Nacelle Load Cell Structural Path Failure Detection

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Solution Overview

Problem

Existing methods for detecting structural load path failures in aircraft propulsion system nacelles are inadequate, as they rely on periodic visual inspections that are time-consuming and may not detect latent failures.

Innovation Solution

An assembly for an aircraft propulsion system that includes a gas turbine engine, a nacelle housing the engine, a load cell to measure loading at structural load paths, and a controller to compare engine output parameters and measured loadings to identify structural load path failures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If periodic visual inspections are performed to identify nacelle structural load path wear, degradation, and failure, then some instances of wear, degradation, and failure can be identified, but latent failures remain undetected and inspection time is consumed

Engineering Contradiction:

Improvedetection reliabilityVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces periodic visual inspections with an automated load cell monitoring system that continuously measures mechanical loading. The load cell provides real-time data on structural load paths, enabling detection of latent failures without time-consuming visual inspections. The system automatically compares measured loading against threshold values to identify failures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements continuous monitoring of structural load paths through load cells that operate continuously during engine operation. This continuous action replaces periodic inspections, providing ongoing detection capability that captures latent failures as they occur rather than relying on intermittent visual checks.

Inventive Principle:

Principle #20Continuity of useful action

2Reliability

If visual inspections are used to detect structural load path failures, then some failures can be identified, but latent failures are difficult or impossible to detect

Engineering Contradiction:

Improvefailure detection capabilityVSAvoidlatent failure detection difficulty

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent substitutes visual inspection with mechanical sensing through load cells embedded in structural load paths. These load cells convert mechanical loading into measurable electrical signals, enabling detection of latent failures that are invisible to visual inspection but detectable through continuous mechanical monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces load cells as intermediary sensing elements between the structural load paths and the detection system. These load cells act as mediators that translate internal structural loading conditions into measurable signals, bridging the gap between hidden latent failures and detectable parameters.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If load cells are installed to continuously monitor structural load paths, then latent failures can be detected early, but device complexity increases

Engineering Contradiction:

Improveearly failure detectionVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the monitoring function from complex visual inspection procedures and isolates it into discrete load cell sensors embedded in critical structural load paths. This extraction simplifies the overall system by replacing complex inspection processes with simple mechanical sensing elements that provide targeted monitoring.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The load cells are designed to be self-monitoring, automatically measuring and reporting structural loading without requiring external inspection systems. The system uses the engine's own operation to generate the monitoring function, where load cells continuously measure loading during normal engine operation without requiring separate inspection activities.

Inventive Principle:

Principle #25Self-service

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 enables early detection of structural load path failures, reducing the need for time-consuming visual inspections and improving aircraft operational efficiency by identifying latent failures during high-power engine conditions.

Implementation Method 1

The load cell is configured to measure a loading of the nacelle at a structural load path position of the nacelle

Methodology Applied

Scientific EffectLoad cell measurement:

Data Source

PatentUS20250051021A1Loss of load path detection system for aircraft propulsion system nacelle and method for using same

Publication Date: 2025.02.13 ROHR INC

AI summary

An assembly for an aircraft propulsion system includes a gas turbine engine, a nacelle housing the gas turbine engine, a load cell disposed on the nacelle, and a controller. The load cell is configured to measure a loading of the nacelle at a structural load path position of the nacelle. The controller is connected in signal communication with the load cell. The controller is configured to compare an engine output parameter of the gas turbine engine to a threshold engine output parameter to identify the engine output parameter is greater than or less than the threshold engine output parameter, compare the measured loading of the load cell to a zero-load value for the structural load path position to identify the measured loading is greater than or less than the zero-load value, and identify a structural load path failure for the structural load path position.