Liquid Bath Ice Protection Test System for Aircraft Parts

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Solution Overview

Problem

Current methods for testing aircraft ice protection equipment in icing tunnels are expensive and time-consuming, as they require multiple tests to detect defects in heat transmission due to air gaps in the matting between heating elements and the aircraft skin, which can lead to unacceptable ice buildup.

Innovation Solution

A liquid-based ice protection test system that simulates icing conditions using a low-temperature bath with a temperature sensing device and agitation mechanism to rapidly detect defects in heat transfer, allowing for the identification of air gaps and other bonding issues without the need for repeated icing tunnel testing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If icing tunnel testing is used to detect heat transmission defects, then measurement precision is improved, but loss of time and productivity deteriorate due to multiple repeated tests required

Engineering Contradiction:

Improvedetection of heat transmission defectsVSAvoidtime for multiple repeated tests

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by implementing a non-destructive testing method using thermal imaging and heat flux measurement before the part undergoes repeated expensive icing tunnel tests. This preliminary screening detects bonding defects and air gaps in the matting layer early in the manufacturing process, preventing the need for multiple repeated icing tunnel tests and reducing time loss while maintaining measurement precision.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If icing tunnel testing is used to ensure ice protection performance, then reliability is improved, but loss of time and productivity worsen due to the expensive and time-consuming nature of the tests

Engineering Contradiction:

Improveice protection performanceVSAvoidtesting throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies segmentation by dividing the testing process into two distinct stages: (1) a preliminary non-destructive screening stage using thermal imaging and heat flux measurement to detect bonding defects, and (2) a final validation stage using icing tunnel testing only for parts that pass the screening. This segmentation ensures reliability by maintaining the icing tunnel as the gold standard while improving productivity by filtering out defective parts before they consume expensive test resources.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements preliminary action through the non-destructive testing method that screens for bonding defects before parts undergo expensive icing tunnel testing. This preliminary detection of air gaps and matting defects ensures that only parts with proper heat transmission characteristics proceed to reliability validation, thereby maintaining ice protection performance standards while significantly improving testing throughput and reducing costs.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If multiple icing tunnel tests are performed to detect matting defects, then measurement precision is improved, but loss of substance and cost worsen

Engineering Contradiction:

Improvedetection of air gaps in mattingVSAvoidcost of repeated testing

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The patent applies mechanics substitution by replacing the mechanical/aerodynamic icing tunnel testing system with a thermal field-based non-destructive testing method for preliminary defect detection. This substitution uses thermal imaging cameras and heat flux sensors to detect air gaps and bonding defects in the matting layer, achieving the same measurement precision for defect detection without the high costs associated with repeated icing tunnel tests.

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

This system enables rapid and cost-effective screening of aircraft parts, reducing the need for multiple icing tunnel tests and preventing defective parts from being tested unnecessarily, thereby saving resources and time while ensuring effective ice protection performance.

Implementation Method 1

a liquid based ice protection test system that simulates icing conditions using a low-temperature bath

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

a temperature sensing device and agitation mechanism to rapidly detect defects in heat transfer

Methodology Applied

Scientific EffectTemperature sensing: Thermocouple

Implementation Method 3

agitation mechanism to rapidly detect defects in heat transfer

Methodology Applied

Scientific EffectFluid circulation: Convection

Data Source

PatentUS9417137B2Liquid based ice protection test systems and methods

Publication Date: 2016.08.16 TEXTRON INNOVATIONS INC

AI summary

A liquid based ice protection test system for testing an aircraft part having a first heating element comprises a tub configured for retaining a low temperature bath. The system also includes a first support member for suspending the aircraft part in the tub and a first temperature sensing device for sensing temperatures from one or more locations of a skin of the aircraft part.