Aircraft engine sensing apparatus with insulated connection wires
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Solution Overview
Problem
Sensors, particularly rotational speed sensors, face challenges in high temperature and ultra-high temperature environments due to the difficulty in maintaining adequate electrical insulation of connection wires, leading to potential dielectric failures and health, safety, and environmental issues.
Innovation Solution
The use of ceramic insulators, such as alumina or glass-ceramic materials, to insulate connection wires within aircraft engines, providing effective electrical insulation and durability in extreme temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation materials are used for connection wires in high temperature environments, then the device complexity remains low, but the reliability deteriorates due to dielectric failures
Solution Approach 1:
The patent applies composite materials by combining ceramic insulator segments with metal connection wires. The ceramic insulator segments are positioned along the connection wires to provide high-temperature electrical insulation, creating a composite structure that maintains insulation reliability in extreme temperature environments where conventional single materials would fail.
Solution Approach 2:
The patent segments the insulation function by dividing the connection wire assembly into distinct sections: conductive metal wire segments for electrical connection and non-conductive ceramic insulator segments for electrical isolation. This segmentation allows each component to perform its specific function optimally, with the ceramic segments providing distributed insulation along the wire length.
2Reliability
If ceramic insulators are added to connection wires, then the reliability improves through better insulation, but the device complexity increases
Solution Approach 1:
The patent implements the nesting principle by placing ceramic insulator segments directly along the connection wires, with the insulators nested within or alongside the wire assembly. This integrated nesting approach allows the insulation function to be embedded within the existing wire structure rather than adding separate external insulation components.
Solution Approach 2:
The ceramic insulator segments act as intermediary elements between adjacent metal wire segments or between the wire and surrounding conductive structures. These insulator intermediaries prevent direct electrical contact where it should be prohibited, serving as mediating components that enable reliable electrical isolation in high-temperature environments.
3Object-affected harmful factors
If insulated connection wires are used in high temperature environments, then the safety improves, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-attaching or pre-positioning ceramic insulator segments onto or alongside the connection wires before final assembly. This preliminary preparation of insulated wire assemblies simplifies the overall manufacturing process by allowing wire preparation to be done separately and independently from the main sensor assembly operations.
Solution Approach 2:
The patent changes the material parameter of the insulation from conventional organic materials to ceramic materials, which fundamentally alters the temperature resistance parameter. This parameter change enables the insulation to withstand high-temperature environments without degradation, eliminating safety hazards while the modular ceramic segments keep manufacturing complexity manageable.
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
Ceramic insulators ensure compliance with dielectric test requirements and enhance safety and durability, preventing insulation failures and health hazards during sensor operation in high-temperature environments.
Implementation Method 1
the at least one ceramic insulator is positioned within the wire protection housing and defines a plurality of insulator openings. In some embodiments, each of the plurality of connection wires passes through one of the plurality of insulator openings.
Data Source
AI summary
Various examples of the present disclosure provide aircraft engine sensing apparatuses and methods of manufacturing aircraft engine sensing apparatuses. For example, an example aircraft engine sensing apparatus includes an aircraft engine sensor, a plurality of connection wires, and at least one ceramic insulator. In some examples, the aircraft engine sensor is positioned within an aircraft engine. In some examples, the plurality of connection wires connect the aircraft engine sensor to a sensor connector. In some examples, the plurality of connection wires are positioned within a wire protection housing. In some examples, the at least one ceramic insulator is positioned within the wire protection housing and defines a plurality of insulator openings. In some examples, each of the plurality of connection wires passes through one of the plurality of insulator openings.