Air Data Probe Heater Assembly With Protrusions for Reliable Brazing
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Solution Overview
Problem
Existing air data probe heaters face challenges in successfully connecting to the probe head due to poor fit and large gaps, leading to difficulties in brazing and potential overheating, which can result in incomplete attachment and damage.
Innovation Solution
Incorporating protrusions on the heater and probe head surfaces to increase points of contact, allowing for a better interference fit and facilitating easier assembly, while maintaining a controlled gap for optimal thermal conductivity and braze material flow during the brazing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heater is directly connected to the probe head interior surface, then thermal conductivity is improved, but assembly difficulty increases due to poor fit and large gaps
Solution Approach 1:
Protrusions are added to the heater or probe head interior surface before assembly to pre-establish contact points. This preliminary structural modification ensures proper alignment and contact during the brazing process, eliminating assembly difficulties while maintaining thermal conductivity.
2Ease of operation
If protrusions are added to increase contact points, then assembly ease is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of modifying the entire heater or probe head surface, protrusions are added only at specific localized contact points on the interior surface. This selective modification improves assembly ease while minimizing manufacturing complexity by affecting only critical areas rather than the entire component.
3Ease of operation
If large gaps exist between heater and probe head, then assembly is easier, but brazing quality deteriorates leading to incomplete attachment
Solution Approach 1:
The interior surface is segmented into multiple protrusions distributed around the cavity rather than a single continuous surface. This segmentation creates multiple discrete contact points that ensure proper brazing quality while allowing the overall assembly process to remain simple and easy to perform.
4Manufacturing precision
If protrusions are used to define contact, then brazing quality is improved, but the risk of overheating during assembly increases
Solution Approach 1:
Protrusions concentrate the thermal contact at specific localized points rather than across the entire surface. This localized contact improves brazing quality by ensuring proper heat transfer at critical joints while reducing the overall thermal mass in contact, thereby minimizing the risk of overheating during the brazing process.
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 faster and more reliable assembly of the heater within the probe head, ensuring proper thermal conductivity and complete brazing, preventing overheating and ensuring the heater is securely attached, thus improving the functionality and longevity of the air data probe.
Implementation Method 1
a maximum width of the gap being less than or equal to about 0.003 inch (76.2 microns), wherein the gap is completely filled by the braze material after brazing the heater to the probe head
Implementation Method 2
ensuring proper thermal conductivity and complete brazing, preventing overheating and ensuring the heater is securely attached
Data Source
AI summary
An air data probe includes a probe head having an interior surface defining a cavity, a component positioned within the cavity of the probe head, a plurality of protrusions defining contact between the interior surface of the probe head and a peripheral surface of the component prior to brazing the component to the probe head, and a braze material located between the interior surface of the probe head and the peripheral surface of the component as a result of brazing the component to the probe head.