Gas Turbine Temperature Sensor Wire Resonance Control
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Solution Overview
Problem
Existing temperature sensors in gas turbine engines, such as resistance temperature detectors, are prone to failure due to resonance from low-energy, high-frequency vibrations that match the natural resonance frequency of the unsupported wire, leading to potential rupture and reduced reliability.
Innovation Solution
The introduction of potting material at intermediary locations along the wire within the core to increase the natural resonance frequency of the unsupported wire segments, preventing resonance with problematic vibration frequencies and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire is left unsupported in the cavity, then the manufacturing process is simple, but the wire is susceptible to resonance from vibrations causing failure
Solution Approach 1:
The patent applies preliminary action by pre-positioning the wire at the center of the cavity using a mandrel during manufacturing, and by pre-filling the cavity with potting material that will later provide support. This ensures the wire is properly positioned and protected before operation, preventing vibration-induced failure without complicating the manufacturing process
Solution Approach 2:
The patent uses an intermediary approach by introducing potting material as a mediator between the wire and the cavity walls. This potting material fills the space around the wire and provides mechanical support, damping vibrations and preventing resonance while maintaining the simple overall structure of the temperature sensor
2Reliability
If the wire is fully supported along its length, then reliability is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies local quality by providing support only where needed - specifically at the ends of the wire and at intermediary locations along its length - rather than uniformly supporting the entire wire. This targeted approach improves reliability at critical points while minimizing device complexity and avoiding unnecessary structural additions
Solution Approach 2:
The patent changes the physical state of the potting material from liquid (during filling) to solid (after curing) to provide mechanical support. This parameter change allows the same material to serve multiple functions: filling the cavity during manufacturing and providing structural support during operation, thereby improving reliability without increasing complexity
3Reliability
If the wire is supported at intermediary locations, then resonance frequency is increased and reliability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent uses preliminary action by incorporating support structures into the core during manufacturing, before the temperature sensor is assembled. The core is pre-formed with cavities and support features that will later hold the wire at appropriate intervals, ensuring proper wire positioning and resonance control without adding complex assembly steps
Solution Approach 2:
The patent merges multiple functions into the core structure: the core provides mechanical support, houses the cavity for the wire, and incorporates intermediary support features all in one component. This consolidation improves reliability through proper wire support while avoiding the complexity of separate support structures or assembly operations
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 increases the natural resonance frequency of the wire, reducing the likelihood of failure from low-energy vibrations and enhancing the reliability and lifespan of the temperature sensor while maintaining cost and weight considerations.
Implementation Method 1
the potting material to hold a portion of the wire relative to the core thereafter, thereby impeding resonance of the wire at lower frequencies than the natural frequencies of any remaining unsupported portions of the wire
Implementation Method 2
the resistance temperature detector (RTD), which is based on the principle that the resistance of a metal varies depending on the temperature
Data Source
AI summary
The temperature sensor can have a core having a length extending between two ends, the core having a cavity extending along the length, a wire extending in the cavity, along the length, the wire fixed at both ends, the core having a transversal aperture at an intermediary location between the ends, the transversal aperture leading into the cavity, and a potting filling a portion of the cavity and supporting the wire at the intermediary location of the transversal aperture.