A portable auxiliary heat dissipation system for ground testing of an aircraft liquid-cooled heat dissipation controller

Abstract

This invention belongs to the field of aviation equipment testing technology, specifically relating to a portable auxiliary cooling system for ground testing of aviation liquid-cooled heat dissipation controllers. The system includes modules for circulating heat dissipation, temperature monitoring, closed-loop temperature control, and electromagnetic compatibility (EMC) processing. It utilizes a variable-frequency water pump and a lightweight wheeled water tank to enhance portability, and a pre-filter meets EMC requirements. Water temperature is collected by dual high-precision sensors, and the control module calculates heat generation and dynamically adjusts the pump speed, using linear regression to predict water temperature and provide early warnings. This invention is portable, easy to deploy, meets EMC standards, provides precise control, and offers early warning capabilities. It is compatible with ground testing of various aviation liquid-cooled controller models, ensuring test safety and data accuracy.

Description

Technical Field

[0001] This invention belongs to the field of aviation equipment ground testing technology, specifically relating to an auxiliary heat dissipation system that provides enhanced cooling for aviation liquid-cooled heat dissipation controllers in a ground testing environment. Background Technology

[0002] Avionics, especially high-power fuel pump controllers and hydraulic pump controllers, often employ liquid cooling to address high heat density. During their research and manufacturing, a stable and controllable cooling environment is required to simulate their actual operating conditions, ensuring the accuracy of test data and the safety of equipment operation. Existing cooling systems used for ground testing have the following shortcomings: 1. Poor portability: Traditional heat dissipation systems are mostly fixed installation structures, with large and heavy circulating water tanks, making it difficult to quickly transfer to different test sites, resulting in insufficient adaptability; 2. Electromagnetic compatibility performance is not up to standard: Flight safety tests of aircraft controllers often include electromagnetic performance tests. Existing heat dissipation equipment is not specifically designed for electromagnetic interference. The electromagnetic noise generated during operation can easily interfere with the electromagnetic tests of the aircraft controller under test, and cannot meet the design requirements. 3. Low precision of heat dissipation system control: Most systems use fixed-speed water pumps, which can only achieve heat dissipation of a single flow rate. They cannot dynamically adjust the heat dissipation capacity according to the actual heat generation of the controller under test, which can easily lead to insufficient or excessive heat dissipation and affect the test efficiency. 4. Lack of water temperature early warning mechanism: It can only monitor the water temperature in real time, but cannot predict the trend of water temperature change. When the water temperature exceeds the heat exchange allowable range of the controller, it is easy to cause the test to be interrupted or the equipment to be damaged, resulting in insufficient safety.

[0003] Therefore, there is an urgent need for an auxiliary heat dissipation system that combines portability, electromagnetic compatibility, precise control, and early warning functions to address the aforementioned shortcomings of existing technologies. Summary of the Invention

[0004] This invention aims to overcome the shortcomings of existing ground-based heat dissipation methods for aircraft liquid-cooled heat dissipation controllers and provides a portable auxiliary heat dissipation system, specifically addressing the following problems: 1. Improve system portability to meet the need for rapid deployment in multiple locations; 2. Optimize electromagnetic compatibility performance to meet design requirements and avoid interference with electromagnetic testing of aircraft controllers; 3. Achieve dynamic matching between heat dissipation capacity and the heat generation of the controller under test, thereby improving control accuracy; 4. Add water temperature trend prediction and early warning functions to ensure the continuity of the test and the safety of the equipment.

[0005] To achieve the aforementioned objectives, this invention proposes a portable auxiliary cooling system for ground testing of an aviation liquid-cooled heat dissipation controller. This system includes a circulating cooling module, a temperature monitoring module, a temperature closed-loop control module, and an electromagnetic compatibility (EMC) processing module. The circulating cooling module consists of a variable frequency hot water pump and a portable mobile water tank with casters. The water tank outlet connects to the pump, the controller under test, and returns to the water tank inlet to form a closed-loop liquid cooling circuit. The temperature monitoring module collects the inlet and outlet water temperatures of the circuit and transmits them to the temperature closed-loop control module. The control module calculates the heat generation based on the water temperature, outputs a PWM signal to adjust the pump speed, and uses linear regression to predict the water temperature and provide early warning. The EMC processing module is a pre-filter connected in series with the main power supply to suppress electromagnetic interference. All modules work together to achieve dynamic heat dissipation, precise control, and safety warnings.

[0006] Furthermore, the portable mobile water tank is made of lightweight alloy material, has a capacity of 50L, and is equipped with quick connectors and a sealed filling port.

[0007] Furthermore, the hot water pump dynamically adjusts its circulation flow rate according to the heat output of the controller under test, based on the PWM speed control signal of the temperature closed-loop control module.

[0008] Furthermore, the temperature monitoring module includes two PT1000 temperature sensors, which collect the water temperature at the inlet and outlet of the water tank, respectively, and the signals are transmitted via shielded cables.

[0009] Furthermore, the temperature closed-loop control module uses the heat balance formula... Calculate the real-time heat output and adjust the pump speed according to the heat output-pump speed curve.

[0010] Furthermore, the temperature closed-loop control module triggers an audible and visual alarm when it predicts that the water temperature will exceed the threshold within 5 minutes.

[0011] Furthermore, the pre-filter is a common-mode combined with differential-mode structure, which meets electromagnetic compatibility requirements.

[0012] Furthermore, the water tank, hot water pump, and controller under test are sealed together via quick-connect fittings to form a leak-proof closed-loop system.

[0013] The heat dissipation system proposed in this invention can be quickly deployed for different test scenarios to meet system test requirements. Specifically, its integrated design offers excellent portability. Addressing the electromagnetic compatibility requirements of aviation equipment, this invention adds a power filtering module to effectively suppress electromagnetic radiation generated during the operation of the heat dissipation system, preventing interference with the electromagnetic environment of the device under test. This invention precisely adjusts the operating speed of the heat exchange pump according to the heat output of the device under test, avoiding insufficient or excessive heat dissipation. During the test, an audible and visual alarm unit can identify in advance whether the current heat dissipation conditions meet the remaining test time requirements of the device under test when the water temperature does not meet the heat exchange requirements, issuing an alarm to prevent insufficient heat dissipation from affecting the system test progress. This invention is adaptable to the test requirements of different models of liquid-cooled controllers. Specifically, for different types of liquid-cooled controllers, only the quick connector of the heat dissipation system's circulation pipe needs to be replaced with the liquid-cooled pipe socket of the controller to achieve rapid adaptation. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the overall structure of the portable auxiliary heat dissipation system of the present invention.

[0016] Figure 1 The component numbers and corresponding names are as follows: 1-Portable mobile water tank; 2-Hot water pump; 3-Temperature sensor (inlet); 4-Temperature sensor (outlet); 5-Temperature closed-loop control module; 6-Pre-filter; 7-Tested aviation liquid cooling heat dissipation controller; 8-Circulation pipe; 9-Quick connector; 10-Universal roller; 11-Sealed filling port.

[0017] Figure 1 The system's mechanical structure and circulation loop are clearly displayed: the portable mobile water tank 1 is connected to the hot water exchange pump 2 and the controller under test 7 in sequence through the circulation pipe 8 and quick connector 9, forming a closed-loop circulation path; temperature sensors 3 and 4 are embedded in the inner walls of the inlet and outlet pipes of the water tank 1, respectively, to collect the inlet and outlet water temperatures; the pre-filter 6 is connected in series to the system power input terminal, and the temperature closed-loop control module 5 is electrically connected to the hot water exchange pump 2 and temperature sensors 3 and 4 through wires; the portable mobile water tank 1 is equipped with universal casters 10 with brake function at the bottom and a sealed filling port 11 at the top, reflecting the portability and sealing design.

[0018] Figure 2This is a block diagram of the electrical connection of the system modules of the present invention.

[0019] Figure 2 In the diagram, arrows indicate the signal / power transmission direction for each module: the external power supply, after being filtered by a pre-filter, powers the hot water pump and the temperature closed-loop control module; the signal output of the temperature monitoring module is connected to the signal input of the temperature closed-loop control module via a shielded cable to transmit digital water temperature signals; the control output of the temperature closed-loop control module is connected to the control input of the hot water pump to output PWM speed control signals; the temperature closed-loop control module has a built-in audible and visual alarm unit that can trigger an alarm when warning conditions are met. This diagram visually illustrates the electrical connections and signal flow between the modules, while also clearly demonstrating the power supply filtering function of the electromagnetic compatibility processing module.

[0020] Figure 3 This is a schematic diagram of the system workflow of the present invention.

[0021] Figure 3 The system's operational logic is illustrated through a step-by-step process: ① Test Preparation Stage: Adding coolant, connecting the circulation loop, turning on the power, and activating the pre-filter; ② Temperature Acquisition Stage: Sensors 3 and 4 collect inlet and outlet water temperatures in real time and transmit them to the control module; ③ Data Processing Stage: The control module calculates the temperature difference ΔT and derives the calorific value Q based on liquid parameters; ④ Pump Speed ​​Adjustment Stage: Matching the pump speed curve according to Q and outputting a signal to adjust the speed of the hot water exchange pump; ⑤ Water Temperature Prediction Stage: Establishing a trend model based on real-time data to predict water temperature changes; ⑥ Early Warning Judgment Stage: If the predicted water temperature exceeds the threshold within 5 minutes, an audible and visual alarm is triggered; otherwise, the cycle returns to the temperature acquisition stage and continues. This diagram clearly presents the closed-loop working mechanism of "acquisition-calculation-regulation-early warning".

[0022] Figure 4 This is a schematic diagram of the portable auxiliary heat dissipation system of the present invention.

[0023] Figure 4 The component numbers and corresponding names are as follows: 1-Cooling system switch; 2-System power cord; 3-Universal casters; 4-Outlet quick connector (liquid outlet); 5-Water tank drain port; 6-Inlet quick connector (liquid inlet); 7-Alarm light; 8-Temperature display; 9-Water tank filler port; 10-Telescopic rod. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] The features and illustrative embodiments of various aspects of the present invention will now be described in detail. Numerous specific details are set forth in the following detailed description to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of the invention by illustrating examples of the invention. The invention is by no means limited to any specific setups and methods set forth below, but covers any improvements, substitutions, and modifications to structures, methods, and devices without departing from the spirit of the invention. Well-known structures and techniques are not shown in the drawings and the following description to avoid unnecessarily obscuring the invention.

[0026] In the description of this invention, it should be noted that the directions or positional relationships indicated by terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" are based on the directions or positional relationships shown in the accompanying drawings and are only for the convenience of describing and simplifying the invention, and should not be construed as limiting the invention. Furthermore, the use of ordinal numbers (e.g., "first and second," etc.) is for distinguishing objects and is not limited to this order, and should not be construed as indicating or implying relative importance.

[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly, encompassing both direct connection and indirect connection via an intermediate medium. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0028] It should be noted that, unless otherwise specified, the embodiments of the present invention and the features thereof can be combined with each other, and the various embodiments can be referenced and cited in each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0029] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the embodiments of the present invention are not limited thereto.

[0030] The present invention discloses a portable auxiliary heat dissipation system for ground testing of an aviation liquid-cooled heat dissipation controller. This system includes a circulating heat dissipation module, a temperature detection module, a temperature closed-loop control module, and an electromagnetic compatibility processing module. These modules work collaboratively to achieve heat dissipation regulation, status detection, and risk warning. The specific structure is as follows: (a) Circulating heat dissipation module 1. Replace the hot water pump: Use a variable frequency speed control water pump. Its control input terminal is connected to the temperature closed-loop control module. It can adjust the operating speed according to the received speed control signal, thereby changing the circulating liquid flow rate to adapt to different heat dissipation needs. 2. Portable mobile water tank: Made of high-strength lightweight alloy material, with a volume of about 50L. The bottom of the water tank is equipped with silent universal casters, the top has a sealed filling port, and the front has reserved liquid inlet and outlet interfaces. The interfaces are equipped with quick connectors to facilitate the formation of a closed loop circulation circuit with the hot water pump and the controller under test, taking into account portability, sealing and leak prevention.

[0031] (ii) Temperature monitoring module It includes two high-precision temperature sensors, which are fixed to the inner walls of the inlet and outlet pipes of the portable mobile water tank, respectively. The sensors are made of PT1000 platinum resistance material, with a measurement range of -20℃ to 100℃ and an accuracy of ±0.1℃. The signal output terminal of the sensor is electrically connected to the signal input terminal of the temperature closed-loop control module through a shielded cable, which is used to collect water temperature data at the inlet and outlet of the water tank in real time and convert the analog signal into a digital signal for transmission to the control module.

[0032] (III) Temperature Closed-Loop Control Module As the core control unit of the system, it integrates a data processing unit, a pump speed regulation unit, and an early warning judgment unit, with the following specific functions: 1. Data Processing Unit: Receives inlet and outlet water temperature data transmitted from the temperature monitoring module and calculates the temperature difference Δ. T = T in - T out (in T in For the inlet water temperature, T out (For the outlet water temperature), combined with the preset specific heat capacity of the circulating liquid c and the circulating flow rate m corresponding to the current pump speed, the heat balance formula is used. Calculate the real-time heat output Q of the controller under test; 2. Pump speed regulation unit: Based on the calculated heat generation Q, it matches the preset heat generation-pump speed corresponding curve and outputs a PWM speed regulation signal to the hot water exchange pump to realize dynamic adjustment of the pump speed (increase the pump speed when the heat generation increases and decrease the pump speed when the heat generation decreases). 3. Early warning judgment unit: Based on real-time water temperature data, the heat dissipation efficiency corresponding to the current pump speed, and the maximum / minimum hot water exchange temperature threshold allowed by the controller, a water temperature change trend model is established through a linear regression algorithm to predict the future water temperature change trajectory; when it is predicted that the water temperature will exceed the threshold range within 5 minutes, an alarm signal is triggered.

[0033] (iv) Electromagnetic compatibility processing module As a pre-filter, it is connected in series at the input of the system power circuit. The filter adopts a common-mode + differential-mode filter structure, with a rated voltage of 220VAC, a rated current of 10A, and an insertion loss of ≥40dB (150kHz~100MHz). The parameters are designed strictly in accordance with the requirements of CE102 (conducted emission) and RE102 (radiated emission) in GJB151B standard. It is used to suppress electromagnetic interference generated during system operation and avoid interference with the controller under test and test equipment.

[0034] (v) System Connection Relationship The outlet of the portable mobile water tank is connected to the hot water exchange pump and the inlet of the controller under test via a pipeline. The outlet of the controller under test is connected to the inlet of the portable mobile water tank via a pipeline, forming a closed-loop circulation circuit. The temperature monitoring module's sensors are deployed on the inlet and outlet pipelines of the water tank. The temperature closed-loop control module is electrically connected to the temperature monitoring module and the hot water exchange pump. The pre-filter is connected in series to the system's main power input terminal.

[0035] Example 1, such as Figures 1-4 As shown in the figure, the portable auxiliary heat dissipation system for ground testing of an aviation liquid-cooled heat dissipation controller designed in this embodiment includes the following specific design contents: (a) Component selection 1. Replace the hot water pump: Select a DB-30 variable frequency centrifugal pump with a rated flow rate of 30L / min, a head of 15m, a power supply voltage of 220VAC, and support for 0-5V analog speed regulation; 2. Portable mobile water tank: Made of 304 stainless steel, with a maximum capacity of 50L, dimensions of 500×300×400mm, weight of 7.5kg, and four silent universal casters (with brake function) installed at the bottom. 3. Temperature sensor: PT1000 platinum resistance sensor is selected, with a response time ≤500ms, protection level IP65, and signal is transmitted through shielded cable (2m in length); 4. Temperature closed-loop control module: The core chip is an STM32F407 microcontroller, which integrates a 12-bit ADC acquisition module, a PWM output module and an audible and visual alarm module (alarm mode: flashing red LED + 80dB buzzer). 5. Pre-filter: A custom filter of model SFJLC-10A / 220VAC-24280 is selected, which meets the requirements of GJB151B-CE102 and RE102, with an insertion loss of 45dB (150kHz~100MHz).

[0036] (II) Work Process 1. Test preparation: Fill the portable water tank to the specified level (40~50L), connect the hot water pump and the controller under test through quick connectors to form a closed loop; turn on the system power, and the pre-filter will start working to suppress electromagnetic interference; 2. Temperature Acquisition: The two sensors of the temperature monitoring module collect the inlet and outlet water temperatures of the water tank respectively, and transmit them to the temperature closed-loop control module in real time; 3. Heat generation calculation and pump speed regulation: The control module calculates the temperature difference ΔT, and combines this with the specific heat capacity of the liquid (c = 4.2 kJ / (kg•℃) for water) and the current flow rate, through... Calculate the heat output; output a speed control signal based on the heat output to adjust the speed of the hot water pump and achieve heat dissipation adaptation. 4. Water Temperature Prediction and Alarm: The control module predicts water temperature changes based on real-time water temperature (e.g., current inlet water temperature 25℃, outlet water temperature 32℃), current pump speed (e.g., 1500r / min), and the controller's maximum allowable outlet water temperature (e.g., 45℃). If it predicts that the outlet water temperature will rise to 46℃ in 10 minutes, it will immediately trigger an audible and visual alarm to remind the operator to add coolant or adjust the test load.

[0037] (III) Experimental Verification In an electromagnetic test of a certain type of aircraft liquid-cooled heat dissipation controller, the system operated stably. 1. Electromagnetic compatibility: After testing, the system's conducted emissions are ≤40dBμV (150kHz~100MHz) and radiated emissions are ≤30dBμV / m (30MHz~1GHz), which meets the design requirements; 2. Control accuracy: When the calorific value varies within the range of 500-2000W, the pump speed response time is ≤1s and the outlet water temperature fluctuation is ≤±0.5℃; 3. Early warning accuracy: After multiple simulations of water temperature rise scenarios, the early warning lead time is 6-12 minutes, with no missed or false alarms; 4. Portability: Can be moved by a single person, deployment time ≤10min, adaptable to different test station requirements.

[0038] The above detailed embodiments are a description of the present invention. It should not be considered that the specific embodiments of the present invention are limited to these descriptions. For those skilled in the art, several simple deductions and substitutions can be made without departing from the concept of the present invention, and all of these should be considered to fall within the protection scope of the present invention.

Claims

1. A portable auxiliary heat dissipation system for ground testing of an aircraft liquid-cooled heat dissipation controller, characterized in that, The system includes a circulating heat dissipation module, a temperature monitoring module, a temperature closed-loop control module, and an electromagnetic compatibility (EMC) processing module. The circulating heat dissipation module consists of a variable frequency hot water pump and a portable mobile water tank with omnidirectional wheels. The water tank outlet passes through the pump, the controller under test, and returns to the water tank inlet to form a closed-loop liquid cooling circuit. The temperature monitoring module collects the inlet and outlet water temperatures of the circuit and transmits them to the temperature closed-loop control module. The control module calculates the heat generation based on the water temperature, outputs a PWM signal to adjust the pump speed, and uses linear regression to predict the water temperature and provide early warning. The EMC processing module is a pre-filter connected in series with the main power supply to suppress electromagnetic interference. All modules work together to achieve dynamic heat dissipation, precise control, and safety early warning.

2. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 1, characterized in that, The portable water tank is made of lightweight alloy material, has a capacity of 50L, and is equipped with quick connectors and a sealed filling port.

3. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 1, characterized in that, The hot water pump dynamically adjusts its circulation flow rate according to the heat output of the controller under test, based on the PWM speed control signal of the temperature closed-loop control module.

4. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 3, characterized in that, The temperature closed-loop control module uses the heat balance formula. Calculate the real-time heat generation and adjust the speed according to the heat generation-pump speed curve. The inlet and outlet temperature difference is ΔT, the heat generation is Q, the preset specific heat capacity of the circulating liquid is c, and the circulating flow rate corresponding to the current pump speed is m.

5. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 4, characterized in that, When the temperature closed-loop control module predicts that the water temperature will exceed the threshold within 5 minutes, it will trigger an audible and visual alarm.

6. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 1, characterized in that, The temperature monitoring module contains two PT1000 temperature sensors, which collect the water temperature at the inlet and outlet of the water tank, respectively, and the signals are transmitted via shielded cables.

7. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 1, characterized in that, The water tank, hot water pump, and controller under test are connected in a sealed manner through quick connectors to form a leak-proof closed-loop circulation.

8. The portable auxiliary heat dissipation system for ground testing of the aircraft liquid-cooled heat dissipation controller according to claim 1, characterized in that, The pre-filter has a common-mode combined with differential-mode structure, which meets electromagnetic compatibility requirements.

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