Layered Ice Artificial Bird Manufacturing for Aircraft Impact Testing
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Solution Overview
Problem
Current methods for simulating bird strikes in aircraft engine testing lack consistency and reproducibility, as they fail to accurately replicate the physical properties of real birds, such as mass, shape, density, and impact effects.
Innovation Solution
The development of an apparatus and method for manufacturing artificial birds using layered ice, where crushed ice is compressed and re-frozen within a mold to create a uniform density and shape, mimicking the impact effects of real birds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If artificial birds are made using conventional materials and methods, then manufacturing flexibility is maintained, but manufacturing precision and consistency of physical properties (mass, shape, density) deteriorate
Solution Approach 1:
The patent changes the physical state parameter of water from liquid to solid (ice) to create artificial birds with consistent properties. By controlling freezing parameters and using ice as the base material, the invention achieves reproducible mass, shape, and density that match real bird characteristics, resolving the contradiction between manufacturing precision and ease of manufacture.
Solution Approach 2:
The invention utilizes the phase transition of water to ice to create artificial birds. The freezing process transforms liquid water into solid ice with specific density and structural properties, enabling consistent reproduction of bird-like physical characteristics. This phase transition approach directly addresses the need for manufacturing precision while maintaining relative simplicity in the manufacturing process.
2Reliability
If artificial birds are designed to accurately replicate real bird properties, then impact testing reliability is improved, but device complexity increases
Solution Approach 1:
The manufacturing apparatus is divided into distinct functional modules: a forming module that shapes the ice, a freezing module that solidifies the material, and a release module that extracts the artificial bird. This segmentation allows each module to perform its specific function efficiently, achieving reliable artificial bird production without requiring overly complex integrated systems.
Solution Approach 2:
The invention creates simplified copies of real birds using ice that replicate the essential physical properties (mass, shape, density) needed for impact testing. Rather than attempting to perfectly reproduce all biological characteristics, the patent focuses on copying the critical parameters that affect impact dynamics, thereby achieving testing reliability without excessive device complexity.
3Adaptability or versatility
If multiple bird species are simulated, then adaptability of the testing system is improved, but manufacturing precision for each species deteriorates
Solution Approach 1:
The manufacturing apparatus is designed as a universal system that can produce artificial birds representing different species by adjusting key parameters such as size, shape, and mass. The same core device (mold, freezing mechanism, release system) serves multiple functions across different bird types, allowing the system to adapt to various species requirements while maintaining manufacturing precision through controlled parameter variation rather than species-specific complex mechanisms.
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
This approach allows for consistent and reproducible formation of artificial birds that accurately represent the kinetic energy release during bird ingestion, enabling reliable testing and analysis of aircraft engine components.
Implementation Method 1
a compressor to compress an ice surface of at least one of the first layer or the second layer of the crushed ice to form indentations on the ice surface
Implementation Method 2
a freezer to re-freeze the crushed ice layers inside the mold to form an artificial bird
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
Methods and apparatus for artificial bird manufacturing in impact testing is described herein. An apparatus to generate an artificial bird for impact testing includes a mold generator to form a mold based on a bird class identification, a mold filler to fill the mold with a first layer of crushed ice and a second layer of crushed ice, a compressor to compress an ice surface of at least one of the first layer or the second layer of the crushed ice to form indentations on the ice surface, and a freezer to re-freeze the crushed ice layers inside the mold to form an artificial bird.