Gearbox Wireless Sensor In-Situ Charging via Access Port
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Solution Overview
Problem
Wireless sensors attached to the moving features of a rotorcraft gearbox face challenges in battery charging due to the need for costly gearbox rebuilds and the inefficiency of wireless power transmission over long distances, making it difficult to maintain their battery life between rebuilds.
Innovation Solution
A method and apparatus that involve accessing a port in the gearbox housing to align sensors with a charging unit, using either a rigid or articulating borescope to couple power transmission, and charging the sensors' batteries without disassembling the gearbox, allowing for efficient charging of multiple sensors without the need for a full rebuild.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wireless sensors are attached to moving features of the gearbox, then monitoring capability is improved, but battery charging becomes difficult without costly gearbox rebuilds
Solution Approach 1:
The gearbox housing is segmented with a dedicated access port that allows the charging unit to reach the sensor while the gearbox remains assembled. This segmentation enables independent access to the sensor for charging without requiring full disassembly of the gearbox.
Solution Approach 2:
A charging unit with an elongated member acts as an intermediary tool that transmits power through the access port to the sensor's power receiver. This intermediary enables power transmission without direct access to the battery, resolving the contradiction between maintaining gearbox integrity and enabling charging.
2Ease of operation
If sensors are positioned on moving features, then sensor exposure through housing opening is improved, but alignment complexity increases
Solution Approach 1:
Guiding members on the sensor emit light to indicate their position and orientation. This visual feedback mechanism simplifies the alignment process by allowing operators to see when the sensor is properly positioned within the access port, reducing alignment complexity.
Solution Approach 2:
The guiding members provide real-time visual feedback about the sensor's position relative to the access port. This feedback mechanism enables operators to adjust the sensor or charging unit alignment until the guiding members indicate proper positioning, making the alignment process more manageable.
3Productivity
If power transmission uses non-contact interface, then charging efficiency is improved, but transmission distance limitation becomes problematic
Solution Approach 1:
The charging unit's elongated member can be dynamically adjusted in length and positioning to optimize the distance between the power transmitter and the sensor's power receiver. This dynamic adjustment capability allows the system to achieve efficient power transmission while accommodating variations in sensor position and gearbox configuration.
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
Enables the charging of sensors on moving gearbox features without disassembling the gearbox, extending battery life and reducing maintenance costs by allowing for in-situ charging, thus improving the monitoring and detection of gearbox health and potential failures.
Implementation Method 1
the power transmitter of the charging and the first power receiver of the first sensor share a direct contact interface
Implementation Method 2
the power transmitter of the charging and the first power receiver of the first sensor share a non-contact interface
Data Source
AI summary
In an embodiment, an apparatus includes: a gearbox including: a housing having an opening; an input pinion disposed in the housing; a moving feature mechanically coupled to the input pinion, the moving feature and the input pinion being operable to convert between power and torque; and first sensors disposed on the moving feature, the first sensors having batteries, where the moving feature is operable to rotate about a common axis, each of the first sensors being exposed by the opening as the moving feature rotates about the common axis.