Methods and apparatus for artificial bird manufacturing in impact testing
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Solution Overview
Problem
Existing methods for simulating bird strikes in aircraft engine testing lack consistency and reproducibility, as artificial birds do not accurately replicate the physical properties of real birds, leading to inconsistent and unreliable testing results.
Innovation Solution
A method and apparatus for manufacturing artificial birds using layered crushed ice, which are formed in a mold, compressed, and frozen to create a uniform density and shape, mimicking the impact effects of real birds during ingestion events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional artificial bird methods are used, then bird strike simulation can be performed, but consistency and reproducibility of physical properties are poor
Solution Approach 1:
The artificial bird is constructed from multiple discrete ice layers (typically 3-5 layers) rather than a single molded piece. Each layer is formed separately with controlled thickness and density, then bonded together. This segmentation allows precise control over the overall density and physical properties by adjusting individual layer characteristics, ensuring consistency and reproducibility across multiple artificial birds.
Solution Approach 2:
The invention controls physical parameters such as ice layer thickness, compression force, and freezing temperature to achieve consistent density and mechanical properties. By systematically varying and controlling these parameters during the layering process, the artificial birds achieve uniform physical properties that accurately simulate real bird characteristics, improving both manufacturing precision and testing reliability.
2Reliability
If real birds are used for testing, then accurate impact effects are achieved, but ethical concerns and availability issues arise
Solution Approach 1:
The invention creates artificial copies of real birds using ice layers that replicate the mass, density, shape, and impact characteristics of actual birds. These ice-based copies are designed to match the physical properties of target bird species without requiring actual birds, thereby achieving accurate impact simulation while eliminating ethical concerns and availability constraints associated with using real birds for testing.
3Manufacturing precision
If artificial birds are made with uniform density, then manufacturing consistency improves, but ability to simulate different bird species decreases
Solution Approach 1:
The invention enables dynamic adjustment of artificial bird properties by modifying the number of ice layers, individual layer thickness, and compression parameters. This allows the same basic layering process to produce artificial birds with different masses, densities, and dimensions suitable for various bird species, maintaining manufacturing consistency while achieving versatility across different simulation requirements.
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 method allows for consistent and reproducible formation of artificial birds that simulate the kinetic energy release of real birds, ensuring reliable engine component testing and compliance with regulatory guidelines.
Implementation Method 1
a freezer to re-freeze the crushed ice layers inside the mold to form an artificial bird
Data Source
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.