Sensor Probe Anti-Icing Thermal Insulation
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Solution Overview
Problem
Aircraft turbofan engine temperature sensors prone to icing, which can lead to inaccurate temperature measurements due to the operation of conventional anti-icing heaters that heat the ambient air.
Innovation Solution
A sensor probe with an anti-icing device comprising a thermally insulated heating element and a hydrophobic coating, where the heating element is isolated from the probe body and the coating defines the outer surface exposed to airflow, preventing ice formation without significantly affecting temperature measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional heater is used for anti-icing, then ice formation on the probe body is prevented, but the ambient air inside the probe is heated causing inaccurate temperature measurements
Solution Approach 1:
The probe is divided into distinct functional zones: an outer anti-icing device with heating element for ice prevention, and an inner sensing zone for accurate temperature measurement. The thermal insulation layer segments the heat transfer path, preventing heat from the heater from reaching the ambient air inside the probe, thus resolving the contradiction between ice prevention and measurement accuracy.
Solution Approach 2:
A thermal insulation layer is introduced as an intermediary between the heating element and the probe body/ambient air. This intermediary blocks heat transfer from the anti-icing heater to the temperature-sensing environment, allowing the heater to prevent ice formation on the outer surface while keeping the internal ambient air temperature unaffected for accurate measurements.
2Reliability
If a heater is operated continuously for anti-icing, then ice formation is prevented, but energy consumption increases
Solution Approach 1:
The anti-icing device incorporates a temperature sensor that monitors the probe surface temperature and automatically controls the heater operation. The system activates the heater only when icing conditions are detected or temperature drops below a threshold, and deactivates it when the threshold is reached, enabling self-regulated operation that prevents ice formation while minimizing energy consumption.
Solution Approach 2:
A feedback control mechanism is implemented where the temperature sensor continuously monitors the probe surface temperature and provides feedback to the heater control system. Based on this feedback, the heater is activated or deactivated to maintain the probe surface above the icing point, achieving reliable ice prevention with optimized energy usage by avoiding continuous operation.
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 effectively prevents ice formation on the probe while minimizing the impact on temperature measurement accuracy and reducing energy consumption compared to conventional anti-icing methods.
Implementation Method 1
a heating element thermally insulated from the probe body
Implementation Method 2
a thermal insulator bonded to the probe body and covering at least a portion of the heating element
Implementation Method 3
a hydrophobic coating covering the heating element for being heated by the heating element
Data Source
AI summary
Sensor probes with anti-icing and methods for manufacturing such sensor probes are disclosed. An exemplary sensor probe comprises a probe sensor, a probe body housing the probe sensor and an anti-icing device. The anti-icing device is bonded to and covers at least part of the probe body for preventing ice from forming on the probe body. The anti-icing device comprises a heating element thermally insulated from the probe body by a thermal insulator and a hydrophobic coating covering the heating element and defining an outer surface for exposure to an airflow. The heating element may be deposited using a direct write process.