Double Helix Heater Cable for Air Data Probe Anti-Icing
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Solution Overview
Problem
Current air data probes are limited in the amount of power that can be applied to the probe tip for anti-icing protection due to stringent icing conditions, necessitating a more effective heating solution.
Innovation Solution
An air data probe design featuring an electrical heater cable with a compact double layer helix portion that delivers increased heat to the probe tip, eliminating the 180-degree turn-around radius to reduce stress and enhance durability, utilizing materials like nickel and copper alloys for high thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single layer helix heater cable is used, then the structure is simple and easy to manufacture, but the heat delivery to the probe tip is insufficient for demanding icing conditions
Solution Approach 1:
The patent transitions from a single layer helix to a double layer helix configuration, adding a dimensional layer to the heater cable structure. This allows increased heat delivery capacity while maintaining a compact form factor that fits within the probe tip constraints.
Solution Approach 2:
The inner helical part is nested within the outer helical part, creating a compact double layer structure. This nesting arrangement maximizes the heating surface area and heat delivery capability within the limited space of the probe tip, effectively solving the contradiction between heat delivery and structural complexity.
2Ease of operation
If a 180-degree turn-around radius is used in the helix cable, then the cable can be routed back along the probe, but this creates stress concentration and potential failure points
Solution Approach 1:
The patent introduces asymmetry in the helix configuration by eliminating the 180-degree turn-around and instead using a continuous double helix structure that progresses along the probe axis. This asymmetric design avoids the stress concentration at sharp turns while maintaining effective cable routing and heat distribution.
3Reliability
If more heating power is applied to protect against demanding icing conditions, then anti-icing protection is improved, but the probe tip may exceed power limits and cause damage
Solution Approach 1:
The double layer helix structure concentrates the heating elements specifically at the probe tip where icing protection is most critical. This localized quality enhancement provides maximum anti-icing protection exactly where needed while distributing the power load across two layers, preventing any single point from exceeding damage thresholds.
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 double layer helix configuration provides enhanced protection against icing conditions by increasing heat delivery to the probe tip, improving the air data probe's ability to prevent ice formation both before and during flight, while reducing potential failure points and extending the heater cable's lifespan.
Implementation Method 1
Electrical heater coils are commonly used in air data probes for aircraft to protect against icing conditions
Implementation Method 2
utilizing materials like nickel and copper alloys for high thermal conductivity
Data Source
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AI summary
An air data probe comprises an elongated body structure having a proximal end and a distal end, with the elongated body structure including an outer surface and an opposing inner surface that defines an interior channel. A probe tip is located at the distal end of the elongated body structure, with the probe tip including an outer surface and an inner surface that are contiguous with the outer an inner surfaces of the elongated body structure. The probe tip has an opening in communication with the interior channel that allows outside air to pass from the probe tip into the interior channel. An electrical heater cable is coupled to the elongated body structure and the probe tip. The electrical heater cable comprises a compact double layer helix portion coupled to the elongated body structure or the probe tip, or coupled to both the elongated body structure and the probe tip.