Ice Protection System with Feedback Temperature Control
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Solution Overview
Problem
Ice protection systems for aircraft face challenges in maintaining stable temperatures on composite materials to prevent overheating and ice accumulation under varying icing conditions, with existing solutions prone to temperature overshoot and fluctuation.
Innovation Solution
An ice protection system with heater devices and temperature sensors that maintain a substantially constant temperature, using a control system to regulate heat output, ensuring stable operation and reducing the risk of overheating and ice accumulation across a range of icing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heater mat is periodically switched on and off to avoid overheating, then temperature overshoot is reduced, but the surface temperature repeatedly fluctuates
Solution Approach 1:
The patent implements a feedback control system where a temperature sensor continuously monitors the heater mat temperature and feeds this information back to the control system. The control system adjusts the heater mat power output in real-time based on the temperature feedback, maintaining stable surface temperature without repeated on/off cycling. This resolves the contradiction by providing continuous temperature regulation rather than periodic switching.
2Loss of time
If the temperature sensor is moved closer to the heater mat to reduce thermal lag, then temperature measurement responsiveness is improved, but the sensor may move out of the composite material region where temperature control is desired
Solution Approach 1:
The patent uses the composite material structure itself as an intermediary thermal path. The temperature sensor is positioned within the composite material and measures the temperature at the heater mat/composite material interface. This location provides both rapid response (close to heater mat) and accurate representation of the region requiring temperature control (within composite material), resolving the positioning contradiction.
3Productivity
If feedforward control is used to vary heater mat power based on outside air temperature, then response to icing conditions is improved, but other factors controlling heat flow and ice formation are not accounted for
Solution Approach 1:
The patent transitions from feedforward control (based only on outside air temperature) to feedback control (based on actual heater mat and surface temperature measurements). The feedback system automatically adapts to all factors controlling heat flow and ice formation, including but not limited to outside air temperature, by responding to actual temperature conditions. This provides both effectiveness and adaptability, resolving the contradiction.
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 system effectively maintains stable heater device temperatures, reducing the risk of overheating and ice accumulation, even under extreme icing conditions, while simplifying control schemes and predicting power consumption.
Implementation Method 1
Electrothermal ice protection systems comprise a large number of heater devices (such as heater mats)
Implementation Method 2
at least one temperature sensor for outputting at least one temperature signal, said at least one sensor being in thermal contact with at least one said heater device
Data Source
AI summary
An ice protection system for a structure having at least one surface to be protected from a range of icing conditions. The ice protection system includes at least one heater device, arranged in thermal contact with at least one surface to be protected; at least one temperature sensor for outputting at least one temperature signal, the sensor being in thermal contact with the heater device; and a control system for controlling the heat output of the heater device using the temperature signal. The control system is operable to control the heat output of the heater device in order to maintain the temperature of the heater device at a substantially constant temperature.