Flexible Sensor Film for Early Ice Accretion Classification
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Solution Overview
Problem
Aircraft are at risk due to ice buildup on flight components, which can alter flight characteristics and lead to catastrophic events such as engine stall, necessitating early detection systems for ice accretion.
Innovation Solution
A flexible sensor film with water sensors and a sensor head that measures ice distribution and type, predicting ice formation severity and generating warnings or de-icing actions based on data from water and temperature sensors, optionally enhanced by machine learning models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single water sensor is used to detect ice presence, then the device complexity is reduced, but the measurement precision and ice classification capability deteriorate
Solution Approach 1:
The sensor system is segmented into multiple water sensors (first water sensor, second water sensor) with different ice collection efficiencies, allowing differentiated detection capabilities across the sensor array. This segmentation enables the system to classify ice types based on which sensors detect water, resolving the contradiction between simplicity and precision.
Solution Approach 2:
Different regions of the sensor film have different ice collection efficiencies, with the first water sensor having higher collection efficiency than the second water sensor. This local quality variation allows the system to infer ice location and type from the pattern of sensor activation, achieving precise measurement without requiring a single complex sensor.
2Measurement precision
If multiple water sensors with different ice collection efficiencies are used, then the ice classification capability is improved, but the device complexity increases
Solution Approach 1:
The sensor system is segmented into multiple water sensors (first water sensor, second water sensor) with different ice collection efficiencies, allowing differentiated detection capabilities across the sensor array. This segmentation enables the system to classify ice types based on which sensors detect water, resolving the contradiction between simplicity and precision.
Solution Approach 2:
The sensor film serves multiple functions simultaneously: it detects ice presence, determines ice location, classifies ice type, and monitors ice growth rate. By making the sensor system multi-functional, the patent avoids the need for separate systems for each measurement type, thereby managing complexity while achieving comprehensive measurement capabilities.
3Reliability
If early ice detection is implemented, then the safety and reliability are improved, but the loss of time for ice removal increases
Solution Approach 1:
The system performs preliminary detection of ice formation at early stages before ice buildup becomes severe. By detecting ice presence and classification early, the system enables timely de-icing actions to be taken, preventing catastrophic ice accumulation while allowing sufficient time for safe ice removal operations.
Solution Approach 2:
The system continuously monitors ice accretion through the water sensors and provides real-time feedback on ice presence, location, and type. This feedback enables dynamic adjustment of de-icing operations, ensuring that ice removal is timed optimally to maintain flight safety while minimizing time loss.
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 early detection and classification of ice accretion, allowing timely de-icing actions to prevent flight hazards by accurately predicting ice formation and degradation of aerodynamic performance.
Implementation Method 1
The water sensor comprises two or more electrical terminals, the raw data received from the sensor head includes a measure of capacitance between the at least two or more electrical terminals
Implementation Method 2
at least one temperature sensor for measuring the exterior temperature proximate to the exterior surface
Implementation Method 3
the controller being configured to determine an icing pattern on the exterior surface based on the raw data indicating the presence of water or ice, and based on the temperature measurement indicating a temperature less than a freezing temperature of water
Data Source
AI summary
An icing warning system for a structure with an exterior surface is described. The system includes a flexible sensor film including a plurality of water sensors for application to the exterior surface, wherein each water sensor is associated with a different collection efficiency. The system also includes a sensor head in electric communication with each of the water sensors that receives raw data from the water sensors. A controller in communication with the sensor head receives the raw data from each of the plurality of water sensors and receives a temperature measurement. The controller is configured to determine an icing pattern on the exterior surface based on the raw data indicating the presence of water or ice, and based on the temperature measurement indicating a temperature less than a freezing temperature of water.