Magnetostrictive Oscillator Probe Surface Finish Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current magnetostrictive oscillator ice rate sensor systems suffer from accuracy issues worse than 20%, which is unsatisfactory for measuring liquid water content in aviation icing conditions, affecting aircraft safety and performance.
Innovation Solution
An enhanced surface finish on magnetostrictive oscillator detector probes is achieved through statistical process control, involving measurement of external surface roughness and parameters like bath temperature, soak time, and chemical concentration, with optional use of optical instruments or surface profilometers to ensure the surface roughness meets critical values, minimizing liquid water retention post-de-icing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manufacturing processes are used for magnetostrictive oscillator probes, then manufacturing simplicity is maintained, but measurement accuracy deteriorates (worse than 20% error)
Solution Approach 1:
The patent applies parameter changes by establishing specific numerical ranges for surface roughness (Ra ≤ 0.8 μm) and controlling metal plating bath parameters (temperature, concentration, time) to improve measurement accuracy. This directly addresses the contradiction by transforming the manufacturing process parameters to achieve the required surface quality.
Solution Approach 2:
The patent implements feedback through statistical process control where surface roughness is measured on sample probes, the data is recorded and evaluated for trends, and the manufacturing process is adjusted based on this feedback to maintain consistent surface quality and measurement accuracy.
2Measurement precision
If surface roughness is not controlled, then manufacturing complexity is reduced, but liquid water retention increases causing measurement errors
Solution Approach 1:
The patent changes the surface finish parameter from conventional uncontrolled roughness to a specifically controlled range (Ra ≤ 0.8 μm) through standardized metal plating processes, thereby reducing liquid water retention while maintaining manageable manufacturing complexity through established industrial processes.
Solution Approach 2:
The patent utilizes metal plating bath processes (involving liquid chemicals, temperature control, and electrochemical deposition) to control surface roughness. This hydraulic/chemical approach provides systematic control over surface properties without requiring complex mechanical finishing operations.
3Manufacturing precision
If metal plating parameters are not monitored, then manufacturing process simplicity is maintained, but surface roughness consistency deteriorates
Solution Approach 1:
The patent applies feedback through statistical process control where metal plating bath parameters (temperature, chemical concentration, soak time) are measured and recorded, evaluated for trends, and used to adjust the manufacturing process to maintain consistent surface roughness across production batches.
Solution Approach 2:
The patent replaces direct mechanical surface finishing operations with controlled metal plating processes, where electrochemical deposition and standardized bath parameters provide more consistent surface roughness control compared to mechanical methods, while still maintaining manufacturing simplicity through established industrial processes.
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 improves the accuracy of ice rate sensor measurements to 20% or less, meeting design targets for aviation applications by controlling surface roughness and reducing measurement errors.
Implementation Method 1
A current method that is employed to measure LWC utilizes a magnetostrictive oscillator (MRO) vibrating probe that extends into the airstream
Implementation Method 2
a driving circuit that senses the resonant frequency of the probe
Implementation Method 3
As ice accretes on the probe, the probe's resonant frequency decreases due to the increase in mass
Implementation Method 4
At the end of the ice accretion cycle a heater internal to probe is energized to rapidly melt the ice on the surface on the probe
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A method of improving the measurement accuracy of digital ice rate sensors (20) by providing an enhanced surface finish on magnetostrictive oscillator detector probes, further comprising a method of statistical process control, comprising the steps of: measuring external surface roughness on each of the magnetostrictive oscillator detector probes and at least one parameter of a metal plating bath, wherein the at least one parameter is selected from the group consisting of bath temperature, soak time, and chemical concentration, and wherein the measuring occurs on at least a sample of the magnetostrictive oscillator detector probes; recording the external surface roughness and the at least one parameter; evaluating a series of the external surface roughness and the at least one parameter; and determining a trend in the series.