Modular Speed Sensor Diffuser Assembly for Easier ACM Installation
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Solution Overview
Problem
Conventional aircraft environmental control systems face complex installation processes due to the need to thread speed sensor connections through ducting and housings in air cycle machines, making fault diagnosis and maintenance challenging.
Innovation Solution
A speed sensor module with a cylindrical design, including an outer, intermediate, and inner portion aligned on the shaft axis, is connected to a fan inlet and diffuser assembly, featuring a cylindrical assembly that creates an ejector gap for airflow diversion and simplifies installation through a self-contained, easily attachable unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the speed sensor connection is threaded through ducting and housings in conventional air cycle machines, then the speed sensor can measure rotational speed, but the installation process becomes complex and maintenance becomes challenging
Solution Approach 1:
The patent applies segmentation by separating the speed sensor module from the main air cycle machine housing. The speed sensor is mounted on an independently replaceable module that interfaces with the fan shaft, allowing the sensor to be serviced without disassembling ducting and housings. This modular approach divides the system into separable components, simplifying installation and maintenance while maintaining measurement reliability.
Solution Approach 2:
The patent uses an intermediary approach by introducing a modular adapter or interface component between the speed sensor and the fan shaft. This intermediate module provides the connection interface, allowing the sensor to be mounted without threading through existing ducting and housings. The intermediary module serves as a bridge that simplifies the connection process while maintaining functional integrity.
2Ease of operation
If the speed sensor is integrated within the air cycle machine housing, then the system remains compact, but fault diagnosis and maintenance become challenging
Solution Approach 1:
The speed sensor is segmented from the main system and placed on an independently accessible module. This segmentation allows technicians to quickly access and diagnose speed sensor issues without disassembling the entire air cycle machine, significantly improving fault diagnosis ease while managing system integration through standardized interfaces.
Solution Approach 2:
The modular speed sensor module is designed to be easily accessible and replaceable by maintenance personnel without requiring specialized tools or extensive disassembly. The module incorporates self-contained mounting features and clear access points, enabling quick self-service maintenance and diagnosis while maintaining compact system integration through standardized connection interfaces.
3Ease of manufacture
If a modular speed sensor module is used, then installation and maintenance are simplified, but additional components are introduced
Solution Approach 1:
The patent merges multiple functions into the modular speed sensor assembly, including the speed sensor, mounting interface, and sealing elements, into a single integrated module. This combining approach simplifies installation by reducing the number of separate components that need to be assembled, while still maintaining modularity for ease of maintenance. The merged module replaces what would otherwise require multiple separate parts.
Data Source
AI summary
An environmental control system, includes an air cycle machine for conditioning an interior space with cooling air, the air cycle machine including a fan coupled to a shaft that rotates about a shaft axis, the fan being located at a distal end of the air cycle machine; a speed sensor module having a speed sensor for sensing a rotational speed of the shaft; wherein the speed sensor module includes an outer portion having a first bore aligned on the shaft axis, an intermediate portion having a second bore aligned on the shaft axis, and an inner portion aligned on the shaft axis; and a diffuser assembly including a cylindrical assembly for ducting a first portion of the cooling air to an inlet side of the fan and for communicating a second portion of the cooling air directly to a discharge side of the fan without passing the inlet side.