Gearbox Wireless Sensor Integration Through a Sealed Housing

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Solution Overview

Problem

In rotorcrafts, traditional wired sensors are impractical for monitoring components within sealed or inaccessible systems like gearboxes due to the difficulty in accessing or powering them, making real-time monitoring and data collection challenging, especially for components that require significant effort or cost to retrofit.

Innovation Solution

An internal wireless sensor system with a gateway antenna and conductor penetrating the housing allows for wireless data transmission from sensors inside the gearbox to a rotorcraft computer, using a multifunctional antenna penetration that also serves existing operational systems, such as lubrication or debris sensors, reducing the need for multiple penetrations and maintaining a sealed environment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wired sensors are used to monitor components inside sealed gearboxes, then real-time monitoring capability is achieved, but the complexity of installation and maintenance increases significantly due to the need for penetrations and wiring through sealed housings

Engineering Contradiction:

Improvereal-time monitoring capabilityVSAvoidinstallation and maintenance complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces wired mechanical connections with a wireless communication system. A wireless sensor assembly monitors gearbox components and transmits data via radio frequency through the housing wall, eliminating the need for physical penetrations and wiring through sealed structures. This substitution resolves the contradiction by maintaining monitoring capability while removing installation complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts the communication function from the mechanical structure by using wireless transmission. The sensor assembly includes a wireless transceiver that communicates through the housing wall without requiring physical openings, separating the monitoring function from the structural integrity requirements of the sealed gearbox.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If multiple penetrations are created in the gearbox housing for sensors and other systems, then multiple functions are achieved, but the sealed integrity of the system is compromised

Engineering Contradiction:

Improvemulti-functionalityVSAvoidsealed integrity

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent creates a single multifunctional penetration in the gearbox housing that serves multiple purposes: it allows passage for the antenna while maintaining structural integrity and sealed characteristics. This single opening replaces what would otherwise require multiple separate penetrations for different systems, achieving versatility without compromising the housing's sealed nature.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple functions (antenna passage, structural support, and sealed maintenance) into a single integrated penetration design. The antenna passes through a specifically designed opening that maintains the housing's sealed integrity while serving the wireless communication function, merging what would be separate requirements into one solution.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If retrofitted wired sensors are installed in existing gearboxes, then monitoring capability is added, but the cost and effort of modification increases

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidretrofit cost and effort

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces complex mechanical installation requirements with wireless communication technology. The sensor assembly wirelessly transmits data through the existing housing structure without requiring modifications to create wiring pathways, significantly reducing retrofit costs and installation effort while maintaining monitoring capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 efficient real-time monitoring and data collection from internal gearbox components without the need for hardwired connections, reducing costs and complexity, while maintaining the sealed integrity of the system.

Implementation Method 1

a gateway antenna located inside of the gearbox housing configured to wirelessly communicate with the wireless sensor

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Implementation Method 2

a conductor extending through a penetration in the housing and connecting the gateway antenna and the wireless gateway

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11341790B2Gearbox internal sensor integration

Publication Date: 2022.05.24 TEXTRON INNOVATIONS INC

AI summary

An exemplary internal wireless sensor monitoring system includes a wireless sensor positioned inside of an enclosed housing to monitor a condition in the housing, a wireless gateway positioned outside of the housing, a gateway antenna located in the housing configured to wirelessly communicate with the wireless sensor, and a conductor extending through a penetration in the housing and connecting the gateway antenna and the wireless gateway.