METHODS FOR REDUCING ACOUSTIC NOISE ON TOTAL AIR TEMPERATURE SENSORS USING ADDITIVE MANUFACTURING

In one embodiment, a cover for an aircraft sensor includes a leading edge, the leading edge extending along a longitudinal axis. A first side panel extending from the leading edge in a positive x direction transverse to the longitudinal axis and a second side panel extending from the leading edge in the positive x direction. A first trailing edge on the first side panel, the first trailing edge opposite the leading edge. A second trailing edge on the second side panel, the second trailing edge opposite the leading edge. A first plurality of ridges on an outer surface of the first side panel.

BACKGROUND

The present disclose relates to aircraft sensors, and in particular, to total air temperature (TAT) sensors.

Aircraft sensors are important to proper operation of airplanes. Among these aircraft sensors are TAT sensors which measure the temperature of the ambient air as well as the heat caused by the airspeed of the plane. Accurate information from these sensors is important to proper operation of the plane. These sensors often extend outward from the plane to get proper readings. Because TAT sensors extend outward from the plane, TAT sensors can experience unsteady flow which leads to Karman vortices and acoustic noise generation. The acoustic noise can be significant as unsteady flow oscillates from side to side on the TAT sensor. Therefore, solutions to reduce the noise generated by aircraft sensors that extend outward of the plane are desired.

SUMMARY

In one embodiment, a cover for an aircraft sensor includes a leading edge that extends along a longitudinal axis. The cover further includes a first side panel extending from the leading edge in a positive x direction transverse to the longitudinal axis and a second side panel extending from the leading edge in the positive x direction. A first trailing edge on the first side panel is opposite the leading edge. A second trailing edge on the second side panel is opposite the leading edge and a first plurality of ridges on an outer surface of the first side panel.

In another embodiment, a cover is disclosed for at least partially surrounding a strut of a total air temperature sensor. The cover includes a first plate between a leading edge and a first trailing edge. The first plate includes an outer surface and an inner surface opposite the outer surface. A second plate is between the leading edge and a second trailing edge and a surface pattern an outer surface of the first plate. The first plate and the second plate join at the leading edge.

In another embodiment, an aircraft sensor assembly includes a mounting base for attachment to a surface, a probe head, and a strut. The strut includes a first end connected to the mounting base, a second end connected to the probe head, and a strut body extending from the first end of the strut to the second end of the strut. A cover partially encloses the strut body. sensor.

DETAILED DESCRIPTION

This disclosure relates to a cover for an aircraft sensor, and in particular to a cover for a total air temperature sensor. The cover can be additively manufactured. The cover includes surface ridges that can reduce acoustic noise generated by the aircraft sensor by altering a flow over the surface of the aircraft sensor. Further, the cover can reduce corrosion on the aircraft sensor by protecting the aircraft sensor from corrosive environments. This cover will be discussed below with reference toFIGS.1-6C.

FIGS.1and2will be discussed concurrently.FIG.1. is a perspective view of an embodiment of cover12connected to aircraft sensor10. Aircraft sensor10includes probe head14, strut16, strut first end18, strut second end20, and mounting base22.FIG.2. is a perspective view of cover12fromFIG.1removed from aircraft sensor10. Cover12includes first side panel24, second side panel26, leading edge28, first trailing edge30, second trailing edge32, surface ridges34, first flange36, second flange38, longitudinal axis LA, and X axis.

Aircraft sensor10can include any number of aircraft sensors10including a total air temperature sensor, angle of attack sensor, pitot probe, or any other aircraft sensor10which extends beyond a body of an aircraft. When aircraft sensors10extend beyond the body of the aircraft, aircraft sensors10become subject to corrosion by the external environment and become subject to airflow. Airflow over aircraft sensor10can lead to acoustic noise generation. Depending on a shape of aircraft sensor10, the acoustic noise generation can be significant enough to be heard inside of the aircraft leading to a potential discomfort among the aircraft crew and passengers. Cover12can be applied to any portion of aircraft sensor10. Cover12can be applied to strut16of aircraft sensor10. Alternatively, cover12can be applied to a probe head of aircraft sensor10. Alternatively, cover12can be applied to a vane of aircraft sensor10, such as to a vane body of an angle of attack sensor. Cover12partially encompasses the portion of aircraft sensor10to which it is applied.

Inside of probe head14of aircraft sensor10is instrumentation which can detect external conditions. The instrumentation inside of probe head14relays the information collected about the airflow to the aircraft for navigational purposes. Strut16connects to mounting base22at strut first end18and probe head14at strut second end20. Strut16has leading edge LE, trailing edge TE, first surface S1extending from leading edge LE to trailing edge TE and second surface S2extending from leading edge LE to trailing edge TE. Cover12partially encloses a portion of strut16. As shown inFIG.1, first side panel24of cover12contacts and overlays first surface S1of strut16while second side panel26of cover12contacts and overlays second surface S2of strut16. Cover12can extend from strut first end18to strut second end20. Alternatively, cover12can cover any portion of the strut16. Alternatively, cover12can cover any portion of aircraft sensor10. Cover12can be applied when creating aircraft sensor10in a production facility. Application of cover12to strut16in a production facility can enable cover12to be brazed to aircraft sensor10, thus improving the connection between cover12and aircraft sensor10. Alternatively, cover12can be applied to aircraft sensors10that are already installed on airplanes.

When air flows over strut16, the air first encounters leading edge LE. The air will be split so that some of the air flow goes towards first surface S1and the rest will be sent towards second surface S2. Over time the proportion of the air flow that gets sent to the first side vs the second side will change. Without cover12and surface ridges34formed on cover12, the oscillation of air flow between the first side to the second side leads to the formation of Karman vortices, which can lead to audible noise production. Interrupting the air flow via surface ridges34can reduce the formation of Karman vortices and therefore reduce the audible noise generation.

Under first surface S1and second surface S2of strut16are heaters15. Heaters15produce heat and transfer the heat to first surface S1and second surface S2of strut16. Heat produced by heaters15will hamper the formation of ice on strut16. Ice formation on strut16can reduce the ability of the sensors inside probe head14to detect and relay information. Heaters15can use hot bleed air, electrical resistance heating, or any other method of producing heat known to those of skill in the art.

Mounting base22can connect to a surface. The surface can be an aircraft fuselage or any other suitable surface to which one of skill in the art would contemplate attaching aircraft sensor10. Mounting base22can connect to the surface via bolts, screws, welds, brazing, or any other suitable attachment mechanism known to those of skill in the art for adhering one surface to another in aerospace applications.

Cover12is formed by first side panel24and second side panel26which join at leading edge28. Leading edge28extends along longitudinal axis LA. In the embodiment shown inFIG.2, longitudinal axis LA is perpendicular to X axis. First side panel24extends along X axis transverse longitudinal axis LA from leading edge28to first trailing edge30. In alternative embodiments, an angle between the longitudinal axis LA and X axis can be acute. In these alternative embodiments, the angle can be less than 80 degrees, less than 70 degrees, or less than 60 degrees. Second side panel26extends from leading edge28along X axis transverse the longitudinal axis to second trailing edge32. An angle between first side panel24and second side panel26near longitudinal axis LA can be less than 30 degrees, less than 20 degrees, less than 10 degrees, or less than 5 degrees. First side panel24is curved to match a curvature profile of first surface S1of strut16and second side panel26is curved to match a curvature profile of second surface S2of strut16.

In the embodiment shown inFIG.2, first side panel24and second side panel26can be equal in length. A length of first side panel24and a length of second side panel26is a distance along longitudinal axis LA. In an alternative embodiment, first side panel24can be longer than second side panel26. In another alternative embodiment, second side panel26can be longer than first side panel24. In the embodiment shown inFIG.2, a width of first side panel24is equal to the width of second side panel26. The width of first side panel24and the width of second side panel26are a distance along X axis. In an alternative embodiment, the width of first side panel24can be greater than the width of second side panel26. In another alternative embodiment, the width of first side panel24can be less than the width of second side panel26.

In the embodiment shown inFIG.2, first trailing edge30and second trailing edge32are parallel and equidistant from X axis, where the distance between first trailing edge30and second trailing edge32is nonzero. In an alternative embodiment, first trailing edge30and second trailing edge32can be non-parallel. If first trailing edge30and second trailing edge32are non-parallel, first trailing edge30and second trailing edge32can be contacting each other nearest X axis and have a nonzero distance between them furthest X axis. Alternatively, if first trailing edge30and second trailing edge32are non-parallel, first trailing edge30and second trailing edge32can be contacting each other furthest X axis and have a nonzero distance between them nearest X axis. In an alternative embodiment first trailing edge30and second trailing edge32can be on the same side of X axis.

Surface ridges34can be formed on first side panel24. Surface ridges34can also be formed on second side panel26. Surface ridges34can project from an outward surface of cover12. Alternatively, surface ridges34can be formed into a surface of cover12. In the embodiment shown inFIG.2, surface ridges34are formed on first side panel24and surface ridges34are not shown on second side panel26. In alterative embodiments surface ridges34can be formed on first side panel24only, surface ridges34can be formed on second side panel26only, or surface ridges34can be formed on both first side panel24and second side panel26. In the embodiment shown inFIG.2, surface ridges34are formed equidistant leading edge28and trailing edges30,32in the direction of X axis. As discussed below with respect toFIGS.3A-3B, surface ridges34can be formed proximate leading edge28or proximate trailing edges30,32.

First side panel24has first flange36formed thereon. First flange36is formed on first trailing edge30of first side panel24and extends towards second trailing edge32of second side panel26. Second side panel26has second flange38formed thereon. Second flange38is formed on second trailing edge32of second side panel26and extends towards first trailing edge30of first side panel24. First flange36and second flange38together function to hold cover12on aircraft sensor10. First flange36and second flange38hold cover12on aircraft sensor10by partially enclosing trailing edge TE of strut16of aircraft sensor10. First flange36and second flange38contact trailing edge TE of strut16. As such, cover12would need to be pried open at trailing edges (30,32) to remove cover12from strut16of aircraft sensor10. First flange36and second flange38can further secure cover12to aircraft sensor10at attachment points as discussed below with respect toFIGS.4A-4B. A transition between first flange36and first trailing edge30can be sloped or the transition can be a right angle. A transition between second flange38and second trailing edge32can be sloped or the transition can be a right angle.

Cover12can be formed by multiple methods. Cover12along with surface ridges34can be formed via an additive manufacturing process, such as laser powder bed fusion. Surface ridges34formed via an additive manufacturing process will be integral with the outer shell. In the additive manufacturing process, cover12can be formed by forming an outer shell layer-by-layer along with a supportive core enclosed by the outer shell. The supportive core comprises a lattice structure. Surface ridges34can be formed on the outer shell when forming the outer shell. The supportive core is subsequently removed once the additive manufacturing process is complete. Alternatively, cover12can be formed by a combination of rolling and stamping. Cover12can be formed by rolling a sheet of material, trimming the edges of the sheet, stamping surface ridges34into cover12, and bending the sheet into the shape of cover12. By stamping surface ridges34into cover12, surface ridges34are integral with cover12. Alternatively, cover12can be formed via rolling and bending with surface ridges34added to cover12via an additive manufacturing process. Cover12can be formed by milling cover12from a larger block of material. When milling cover12, surface ridges34are milled from the larger block of material so that surface ridges are integral and continuous with cover12.

A corrosion resistant topcoat of another material can be applied to cover12. The corrosion resistant topcoat can be applied via electroplating, chemical vapor deposition, or any other method known to those of skill in the art to apply a corrosion resistant topcoat to another surface. Cover12can be formed of pure copper, a copper alloy, nickel, and combinations thereof. Cover12can be formed of any highly thermally conductive material. A highly thermally conductive material has a heat transfer coefficient of greater than

of greater than

or of greater than

Forming cover12from any highly thermally conductive material enables heat produced in strut16to transfer through cover12. Heat from strut16reduces ice accumulation. Ice accumulation can reduce the accuracy of the instrumentation in probe head14.

FIGS.3A-3Bdisclose alternative locations of surface ridges34and will be discussed together.FIG.3A. is a perspective view of another embodiment of cover12connected to aircraft sensor10where surface ridges34are near leading edge28.FIG.3B. is a perspective view of another embodiment of cover12connected to aircraft sensor10where surface ridges34are near trailing edge30.

Surface ridges34can be formed anywhere on the surface of cover12. As discussed above with respect toFIG.2, the location of surface ridges34inFIG.2are equidistant leading edge28and trailing edges30,32. Surface ridges34ofFIG.2extend substantially in the direction of longitudinal axis LA. In the alternative embodiment ofFIG.3A, surface ridges34are proximate leading edge28of cover12. Surface ridges34ofFIG.3Aextend substantially in the direction of longitudinal axis LA. In the alternative embodiment ofFIG.3B, surface ridges34are proximate trailing edges30,32of cover12. Surface ridges34ofFIG.3Bextend substantially in the direction of longitudinal axis LA. In alternative embodiments not shown in the figures, surface ridges34can extend at an angle with respect to longitudinal axis LA. The angle between a direction that surface ridges34substantially extend and the longitudinal axis LA can be at least 5 degrees, at least 10 degrees, or at least 25 degrees. In alternative embodiments not shown in the figures, there can be multiple columns of surface ridges34. Each column of surface ridges34can have a different orientation with respect to longitudinal axis LA, a different ridge pattern, and/or a different cross-sectional pattern.

FIGS.4A-4Bdisclose alternate attachment mechanisms and will be discussed together.FIG.4A. is a perspective view of another embodiment of cover12where trailing edges30,32of cover12are secured via screw40to aircraft sensor10.FIG.4B. is a perspective view of another embodiment of cover12with welding tabs44on trailing edges30,32of cover12.

Cover12can be secured to strut16via a multitude of alternative methods. Cover12has first flange36and second flange38which hold cover12in place when cover12partially encloses strut16. As shown in the embodiment ofFIG.4A, cover12can be held to strut16via fasteners40. Fasteners40extend through fastener holes42which extend through first flange36and second flange38. Fastener holes42can be placed anywhere on first flange36and second flange38. Fasteners40hold first trailing edge30and second trailing edge32near the trailing edge of strut16. These fasteners are reversible in that fasteners40can be unsecured. As shown in the embodiment ofFIG.4B, cover can be held to strut16via welds. These welds are formed between welding tabs44and trailing edge TE of strut16. Welding tabs44each extend from both first flange36and second flange38. Welding tabs44can vary in thickness based on localized needs of the weld. The varied thicknesses can be obtained via an additive manufacturing process. A varied thickness of welding tabs44can reduce warping of cover12due to the heat differentials created by welding. In alternative embodiments not shown in the figures, cover12can be secured to strut16through adhesives or any other attachment mechanism known to those of skill in the art.

FIGS.5A-5Cdiscuss alternative embodiments and patterns of surface ridges34and will be discussed together.FIG.5Ais a front view of another embodiment of surface ridges34where surface ridges34have V-shaped profile46.FIG.5Bis a front view of surface ridges34where surface ridges34have a wave-shaped profile48and are in rows52,54. In the embodiment ofFIG.5B, wave-shaped profile48of row52is in-phase with wave-shaped profile48of row54.FIG.5Cis a front view of surface ridges34where surface ridges34have wave-shaped profile50and are in rows52,54. As shown inFIG.5C, wave-shaped profile50of row52is out-of-phase50with wave-shaped profile50of row54.

Surface ridges34can have multiple different patterns. Each of the different surface ridges34produce different flow dynamics as air flows over them. As shown in the embodiment ofFIG.5A, surface ridges34can have V-shaped profile46. V-shaped profile46of surface ridges34have multiple V-shaped ridge. V-shaped ridges project from the surface of cover12. The apex of each of V-shaped ridge is arranged in a straight line. The wings of each of V-shaped ridge are equal in length and meet the wings of other V shaped ridges. Alternatively, V-shaped ridges can be formed of indentations into the surface of cover12.

As shown in the embodiment ofFIG.5B, surface ridges34can have wave-shaped profiles48with in-phase sinusoidal ridges. In-phase sinusoidal ridges are composed of alternating rows52,54of surface ridges34. When wave-shaped profiles48of surface ridges34are in-phase sinusoidally, a peak of first row52is in line with a peak of second row54, while a trough of first row52is in line with a trough of second row54. Wave-shaped profiles48can project from the surface of cover12. Alternatively, wave-shaped profiles48can be formed of indentations into the surface of cover12.

As shown in the embodiment ofFIG.5C, surface ridges34can have wave-shaped profiles50that are out-of-phase sinusoidal ridges. Out-of-phase sinusoidal ridges are composed of alternating rows52,54of surface ridges34. When surface ridges34are out-of-phase sinusoidal ridges, a peak of first row52is in line with a trough of second row54, while a trough of first row52is in line with a peak of second row54. Wave-shaped profiles50can project from the surface of cover12. Alternatively, wave-shaped profiles50can be formed of indentations into the surface of cover12. In an alternative embodiment not shown in the figures, surface ridges34can be composed of sinusoidal ridges where a frequency of first row52is not equal to the frequency of second row54. As such, at some points a peak of first row52will align with a peak of second row54, whereas at other points the peak of first row52will not align with the peak of second row54.

FIGS.6A-6Cshow various possible cross-sectional profiles for surface ridges34and will be discussed together. Surface ridges34formed on the surface of cover12can have many different cross-sectional profiles. These cross-sectional profiles change the way that air flows through surface ridges34and can decrease Karman vortices and/or manufacturing costs.FIG.6Ais a cross-sectional view of one possible embodiment of surface ridges34with troughs64and peaks62that are equal in width. Equal width pattern56of surface ridges34includes first width66and first depth68.FIG.6Bis a cross-sectional view of another embodiment of surface ridges34with troughs64that are wider than peaks62. Wide trough pattern58ofFIG.6Bincludes second width70, third width72, and second depth74.FIG.6Cis a cross-sectional view of another embodiment of surface ridges34where surfaces ridges34comprise a triangular cross-sectional profile60. Triangular cross-sectional profile60has fourth width76and third depth78.

As shown in the embodiment ofFIG.6A, surface ridges34can have equal width pattern56. In equal width pattern56, a width of peak62is equal to a width of trough64which is equal to first width66. Troughs64have a depth equal to first depth68. Peaks62and troughs64inFIG.6Ahave substantially flat regions. The transitions between peaks62and troughs64inFIG.6Aare substantially vertical relative the flat regions of peaks62and troughs64. During the manufacture of cover12, troughs64inFIG.6Acan be cut into cover12. Alternatively, peaks62inFIG.6Acan be pressed higher than troughs64. Peaks62ofFIG.6Acan also be additively formed onto cover12.

As shown in the embodiment ofFIG.6B, surface ridges34can have wide trough pattern58. In wide trough pattern58, peaks62have a width equal to second width70while troughs64have a width equal to third width72. Third width72is larger than second width70. Troughs64have a depth equal to second depth74. Troughs64and peaks62can have substantially flat regions. The transitions between troughs64and peaks62can be sloped. During manufacture of cover12, troughs64ofFIG.6Bcan be cut into cover12. Alternatively, peaks62ofFIG.6Bcan be pressed higher than troughs64. Peaks62ofFIG.6Bcan also be additively formed onto cover12.

As shown in the embodiment ofFIG.6C, surface ridges34can have a triangular cross-sectional profile60. Peaks62of triangular cross-sectional profile60are pointed and troughs64of triangular cross-sectional profile60are V-shaped. The width of each triangle is fourth width76while the height of each triangle is equal to third depth78. During manufacture of cover12, troughs64ofFIG.6Ccan be cut into cover12. Alternatively, peaks62ofFIG.6Ccan be pressed higher than troughs64. Peaks62ofFIG.6Ccan also be additively formed onto cover12.

While cover12has been described above, with respect toFIGS.1-4A, to be mountable to strut16of a total air temperature sensor, it will be understood by those skilled in the art that cover12can be mounted to other aircraft sensors and probes. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to a vertical strut of a total air temperature sensor as disclosed with respect toFIGS.1-4A, but that the invention will include all embodiments falling within the scope of the appended claims. For example,FIGS.7A-7Cshow various alternative probes onto which cover12can be placed. Cover12according to an exemplary embodiment of this disclosure, among other possible things can be placed onto pitot tube80as discussed inFIG.7A, total air temperature sensor96as described inFIG.7B, angle of attack sensor112as described inFIG.7C, and any other aircraft probe.

As best shown inFIG.7A. Pitot probe80can be a pitot-static probe or any other suitable air data probe. Body82of pitot probe80is formed by probe head84and strut86. Probe head84is the sensing head of pitot probe80. Probe head84is a forward portion of pitot probe80. Probe head84has one or more ports positioned in probe head84. Internal components of pitot probe80are located within probe head84. Probe head84is connected to a first end of strut86. Probe head84and strut86make up body82of pitot probe80. Strut86can be blade shaped. Internal components of pitot probe80are located within strut86. Strut86is adjacent mounting flange88. A second end of strut86is connected to mounting flange88. Mounting flange88makes up a mount of pitot probe80. Mounting flange88is connectable to an aircraft.

Probe head84has tip90at a forward, or upstream, portion of probe head84. Tip90is at the end of probe head84opposite the end of probe head84connected to strut86. Strut86has leading edge92at a forward, or upstream, side of strut86and trailing edge94at an aft, or downstream, side of strut86. Leading edge92is opposite trailing edge94.

Pitot probe80can be installed on an aircraft. Pitot probe80can be mounted to a fuselage of the aircraft via mounting flange88and fasteners, such as screws or bolts. Strut86holds probe head84away from the fuselage of the aircraft to expose probe head84to external airflow. Probe head84takes in air from surrounding external airflow and communicates air pressures pneumatically through internal components and passages of probe head84and strut86. Pressure measurements are communicated to a flight computer and can be used to generate air data parameters related to the aircraft flight condition. Cover12can be applied to strut86. Cover12can extend from probe head84to mounting flange88. Cover12can extend from leading edge92to trailing edge94. Cover12and surface pattern34provide the same benefits to pitot probe80as described above with reference toFIG.2.

FIG.7Bis a perspective view of total air temperature probe96. Total air temperature probe96includes body98, with head100and strut102, and mounting flange104. Head100includes inlet scoop106. Strut102includes leading edge108and trailing edge110. Cover12with surface ridges34can be applied to strut102. As best shown inFIG.7B, body98of total air temperature probe96is formed by head100and strut102. Head100is connected to a first end of strut102. Head100and strut102make up body98of total air temperature probe96. Internal components of total air temperature probe96are located within strut102. Strut102is adjacent mounting flange104. A second end of strut102is connected to mounting flange104. Mounting flange104makes up a mount of total air temperature probe96. Mounting flange104is connectable to an aircraft.

Head100has inlet scoop106, which is a forward portion of total air temperature probe96. Inlet scoop106is an opening in a forward, or upstream, end of head100. Strut102has leading edge108at a forward, or upstream, side of strut102and trailing edge110at an aft, or downstream, side of strut102. Leading edge108is opposite trailing edge110.

Total air temperature probe96can be installed on an aircraft. Total air temperature probe96can be mounted to a fuselage of the aircraft via mounting flange104and fasteners, such as screws or bolts. Strut102holds head100away from the fuselage of the aircraft to expose head100to external airflow. Air flows into total air temperature probe96through inlet scoop106of head100. Air flows into an interior passage within strut102of total air temperature probe96, where sensing elements measure the total air temperature of the air. Total air temperature measurements of the air are communicated to a flight computer. Such measurements can be used to generate air data parameters related to the aircraft flight condition. Cover12can be applied to strut102. Cover12can extend from head100to mounting flange104. Cover12can extend from leading edge108to trailing edge110. Cover12and surface pattern34provide the same benefits to total air temperature probe96as described above with reference toFIG.2.

FIG.7Cis a perspective view of angle of attack sensor112. Angle of attack sensor112includes body114, formed by vane116and faceplate118, and housing120. Vane116includes leading edge122and trailing edge124. Cover12with surface ridges34can be applied to vane116. As best shown inFIG.7C, body114of angle of attack sensor112is formed by vane116and faceplate118. Vane116is adjacent faceplate118. Vane116and faceplate118make up body114of angle of attack sensor. Faceplate118makes up a mount of angle of attack sensor112. Faceplate118is connectable to an aircraft. Faceplate118is positioned on and connected to housing120. Internal components of angle of attack sensor112are located within housing120. Vane116has leading edge122at a forward, or upstream, side of vane116and trailing edge124at an aft, or downstream, side of vane116. Leading edge122is opposite trailing edge124.

Angle of attack sensor112is installed on an aircraft. Angle of attack sensor112can be mounted to a fuselage of the aircraft via faceplate118and fasteners, such as screws or bolts. Vane116extends outside an exterior of the aircraft and is exposed to external airflow, and housing120extends within an interior of the aircraft. External airflow causes vane116to rotate with respect to faceplate118via a series of bearings within angle of attack sensor112. Vane116rotates based on the angle at which the aircraft is flying relative to the external oncoming airflow. Vane116causes rotation of a vane base and vane shaft within housing120. The vane shaft is coupled to a rotational sensor that measures the local angle of attack or angle of the airflow relative to the fixed aircraft structure. The measured angle of attack is communicated to a flight computer and can be used to generate air data parameters related to the aircraft flight condition. Cover12can be applied to vane116. Cover12can extend from a tip of vane116to a base of vane116. The tip is opposite the base, while the base is the portion of vane116which is nearest to faceplate118. Cover12can extend from leading edge122to trailing edge124. Cover12and surface pattern34provide the same benefits to angle of attack sensor112as described above with reference toFIG.2.

Discussion of Possible Embodiments

A cover according to an exemplary embodiment of this disclosure, among other possible things includes a leading edge, the leading edge extending along a longitudinal axis, a first side panel extending from the leading edge in a positive x direction transverse to the longitudinal axis, and a second side panel extending from the leading edge in the positive x direction. The cover also includes a first trailing edge on the first side panel, the first trailing edge opposite the leading edge and a second trailing edge on the second side panel, the second trailing edge opposite the leading edge. The cover also includes a first plurality of ridges on an outer surface of the first side panel.

A further embodiment of the foregoing cover, wherein the second side panel further comprises a second plurality of ridges on an outer surface of the second side panel.

A further embodiment of any of the foregoing covers, wherein the first side panel further comprises a first flange on the first trailing edge and extending toward the second trailing edge and the second side panel further comprises a second flange on the second trailing edge extending toward the first trailing edge.

A further embodiment of any of the foregoing covers, wherein the first plurality of ridges extends along the longitudinal axis.

A further embodiment of any of the foregoing covers, wherein ridgelines of the first plurality of ridges are V-shaped.

A further embodiment of any of the foregoing covers, wherein the first plurality of ridges comprises a first column of ridges and a second column of ridges, wherein the first column of ridges is in phase with the second column of ridges in the x direction.

A further embodiment of any of the foregoing covers, wherein the first plurality of ridges comprises a first column of ridges and a second column of ridges, wherein the first column of ridges is out of phase with the second column of ridges in the x direction.

A further embodiment of any of the foregoing covers, wherein the cover is manufactured via an additive manufacturing process and the first side panel and the second side panel are both convex.

A cover for at least partially surrounding a strut of a total air temperature sensor, according to an exemplary embodiment of this disclosure, among other possible things includes a first plate between a leading edge and a first trailing edge, wherein the first plate includes an outer surface, and an inner surface opposite the outer surface. The cover also includes a second plate between the leading edge and a second trailing edge and a surface pattern on the outer surface of the first plate, wherein the first plate and the second plate join at the leading edge.

A further embodiment of the foregoing cover, wherein the surface pattern is proximate the leading edge.

A further embodiment of any of the foregoing covers, wherein the surface pattern is proximate the trailing edge.

A further embodiment of any of the foregoing covers, wherein the surface pattern is equidistant between the leading edge and the trailing edge on the outer surface of the first plate.

A further embodiment of any of the foregoing covers, wherein the cover further includes a first welding tab extending from the first trailing edge and a second welding tab extending from the second trailing edge.

A further embodiment of any of the foregoing covers, wherein the cover further includes a first tab extending from the first trailing edge toward the second trailing edge and a second tab extending from the second trailing edge toward the first trailing edge. The cover also includes a first hole in the first tab, a second hole in the second tab, a first fastener for insertion into the first hole, and a second fastener for insertion into the second hole.

A further embodiment of any of the foregoing covers, wherein the cover further includes a pattern of troughs and peaks, wherein a width of each trough is equal to a width of each peak in the pattern.

A further embodiment of any of the foregoing covers, wherein the cover further includes a pattern of troughs and peaks, wherein a width of a trough in the pattern is wider than a width of a peak in the pattern.

A further embodiment of any of the foregoing covers, wherein a cross-sectional profile of the surface pattern is triangular.

An aircraft sensor assembly according to an exemplary embodiment of this disclosure, among other possible things includes a mounting base for attachment to a surface, a probe head, and a strut. The strut includes a first end connected to the mounting base, a second end connected to the probe head, and a strut body extending from the first end of the strut to the second end of the strut. The aircraft sensor assembly further includes a cover which partially encloses the strut body.

A further embodiment of the foregoing aircraft sensor assembly, wherein an inside surface of the cover contacts an outside surface of the strut body.

A further embodiment of any of the foregoing aircraft sensors assembly, wherein the strut further includes a heater element within the strut body beneath the outside surface of the strut body.