Electronic Warfare Pressure Test Set for Dual-Pressure Leak Detection
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Solution Overview
Problem
Existing methods for testing aircraft defense systems fail to simulate the full range of pressures encountered by aircraft, limiting the detection of leaks and faults in onboard low-pressure systems.
Innovation Solution
A B-52 Electronic Warfare Pressurizing Test Set that applies both positive and negative pressures, utilizing durable mechanical and electrical systems with standardized components, and incorporates self-diagnostic functions to detect faults and leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional testing methods are used, then the testing process is simple, but the ability to simulate full range of pressures is limited
Solution Approach 1:
The test set integrates multiple functions into a single device: it can apply both positive and negative pressures, perform leak detection, conduct fault detection, and simulate various environmental conditions. This multi-functional design resolves the contradiction by enabling comprehensive pressure simulation capability while consolidating what would otherwise require multiple separate testing devices.
Solution Approach 2:
The patent introduces a microprocessor-based control system as an intermediary that coordinates the complex interactions between the pressure pump, valves, sensors, and display components. This intelligent mediator manages the dual-pressure system and various testing modes, making the complex device user-friendly and systematically controllable.
2Adaptability or versatility
If custom programmable elements are used, then functionality can be enhanced, but longevity is reduced and obsolescence risk increases
Solution Approach 1:
The patent uses a microprocessor to copy and store testing programs and parameters in non-volatile memory. This allows the system to retain testing functionality and configurations without requiring complex custom hardware for each function. The microprocessor-based approach provides flexibility while maintaining reliability through software-based control rather than fragile custom programmable elements.
Solution Approach 2:
The system allows testing parameters such as pressure levels, test durations, and thresholds to be modified through software configuration rather than requiring hardware changes. This parameter flexibility achieves enhanced functionality while maintaining system longevity through standardized, maintainable components.
3Measurement precision
If comprehensive fault detection systems are added, then leak and fault detection capability is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical detection systems with electronic sensors and microprocessor-based analysis. Pressure transducers and electronic monitoring circuits detect leaks and faults with high precision, while the microprocessor analyzes sensor data to identify various fault conditions. This substitution reduces mechanical complexity while improving detection accuracy.
Solution Approach 2:
The system incorporates feedback loops where sensors continuously monitor pressure changes and provide data to the microprocessor, which then adjusts testing parameters or alerts operators to detected faults. This intelligent feedback mechanism achieves comprehensive fault detection through coordinated sensor-controller-action cycles rather than complex parallel detection hardware.
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
Effectively simulates aircraft environmental conditions, ensuring reliable detection of leaks and faults in low-pressure systems, with enhanced durability and reduced maintenance needs.
Implementation Method 1
pressure decay monitored over time using an onboard pressure transducer
Implementation Method 2
The system allows the test volume to be pressurized to a preset or user-defined level
Implementation Method 3
The system also supports evacuation, reducing pressure to a user-selected absolute value
Implementation Method 4
Internal rechargeable Bren-tronics 24 VDC low-temperature-capable batteries
Data Source
AI summary
This invention is a robust pressure testing system designed for harsh environments with minimal user interaction and easy maintenance. It utilizes standardized electromechanical components and relay logic, avoiding custom elements to ensure long-term reliability and reduce obsolescence. The system operates at 24 VDC and accepts AC, internal battery, or external DC power, with overcurrent protection provided by fuses and breakers. It can pressurize and evacuate test volumes to user-specified levels, monitoring for leaks through pressure decay. The pneumatic system generates positive and negative pressures, controlled by electrically actuated valves, with filters and dryers preventing contamination. The instrumentation includes a pressure transducer and process timer for precise measurements, enhancing usability and adaptability in varied environments. Modular components and self-diagnostic features further improve system performance and compatibility.