Aircraft Window Laminate Sensor Replacement Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Aircraft window laminates often require discarding the entire window due to failure of the embedded heat control sensor, which is costly and inefficient.
Innovation Solution
A method involving infrared camera inspection, ohmmeter testing, drilling, and encapsulation to replace the defective heat control sensor within the laminate, ensuring minimal disruption to the electrical heating ply and using a reversed engineered sensor with proper sealing to maintain functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat control sensor is embedded in the aircraft window laminate, then the sensor can effectively control the heating of the window, but the failure of the sensor results in discarding the entire window laminate
Solution Approach 1:
The invention segments the sensor replacement process into discrete steps: drilling a hole through the laminate, inserting the new sensor, and sealing the hole. This allows replacement of only the defective sensor component rather than discarding the entire window laminate assembly.
Solution Approach 2:
The defective sensor is extracted from the laminate by drilling a hole through it, allowing removal and replacement of only the sensor component while leaving the rest of the window laminate intact and reusable.
2Reliability
If the heat control sensor is embedded in the aircraft window laminate, then the sensor can effectively control the heating of the window, but replacement of the sensor requires complex procedures
Solution Approach 1:
The replacement procedure is segmented into three simple steps: drill a hole, insert the sensor, and seal the hole. This breakdown makes the repair process manageable and can be performed without specialized equipment or complex procedures.
Solution Approach 2:
The aircraft operator can perform the sensor replacement themselves using basic tools, eliminating the need for specialized service facilities or complex repair procedures. The process is designed to be self-serviceable.
3Reliability
If the entire window laminate is discarded due to sensor failure, then the aircraft can maintain safety standards, but the cost and time for replacement increase
Solution Approach 1:
By segmenting the window laminate into replaceable sensor components and permanent laminate structure, the invention allows rapid replacement of only the defective sensor, significantly reducing maintenance time compared to replacing the entire window assembly.
Solution Approach 2:
The invention recovers and reuses the majority of the window laminate structure by replacing only the defective sensor component, thereby reducing waste and decreasing the time and resources required for maintenance while maintaining safety standards.
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 cost-effective and efficient replacement of defective heat control sensors in aircraft window laminates, extending the life of the window without affecting the electrical heating functionality, thus reducing waste and maintenance costs.
Implementation Method 1
photographing the window laminate using an infrared camera to determine heat conformity throughout the window laminate
Implementation Method 2
an ohmmeter is connected across the heat sensor terminals to observe an increase in sensor resistance
Implementation Method 3
a heated aluminum plate is placed against the pane of the window laminate, directly over the sensor
Data Source
AI summary
A method for installing a replacement electrical heat sensor in a heatable aircraft window laminate structure comprising the steps of: drilling a blind hole in the edge of the window laminate; routing a channel in the edge of the window laminate from the blind hole to a terminal block of an originally installed heat sensor; inserting the replacement heat sensor into the hole; filling the hole with a material to seal the hole and the heat sensor from contamination; heating the window laminate; photographing the window laminate using an infrared camera to determine uniformity of heat distribution; placing a heated plate against the exterior surface of the window laminate directly over the position of the replacement heat sensor; measuring an electrical resistance of the replacement heat sensor to confirm proper operation of the replacement heat sensor.