Embedded Heater Probe Head for Faster Aircraft Ice Detection Reset
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Solution Overview
Problem
Existing magnetostrictive oscillating ice detector (MSO ID) sensors for aircraft face challenges in efficiently and energy-efficiently removing ice accumulation on detector probes and struts, leading to slow melting and high power consumption.
Innovation Solution
The integration of a heater element within the probe head and support strut of the MSO ID sensor, formed through additive manufacturing with layered materials, including insulative and heater elements, optimized for efficient heat distribution and reduced exposure to the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heaters are used to melt ice on the detector probe and strut, then the ice removal function is achieved, but the process is slow and energy intensive
Solution Approach 1:
The heater element is strategically positioned within the hollow cylindrical portion of the probe head, specifically in the radially outer side, to provide localized heating where ice accumulation occurs most frequently. This targeted approach concentrates thermal energy at the critical melting zone rather than heating the entire sensor assembly, thereby increasing melting speed while reducing overall power consumption.
Solution Approach 2:
The probe head incorporates a composite structure combining the hollow cylindrical portion material with the heater element material and electrically insulative layer material. This composite design allows for integrated thermal management where the heater element is embedded within the probe head body, creating a multi-material system that optimizes both thermal efficiency and electrical insulation to enhance ice melting performance.
2Reliability
If heaters are used to melt ice on the detector probe and strut, then the sensor can be reset, but the process consumes excessive energy
Solution Approach 1:
The heater element is positioned specifically within the hollow cylindrical portion of the probe head to provide localized heating at the ice accumulation zone. This targeted heating approach ensures reliable ice melting and sensor reset while minimizing energy consumption by concentrating thermal energy only where needed for the reset function.
Solution Approach 2:
The electrically insulative layer surrounding the heater element acts as an intermediary that prevents direct electrical contact between the heater and the probe head body. This insulative layer ensures safe and efficient energy transfer to the ice while preventing energy loss through electrical conduction, thereby maintaining reliable reset capability with optimized energy usage.
3Productivity
If a heater element is integrated into the probe head, then ice melting efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The heater element, electrically insulative layer, and probe head body are merged into a single integrated component structure. The heater element is embedded within the hollow cylindrical portion of the probe head body, with the insulative layer surrounding it, creating a unified assembly that reduces the number of separate parts and simplifies manufacturing while maintaining high ice removal efficiency.
Solution Approach 2:
The hollow cylindrical portion of the probe head serves multiple functions: it provides structural support, contains the heater element for ice melting, and houses the electrically insulative layer for electrical isolation. This multi-functional design reduces the overall device complexity by combining several components into a single integrated structure that achieves both mechanical strength and thermal management.
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 design enhances ice melting speed and reduces power consumption by optimizing heat distribution and insulation, improving the operational efficiency of the MSO ID sensors.
Implementation Method 1
heaters heat the detector probe and strut to melt the ice off the detector probe and strut
Implementation Method 2
an electrically insulative layer around the heater element
Implementation Method 3
magnetostrictive oscillating (MSO) ice detector (ID) sensors
Data Source
AI summary
A probe head of a magnetostrictive oscillator includes a probe head body which includes a hollow cylindrical portion with a first end, a second end, a radially inner side, and a radially outer side. The probe head body further includes a hemispherical portion connected to the first end of the hollow cylindrical portion. The probe head further includes a heater element within the radially outer side of the hollow cylindrical portion and an electrically insulative layer around the heater element. The heater element and the electrically insulative layer are integral with the probe head body.