Foldable HFCT Sensor for Aircraft Partial Discharge Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for detecting defects in aircraft wiring, such as visual inspection, are slow and unreliable, and commercially available high-frequency current transformers (HFCTs) are too large and heavy for permanent installation in aircraft wiring systems, necessitating a lightweight, high-bandwidth sensor for effective partial discharge monitoring.
Innovation Solution
A high-frequency current transformer (HFCT) sensor with an electrically conductive pattern on a flexible substrate, featuring segmented regions connected by intermediate regions for folding, and enhanced with magnetic material for sensitivity, designed to detect partial discharges in aircraft wiring systems, integrated with a data acquisition system for monitoring signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If commercially available high-frequency current transformers (HFCTs) are used for partial discharge detection, then detection capability is achieved, but the sensor becomes too large and heavy for permanent aircraft installation
Solution Approach 1:
The substrate is divided into multiple segmented regions connected by intermediate regions that can be folded along fold lines. This segmentation allows the substrate to be collapsed into a compact form during installation while maintaining the full sensing area when deployed, dramatically reducing the effective volume and weight footprint of the sensor in its installed state.
Solution Approach 2:
The substrate is configured to be folded along multiple fold lines between segmented regions to form a compact nested structure when not in use or during installation. This nesting principle allows the sensor to occupy minimal space and weight during permanent installation while providing sufficient sensing area when operational.
2Reliability
If visual inspection by maintenance personnel is used to detect wiring defects, then inspection can be performed, but the process is slow and unreliable
Solution Approach 1:
The monitoring system enables continuous automatic detection of partial discharges and wiring defects without requiring manual intervention. The system self-monitors the wiring system by detecting high-frequency signals generated during partial discharge events, eliminating the need for slow manual visual inspections while providing reliable, continuous defect detection.
Solution Approach 2:
The patent replaces manual visual inspection (mechanical human operation) with electronic sensing and signal processing. High-frequency current transformers detect electrical signals from partial discharges, and a data acquisition system processes these signals to identify wiring defects, providing both faster and more reliable detection than human visual inspection.
3Reliability
If manual visual inspection is performed by twisting wiring to check for chafing, then defect detection is attempted, but the inspection may cause additional problems
Solution Approach 1:
The patent replaces mechanical manipulation of wiring (twisting and physical inspection) with non-contact electrical field sensing. High-frequency current transformers detect partial discharge signals generated by insulation defects without requiring physical contact or manipulation of the wiring, thereby eliminating the risk of causing additional damage during inspection.
Solution Approach 2:
The patent introduces an intermediary sensing mechanism (electromagnetic field detection) between the inspector and the wiring system. Instead of directly manipulating the wiring with hands and tools, the system uses electromagnetic fields to detect insulation defects, eliminating direct mechanical contact that could cause harm.
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 HFCT sensor provides efficient and reliable detection of partial discharges in aircraft wiring, enhancing safety and reducing the risk of arcing, while being lightweight and suitable for permanent installation, improving the speed and accuracy of defect detection beyond traditional methods.
Implementation Method 1
partial discharge signal detection can be used to characterize the condition of wiring. If a partial discharge occurs, the discharge will generate high frequency electrical signals traveling along the cable. This high frequency electrical signal can be detected with high frequency current transformers (HFCTs).
Implementation Method 2
at least one electrically conductive pattern formed on a substrate
Data Source
AI summary
A high frequency current transformer (HFCT) sensor for detecting partial discharges produced by a component is disclosed. The HFCT sensor includes at least one electrically conductive pattern formed on a substrate, where the substrate comprises multiple segmented regions connected by intermediate regions for folding along multiple fold lines between the segmented regions to form the HFCT sensor. A system for monitoring at least one component of an aircraft wiring system is also disclosed. The monitoring system includes at least one of the HFCT sensors for detecting partial discharges produced by the aircraft wiring system component. The monitoring system further includes a data acquisition system configured to monitoring signals from the HFCT sensor(s).