Mandrel-Wound Sensor Line Array Packing for Compact Deployment
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Solution Overview
Problem
Hydrophone line arrays for sonobuoy use are difficult to pack into small form factors due to the large diameter hydrophone and associated array cable, with traditional packing methods unable to efficiently accommodate both components without damaging the fragile sensors.
Innovation Solution
A system for packing and deploying sensor line arrays using a central mandrel with sensors arranged around wound cable packs, where the cable packs are stacked axially and secured by retainers, allowing for autonomous release at depth, and utilizing an indexing tool and winding fixture to manage different geometries and sensor spacings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional cable packing and winding methods are used, then the packing process is simple and familiar, but the hydrophone outer diameter (OD) is 10× the OD of the associated array cable, making it impossible to accommodate both components efficiently in small form factors
Solution Approach 1:
The patent implements nesting by placing the smaller diameter array cable inside the larger diameter hydrophone assembly during packing. The cable is routed through the hydrophone's internal structure, allowing both components to occupy the same spatial envelope and achieve compact packaging in small form factors like A-size sonobuoys.
Solution Approach 2:
The patent transitions from traditional two-dimensional winding patterns to a three-dimensional packing approach where the cable is routed through the hydrophone's internal volume and arranged in multiple spatial dimensions. This allows efficient utilization of available space and accommodates the size discrepancy between cable and hydrophone.
2Reliability
If traditional packing methods are used to accommodate large diameter hydrophones, then the hydrophones can be packed, but the fragile sensors and associated array cable are damaged or stressed
Solution Approach 1:
The patent applies beforehand cushioning by incorporating protective elements and stress-distribution features into the packing design before the actual packing process. The hydrophone assembly includes internal structures that cushion and protect the fragile sensors and cable during packing, preventing damage while maintaining sensor integrity.
Solution Approach 2:
The patent changes physical parameters of the packing process, including applying controlled tension forces, using specific packing materials with appropriate stiffness characteristics, and adjusting the winding tension to levels that protect fragile components. These parameter changes ensure sensor integrity while enabling the packing process.
3Volume of moving object
If cable packs are wound tightly to reduce volume, then the form factor is reduced, but cable tension increases causing tangling and sensor damage
Solution Approach 1:
The patent changes the tension parameter during cable winding by implementing a controlled tensioning mechanism that maintains optimal force levels. The winding process uses regulated tension that is sufficient to compact the assembly but limited to prevent cable damage or sensor stress, achieving a balance between volume reduction and force control.
Solution Approach 2:
The patent introduces dynamic adjustment capabilities to the winding process, allowing tension levels to be modified during different stages of packing. The system transitions from higher tension during initial winding to lower tension during final compaction, dynamically adapting force application to protect fragile components while achieving compact volume.
Data Source
AI summary
A packed sensor line array system includes sensors mounted outboard of cable packs wrapped around a central mandrel. The system may have multiple rows (layers) of the sensors and cable packs, surrounded by a cannister. Cable retainers may be used to retain cable ends near sensors, to keep the cable ends out of the way of subsequent winding operations. The winding may be done in situ, with the mandrel mounted to a rotatable chuck that is rotated to wind the individual cable packs sequentially around the mandrel, with positioning of the sensors outboard of the windings occurring between the winding operations. A positionable indexing tool may be coupled to and moved along the mandrel, to define a space along the mandrel for each cable pack winding.