive heater wire coils therein wrapped around the mandrel bulkhead
Implementation Method 2
The pitot chamber can include a plurality of dams extending part way radially into the pitot chamber defining a labyrinthine path through the pitot chamber for ice and moisture damming
Data Source
AI summary
An air-data probe component includes an additively manufactured inner member. The inner member includes integrally formed, monolithic structures including a mandrel bulkhead defining a plurality of pneumatic chambers therein in fluid communication with an outer surface of the mandrel bulkhead through respective pressure ports, and a plurality of pneumatic tubes extending aft of the mandrel bulkhead along a probe axis, each in fluid communication with a respective one of the plurality of pneumatic chambers. An outer cover tip can be engaged about the mandrel bulkhead with a plurality of bores therethrough for fluid communication of outside air pressure into the plurality of pneumatic tubes through the outer cover tip. A forward surface of the outer cover tip can be flush, conformal, and continuous with an aerodynamic outer surface of an aircraft.