Monolithic Magnetostrictive Load Sensor for Aircraft Braking
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Solution Overview
Problem
Conventional load sensors are costly, inaccurate when force is not applied uniformly, and have size limitations due to their diameter to thickness ratio, making them unsuitable for applications like aircraft braking systems where weight and accuracy are critical.
Innovation Solution
A monolithic load sensor using a magnetostrictive material with a wire disposed in a dado or channel, allowing for accurate measurement of mechanical loads through changes in magnetic flux, which is less affected by the location of the applied load and can be manufactured with a more favorable diameter to thickness ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional resistance elements are glued to elastic bodies, then load measurement can be achieved, but manufacturing cost increases and manufacturing precision requirements become more stringent
Solution Approach 1:
The patent combines the elastic body and resistance element into a single monolithic magnetostrictive component. The magnetostrictive material itself serves as both the elastic structure and the sensing element, eliminating the need for separate resistance elements and bonding processes. This integration reduces manufacturing steps and cost while maintaining measurement accuracy through the inherent magnetostrictive properties of the material.
Solution Approach 2:
The patent replaces the mechanical bonding process (gluing resistance elements to elastic bodies) with a magnetic field-based sensing mechanism. The magnetostrictive material converts mechanical stress directly into magnetic flux changes, which are detected by the coil winding. This substitution eliminates the need for precise mechanical bonding and reduces manufacturing complexity.
2Strength
If conventional sensors are made with diameter to thickness ratio of three to one, then structural integrity is maintained, but sensor thickness becomes excessive for weight-sensitive applications
Solution Approach 1:
The patent changes the fundamental parameter of the sensing mechanism from electrical resistance to magnetic flux. This parameter change allows the sensor to achieve structural integrity with a much lower diameter to thickness ratio. The magnetostrictive material can be made thinner while still providing sufficient structural strength, thereby reducing sensor weight for aircraft applications.
3Adaptability or versatility
If conventional sensors are used where force is not applied uniformly, then general load sensing is possible, but measurement accuracy deteriorates
Solution Approach 1:
The patent creates a universal sensor design where the magnetostrictive material's inherent properties allow it to function accurately regardless of load application location. The monolithic structure with integrated coil winding provides multi-functionality, enabling the sensor to measure load accurately whether force is applied uniformly or non-uniformly, making it suitable for diverse applications including aircraft braking systems.
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 solution provides a cost-effective, accurate, and robust load sensor that can measure mechanical loads with improved size efficiency, accommodating uneven force distribution and temperature variations, making it suitable for applications like aircraft braking systems.
Implementation Method 1
A monolithic load sensor using a magnetostrictive material with a wire disposed in a dado or channel, allowing for accurate measurement of mechanical loads through changes in magnetic flux
Data Source
AI summary
A load sensor is provided comprising a magnetostrictive material and a wire. The magnetostrictive material may comprise an aperture, a first face, a second face, a thickness, and a first dado. The wire is disposed at least partially in the first dado, wherein the first dado at least partially transverses at least one of the first face and the second face, wherein the wire at least partially transverses the first face and the second face. The load sensor may also comprise a magnetostrictive material comprising an aperture, a first face, a second face, a thickness, and a first channel, and a wire disposed at least partially in the first channel, wherein the first channel at least partially transverses at least one of the first face and the second face, wherein the wire at least partially transverses the first face and the second face.