Remote Inline Heater Control for Lightweight Aircraft Tubing
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Solution Overview
Problem
Conventional thermostats for aircraft systems require local mounting, adding weight and complexity, and lack efficient fault monitoring and control capabilities.
Innovation Solution
An inline heater controller with a resistive temperature sensor and printed circuit board design, mounted on an aerospace connector, providing modular fault monitoring and control, reducing space requirements and enabling remote monitoring and control of aircraft system components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermostats are locally mounted to heated hardware, then temperature control function is achieved, but weight and device complexity increase
Solution Approach 1:
The patent extracts the temperature sensing function from the heater assembly by using a separate temperature sensor (discrete component or integrated sensor) that can be positioned remotely. The controller receives temperature data from this separate sensor via a wire harness, eliminating the need to mount a thermostat directly on the heated hardware, thereby reducing weight and complexity of the heater assembly while maintaining temperature control functionality.
2Reliability
If conventional thermostats are locally mounted to heated hardware, then temperature control function is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the temperature control logic from the heater assembly into a separate controller unit. This controller integrates the temperature sensor interface, control algorithm, and actuator control in one modular unit that communicates with the heater via electrical signals, simplifying the overall system architecture and reducing the complexity of the heated hardware assembly.
Solution Approach 2:
The controller is designed as a multi-functional unit that can interface with different types of temperature sensors, control various types of heaters, and provide multiple output modes (PWM, relay, solid state). This universal design reduces the need for specialized components for each application, thereby reducing overall device complexity.
3Volume of moving object
If inline heater controller is mounted on aerospace connector back shell, then space requirements are reduced, but mounting precision requirements increase
Solution Approach 1:
The patent merges the controller mounting structure with the existing aerospace connector back shell. The controller is mounted directly to the back shell, which serves as an existing structural component. This integration eliminates the need for separate mounting brackets or housings, reducing overall space requirements while utilizing the precision already inherent in the connector assembly.
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
Enables efficient temperature monitoring and control of aircraft components, reduces weight and space requirements, and facilitates quick identification and isolation of faults, allowing for reduced maintenance downtime.
Implementation Method 1
The inline heater controller interfaces to a heater by means of a wire harness. The wire harness may include a resistive temperature sensor locally mounted on the heater.
Data Source
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AI summary
An inline heater system on board an aircraft includes a heater element positioned within a tubing, at least one sensor positioned within the tubing configured to monitor the temperature within the tubing, and an inline heater controller configured to receive information regarding the heater element via the at least one sensor. The inline heater controller is positioned at a location spaced away from the heater element and the tubing. The inline heater controller includes a printed circuit board configured to receive the information regarding the heater element via the at least one sensor, and an aerospace connector configured to transmit the information regarding the heater element via the at least one sensor to the aircraft.