US-12623784-B2 - Additive material integrated heater deposited or embedded within magnetostrictive oscillating ice detector sensor

US12623784B2US 12623784 B2US12623784 B2US 12623784B2US-12623784-B2

Abstract

A probe head of a magnetostrictive oscillator includes a probe head body which includes a hollow cylindrical portion with a first end, a second end, a radially inner side, and a radially outer side. The probe head body further includes a hemispherical portion connected to the first end of the hollow cylindrical portion. The probe head further includes a heater element within the radially outer side of the hollow cylindrical portion and an electrically insulative layer around the heater element. The heater element and the electrically insulative layer are integral with the probe head body.

Inventors

Jamison K. Roman
Matthew Webb
Jeremiah Schweitzer

Assignees

ROSEMOUNT AEROSPACE INC.

Dates

Publication Date: 20260512
Application Date: 20220617

Claims (4)

1 . An ice detector comprising: a mounting base; a support strut connected to the mounting base; a magnetostrictive oscillator probe head connected to the support strut opposite the mounting base, wherein the magnetostrictive oscillator probe head comprises: a radially outer side; a radially inner side; and a probe cavity formed within the radially inner side of the magnetostrictive oscillator probe head; and a heater element within the probe cavity and formed on the radially inner side, wherein the heater element extends circumferentially on the radially inner side, and wherein the heater element is additively manufactured.
2 . The ice detector of claim 1 , wherein the mounting base connects to an aircraft.
3 . The ice detector of claim 1 , wherein the support strut is airfoil shaped.
4 . The ice detector of claim 1 , wherein the magnetostrictive oscillator probe head and the heater element are additively manufactured together.

Description

BACKGROUND The present disclosure relates to aircraft sensors, and in particular, to magnetostrictive oscillating (MSO) ice detector (ID) sensors. Aircraft sensors are important to proper operation of airplanes. Among these aircraft sensors are MSO ID sensors which collect and detect liquid ice (supercooled water droplets) during flight. MSO ID sensors can further detect the rate of ice accretion on an aircraft. Accurate information from these sensors is important to proper operation of the aircraft. During operation, these sensors accumulate ice on a detector probe and strut. To remove the ice on the detector probe and strut and reset the sensor, heaters heat the detector probe and strut to melt the ice off the detector probe and strut. Melting the ice off the detector probe and strut can be slow and energy intensive. Therefore, solutions to reduce power consumption and increase melting speed are desired. SUMMARY In one embodiment, a probe head of a magnetostrictive oscillator includes a probe head body. The probe head body includes a hollow cylindrical portion with a first end, a second end, a radially inner side, and a radially outer side. The probe head body further includes a hemispherical portion connected to the first end of the hollow cylindrical portion. The probe head further includes a heater element within the radially outer side of the hollow cylindrical portion and an electrically insulative layer around the heater element. The heater element and the electrically insulative layer are integral with the probe head body. In another embodiment, a method of forming a probe head of a magnetostrictive oscillator includes depositing an outside layer. Depositing the outside layer includes depositing a first layer of powder, where the first layer of powder is a first material. Depositing the outside layer further includes sintering the first layer of powder. The method of forming the probe head further includes depositing an insulator layer which includes depositing a second layer of powder on the outside layer. A first portion of the second layer of powder is the first material, a second portion of the second layer of powder is a second material, a third portion of the second layer of powder is the first material. The second portion of the second layer of powder is between the first portion and the third portion of the second layer of powder. Depositing the insulator layer further includes sintering the second layer of powder. The method of forming the probe head further includes depositing a heater element layer which includes depositing a third layer of powder on the insulating layer. A first portion of the third layer of powder is the first material, a second portion of the third layer of powder is the second material, and a third portion of the third layer of powder is a third material. The third layer of powder further includes a fourth portion of the third layer of powder which is the second material, and a fifth portion of the third layer of powder which is the first material. In the third layer of powder, the second portion is between the first portion and the third portion, and the fourth portion is between the third portion and the fifth portion. Depositing the heater element layer further includes sintering the third layer of powder. The method of forming the probe head further includes depositing a second insulator layer above the heater element layer by repeating the insulator layer above the heater element layer, thereby forming a continuous conduit of the third material surrounded by the second material. The method of forming the probe head further includes depositing a second outside layer above the second insulator layer by repeating the outside layer above the second insulator layer. In another embodiment, an ice detector includes a mounting base and a support strut connected to the mounting base. The ice detector further includes a magnetostrictive oscillator probe head connected to the support strut opposite the mounting base. A heater element is within the magnetostrictive oscillator probe head. The heater element is additively manufactured. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an embodiment of a magnetostrictive oscillating ice detector sensor. FIG. 2A is a cross-sectional view of a probe of a magnetostrictive oscillating ice detector sensor where a heater element zigzags from a first end to a second end of the probe. FIG. 2B is a cross-sectional view of a probe of a magnetostrictive oscillating ice detector sensor where a heater element spirals from a first end to a second end of the probe. FIG. 2C is a cross-sectional view of the probe of the magnetostrictive oscillating ice detector sensor of FIG. 2A taken along line A-A. FIG. 3A is a perspective view, with a cutout, of an embodiment of a probe of a magnetostrictive oscillating ice detector sensor with heater elements within a wall of the probe. FIG. 3B is a cross-sectional view of the probe of the