Ice-Processing Device for Engine Component Testing
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Solution Overview
Problem
Conventional methods for certifying gas turbine engines against ice ingestion are inefficient, as they require testing the entire engine and make it difficult to visually inspect components after a failure, as ice melts before individual components can be disassembled and inspected.
Innovation Solution
An ice-processing device that simulates the effects of ice on gas turbine engine components by producing an adjustable ice stream with varying particle sizes and velocities, allowing individual components to be tested separately and mimicking the natural conditions encountered during engine operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire engine is subjected to a stream of ice particles for certification testing, then the certification can be performed according to FAA requirements, but it becomes difficult to visually inspect individual engine components to determine the cause of failure
Solution Approach 1:
The patent divides the engine testing process into segmentable components. Instead of testing the entire engine as one unit, the device allows individual components or assemblies to be tested separately by positioning them in the ice particle stream. This segmentation enables operators to isolate and inspect specific components after testing to determine failure causes, while still maintaining certification validity through systematic testing of all necessary components.
Solution Approach 2:
The patent introduces a positioning mechanism as an intermediary between the ice particle stream and the engine components. This intermediary system allows precise control of component placement within the test area, enabling selective exposure of specific components to ice particles. The positioning mechanism facilitates both the certification process and subsequent failure analysis by controlling which components are exposed and how they can be accessed for inspection.
2Reliability
If standard-size ice particles are discharged in large quantities to simulate a hailstorm, then the certification test can be performed, but the ice particles may build up in components making visual inspection difficult before the ice melts
Solution Approach 1:
The patent implements dynamic control of the ice particle discharge system, allowing adjustment of particle size, discharge velocity, and quantity based on specific testing requirements. This dynamic capability enables operators to optimize the ice stream parameters for each component being tested, achieving sufficient ice accumulation to simulate hailstorm conditions while maintaining component accessibility for inspection by controlling the intensity and duration of exposure.
Solution Approach 2:
The patent employs parameter changes in the ice particle characteristics (size, velocity, quantity) to resolve the contradiction. By varying these parameters, the system can create appropriate ice conditions for certification while avoiding excessive ice buildup that would prevent inspection. The ability to adjust parameters allows tailoring the test conditions to specific component requirements and inspection needs.
3Reliability
If a full-size working engine is used in the testing process, then the natural ice particle size and velocity distribution is achieved, but the device lacks controls for adjusting ice particle size and discharge velocity to simulate specific conditions
Solution Approach 1:
The patent creates a universal testing device that can accommodate different engine components and simulate various ice conditions through adjustable parameters. The system is designed to handle both full-size engine testing and individual component testing, and can adjust ice particle characteristics to match different operating conditions. This multi-functionality allows the device to replicate natural hailstorm conditions when needed while also enabling controlled simulations of specific ice exposure scenarios for different components and operating conditions.
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 precise testing and certification of gas turbine engine components by simulating the specific ice conditions each component would face, facilitating easier identification of failure causes and improving the certification process.
Implementation Method 1
a vacuum source positioned downstream of the component to simulate engine operating conditions that draw the ice stream through the component
Data Source
AI summary
An ice-processing device is configured to test a consequence of ice on an aircraft engine component by simulating an effect on the ice upstream of the component.