Integrated Flow Sensor Fastener Assembly for Aircraft
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Solution Overview
Problem
Conventional flow sensors in aircraft require additional fasteners for installation, which can create structural weaknesses and necessitate redesign or re-certification, as they cannot be integrated into existing fasteners without compromising load-carrying capacity or fitting flush with the surface.
Innovation Solution
A flow sensor and fastener assembly where the sensor is integrated into a conventional fastener, featuring a sensor housing and a threaded shank with a bore to house the sensor, allowing it to be replaced without removing the fastener, maintaining structural integrity and compatibility with existing fastening systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flow sensor is installed using additional fasteners, then the sensor can be securely attached to the aircraft structure, but the structural integrity is compromised and redesign or re-certification is required
Solution Approach 1:
The patent combines the fastener and flow sensor into a single integrated assembly. The sensor is mounted within the fastener head, allowing the same component to perform both fastening and sensing functions. This eliminates the need for separate sensor mounting fasteners, thereby avoiding additional structural penetrations and preserving structural integrity while maintaining reliable sensor attachment.
Solution Approach 2:
The fastener is designed to serve multiple functions: it provides mechanical fastening capability while simultaneously housing and positioning the flow sensor. The integrated assembly acts as both a structural connector and a sensing device mount, reducing the total number of components and fastener holes required in the aircraft structure.
2Object-affected harmful factors
If a flow sensor is integrated into a fastener, then additional structural penetrations are avoided, but the load-carrying capacity of the fastener may be compromised
Solution Approach 1:
The flow sensor is nested within the hollow interior of the fastener head. The sensor housing is positioned inside the fastener head cavity, with the sensor sensing surface flush with the external surface of the fastener head. This nesting arrangement utilizes the existing fastener head volume to house the sensor without requiring additional structural modifications or penetrations beyond the original fastener hole.
3Shape
If conventional fasteners are used for sensor installation, then the sensor can be fitted flush to the surface, but additional fasteners are required creating structural weaknesses
Solution Approach 1:
The fastener and flow sensor are merged into a single integrated assembly where the sensor is mounted within the fastener head. This combination eliminates the need for separate sensor mounting fasteners while maintaining the flush surface alignment capability, as the sensor sensing surface is positioned flush with the external surface of the fastener head.
Data Source
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AI summary
A flow sensor and fastener assembly (101, 102, 103, 104), comprising at least the following modules: a sensor housing (4, 54, 74) and a fastener element(6, 62); wherein : the sensor housing (4, 54, 74) is adapted to receive a flow-based sensor (2), e.g. a MEMS airflow sensor; the sensor housing (4, 54, 74) comprises connection means (20, 50, 80) for transmitting sensing signals from a fitted flow-based sensor(2); the fastener element (6; 62) comprises a head (22) and a shank (24), at least part of the shank (24) being externally threaded (26); the fastener element (6, 62) comprises a bore (28) extending through the whole length of the fastener element (6, 62); and the bore (28) is shaped at the head (22) end of the fastener element (6, 62) to provide a sensor housing receiving part(30).