An intelligent air cooling system for aircraft environmental control module testing

Abstract

This invention discloses an intelligent air-cooling system for testing aircraft environmental control modules. The system utilizes a high-pressure fan module with stepless pressure regulation technology to achieve continuous airflow pressure adjustment. A two-stage cooling module employs a fuzzy control algorithm for segmented cooling. An electric heating module uses a distributed PTC ceramic layout for precise temperature compensation. Each module has independent status monitoring and power adjustment capabilities. The system control module incorporates a database of environmental control tests for mainstream civil aviation aircraft models. A model identification unit automatically matches test parameters. An intelligent scheduling unit, based on real-time collected airflow parameters, uses a combination of PID and fuzzy control algorithms to dynamically and collaboratively regulate each module, achieving dynamic response and correction of airflow pressure, temperature, and flow rate. This system can be used for R&D testing, production line inspection, and in-service maintenance verification of environmental control modules for various narrow-body, wide-body, and regional jet aircraft.

Description

Technical Field

[0001] This invention belongs to the field of aircraft ground testing technology, specifically relating to an intelligent air-cooling system for testing aircraft environmental control modules. Background Technology

[0002] With the rapid development of the aviation industry, the performance requirements of aircraft environmental control systems are constantly increasing, and their testing accuracy and efficiency directly affect the safety and comfort of the aircraft. Traditional testing methods for air-cooled systems in aircraft environmental control modules generally suffer from the following technical problems: a) Insufficient airflow control precision. Most systems use a gear-type pressure regulation method, which cannot achieve continuous and smooth adjustment of airflow pressure and is difficult to meet the pressure control precision requirements of modern environmental control systems. b) Limited temperature control capability. Traditional refrigeration or heating systems mostly adopt a single-stage control mode, which has a long temperature adjustment response time and low temperature control accuracy, and cannot match the high precision requirement of ±0.5℃ for temperature control of new environmental control modules. c) Low level of intelligence. Existing systems rely heavily on manual preset test parameters and lack adaptive matching capabilities for different aircraft models. The test process is cumbersome and the data management efficiency is low. When testing the same aircraft model, airflow parameters need to be repeatedly adjusted, which affects test efficiency and the accuracy of test results. d) Poor system integration, with independent control of modules such as fans, refrigeration, and heating, lacking a unified intelligent scheduling unit, resulting in low efficiency of collaborative work among modules and high energy consumption.

[0003] To address the aforementioned issues, this invention proposes an intelligent air-cooling system for testing aircraft environmental control modules. By employing stepless pressure regulation technology of a high-pressure fan module, a composite temperature control technology combining two-stage refrigeration and distributed electric heating, and an intelligent scheduling system with a built-in aircraft model test database, it achieves precise and coordinated control of airflow pressure, temperature, and flow rate, providing an efficient and reliable testing platform for the research and development and verification of aircraft environmental control modules. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent air-cooled system for testing aircraft environmental control modules. This system utilizes a high-pressure fan module with stepless pressure regulation technology to achieve continuous airflow pressure adjustment. A two-stage cooling module employs a fuzzy control algorithm for segmented cooling. An electric heating module uses a distributed PTC ceramic layout for precise temperature compensation. Each module has independent status monitoring and power adjustment capabilities. The system control module incorporates a database of environmental control tests for mainstream civil aviation aircraft models. A model identification unit automatically matches test parameters. An intelligent scheduling unit, based on real-time collected airflow parameters, uses a combination of PID and fuzzy control algorithms to dynamically coordinate and regulate each module, achieving dynamic response and correction of airflow pressure, temperature, and flow rate. The system control module allows users to remotely control preset test conditions via a touch interface or API. The system automatically generates visual test reports and has an anomaly warning function. When data exceeds a threshold, an alarm is automatically triggered and operating parameters are adjusted, significantly improving the testing accuracy of aircraft environmental control modules.

[0005] This invention is achieved through the following technical solution: An intelligent air-cooled system for testing aircraft environmental control modules includes: A high-pressure blower module is used to provide a stable high-pressure airflow for testing aircraft parts. The high-pressure blower module can be infinitely adjusted according to different test conditions. A two-stage refrigeration module is used to perform segmented refrigeration on the airflow output by the high-pressure blower module; An electric heating module is used to compensate the temperature of the airflow after it has been processed by a two-stage cooling module, so that the airflow temperature matches the target temperature value for testing aircraft parts, and the temperature control accuracy reaches ±0.5℃. The system control module stores test data of historical models and corresponding environmental control modules for each model. The system control module calls up the test data of historical models according to the model under test, and coordinates and controls the operation status of the high-pressure fan module, the two-stage refrigeration module, and the electric heating module to achieve precise control of airflow pressure, temperature, and flow rate.

[0006] Preferably, the high-pressure blower module includes at least one set of blower units, which are used to provide continuous and stable high-pressure airflow output for multi-system testing of the aircraft. Each set of blower units is equipped with an independent variable frequency speed control subunit, which can realize stepless pressure and speed regulation according to the test conditions. The blower units are connected to a two-stage cooling module.

[0007] Preferably, the two-stage refrigeration module includes a first refrigeration unit and a second refrigeration unit. The system control module combines a fuzzy control algorithm or a neural network algorithm to control the first refrigeration unit and the second refrigeration unit to work together, and dynamically adjusts the operating status and capacity output of the two refrigeration units according to the real-time cooling load.

[0008] Preferably, the electric heating module includes: The PTC ceramic heating unit adopts a distributed layout, which can perform segmented temperature compensation on the airflow after it has been processed by two-stage refrigeration modules. The temperature acquisition unit collects airflow temperature data before and after heating in real time and feeds it back to the system control module.

[0009] Preferably, the PTC ceramic heating unit includes a power adjustment subunit, which dynamically adjusts the output power of the PTC ceramic heating unit using pulse width modulation according to the instructions of the system control module, thereby achieving precise control of the airflow temperature.

[0010] Preferably, the system control module includes: The data storage unit is used to store the test parameter package, historical test data and operating condition matching rules of the environmental control module of mainstream civil aviation aircraft models, so as to provide data support for system operation. The intelligent scheduling unit coordinates and controls the operation of the high-pressure fan module, the two-stage refrigeration module, and the electric heating module based on preset parameters of the data storage unit or user input commands, so as to achieve precise regulation of airflow pressure, temperature, and flow rate.

[0011] Preferably, the data storage unit includes a model identification subunit, which supports identifying the model to be tested by searching the model number, scanning the QR code on the machine body, or importing the model configuration file, and can automatically match the environmental control module test parameter library of the corresponding model.

[0012] Preferably, the intelligent scheduling unit includes a status monitoring subunit, which collects the operating status data of each module in real time and feeds the collected data back to the intelligent scheduling unit. The operating status data includes airflow parameters, equipment temperature, and operating power.

[0013] Preferably, the intelligent scheduling unit includes an early warning subunit, which is equipped with an anomaly early warning algorithm. When the data exceeds a set threshold, it can automatically trigger an audible and visual alarm and adjust the operating parameters.

[0014] Preferably, the intelligent scheduling unit includes a user interaction subunit, which provides a touch-screen operation interface and an API remote control interface, supports users to preset test condition parameters, customize test processes, and export test data reports. The unit has a built-in test template library, which allows users to directly call templates in the template library and modify parameters based on the templates.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects: 1) In this invention, the high-pressure fan module uses stepless pressure regulation technology to achieve continuous airflow pressure adjustment, the two-stage refrigeration module uses fuzzy control algorithm to achieve segmented refrigeration, and the electric heating module uses a distributed PTC ceramic layout to achieve precise temperature compensation. Each module has independent status monitoring and power adjustment capabilities. The system control module has a built-in environmental control test database for mainstream civil aviation aircraft models. The test parameters are automatically matched through the aircraft model identification unit. The intelligent scheduling unit uses a combination of PID and fuzzy control algorithms to dynamically coordinate and regulate each module based on real-time collected airflow parameters, thereby achieving dynamic response and correction of airflow pressure, temperature, and flow rate. The system control module allows users to remotely control preset test conditions via touch interface or API. The system automatically generates visual test reports and has an anomaly warning function. When the data exceeds the threshold, it can automatically trigger an alarm and adjust the operating parameters, significantly improving the testing accuracy of the aircraft environmental control module. This system can be used for R&D testing, production line inspection, and in-service maintenance verification of environmental control modules for various models of narrow-body aircraft, wide-body aircraft, and regional jets. It supports various testing needs such as performance verification, fault simulation, and life testing of environmental control system components, providing an efficient and reliable intelligent solution for the R&D and maintenance of aviation environmental control systems.

[0016] 2) In this invention, the two-stage refrigeration module adopts a fuzzy control algorithm to achieve segmented collaborative refrigeration, which has significant advantages over the traditional single-stage refrigeration system. By dynamically adjusting the operating status of the two refrigeration units, the refrigeration capacity can be accurately matched according to the real-time cooling load, and the overall refrigeration efficiency is improved. The segmented refrigeration combined with the fuzzy control algorithm shortens the airflow temperature adjustment response time to ≤5s and the temperature control accuracy reaches ±0.3℃, which can meet the highest accuracy requirements for environmental control module testing in civil aviation airworthiness standards. It can adapt to the wide temperature range testing requirements of -40℃ to 80℃ and supports full-condition simulation from low-speed cruise to high-speed flight, providing a more realistic testing environment for the research and development of new environmental control modules. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a logic block diagram of the intelligent air-cooling system in this invention. Detailed Implementation

[0019] 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 some embodiments of the present invention, but not all embodiments. Example 1:

[0020] An intelligent air-cooling system for testing aircraft environmental control modules, such as Figure 1 As shown, it includes: The high-pressure blower module provides a stable high-pressure airflow for aircraft component testing. It allows for stepless pressure adjustment based on different testing conditions. The module comprises two blower units, each providing a continuous and stable high-pressure airflow output for multi-system aircraft testing. Each blower unit is equipped with an independent variable frequency speed control subunit, enabling stepless pressure and speed adjustment according to testing requirements. The blower units are connected to a two-stage cooling module. The airflow generated by the blower units enters the two-stage cooling module through a buffer flow equalization chamber. This chamber rectifies and stabilizes the high-pressure airflow, preventing airflow pulsations from impacting the cooling unit.

[0021] The two-stage cooling module is used to cool the airflow output from the high-pressure blower module in stages. The two-stage cooling module includes a first cooling unit and a second cooling unit. The system control module uses fuzzy control or neural network algorithms to control the first and second cooling units to work together, dynamically adjusting their operating status and capacity output based on real-time cooling load. The first cooling unit pre-cools the airflow to -10℃ to 0℃ before sending it to the second cooling unit for deep cooling. The second cooling unit uses cascade cooling technology to further reduce the airflow temperature to a preset temperature. Heat transfer is achieved through an intermediate heat exchanger. The fuzzy control algorithm dynamically adjusts the operating status of the two cooling units, achieving an airflow temperature control accuracy of ±0.3℃, meeting the testing requirements of the aircraft environmental control module under extreme conditions. Fuzzy control algorithms are common in the field of intelligent control, often used in dynamic control scenarios of complex nonlinear systems, especially suitable for industrial control systems with time-varying parameters. This algorithm is based on fuzzy set theory, simulating human thinking to transform expert experience into fuzzy rules, achieving adaptive control of the system. In the two-stage refrigeration module, the fuzzy control algorithm dynamically adjusts the operating power and start / stop status of the two refrigeration units by collecting data such as airflow temperature, cooling load, and refrigeration unit operating status in real time, so that the refrigeration system is always in the optimal operating state. Compared with the traditional PID control algorithm, the fuzzy control algorithm is more adaptable to changes in system parameters and can maintain stable control accuracy within a parameter fluctuation range of ±10%. This significantly shortens the airflow temperature adjustment response time and achieves a temperature control accuracy of ±0.3℃, meeting the testing requirements of the aircraft environmental control module under extreme conditions.

[0022] The electric heating module compensates for the temperature of the airflow after it has been processed by the two-stage cooling module, ensuring that the airflow temperature matches the target temperature value for aircraft component testing, with a temperature control accuracy of ±0.5℃. The electric heating module includes PTC ceramic heating units, which employ a distributed layout to provide segmented temperature compensation for the airflow after the two-stage cooling module, achieving temperature uniformity before the airflow enters the testing chamber, with a temperature field distribution deviation ≤±0.2℃. The power adjustment range of a single PTC ceramic heating unit is 0-5kW, with a response time ≤1s. It can dynamically adjust the heating power using pulse width modulation based on real-time acquired airflow temperature data, achieving accurate temperature compensation across the entire temperature range from -40℃ to 80℃. The electric heating module incorporates an overheat protection sensor. When the airflow temperature exceeds a set threshold of 2℃, it automatically cuts off the power supply to the corresponding heating unit and sends an alarm signal to the system control module to prevent damage to the test component due to overheating. Furthermore, the PTC ceramic heating units have automatic temperature control characteristics, allowing stable operation at rated power without the need for an additional temperature control loop, reducing system complexity and maintenance costs.

[0023] The temperature acquisition unit collects airflow temperature data in real time before and after heating and feeds it back to the system control module. The system control module can dynamically adjust the heating power of the electric heating module according to the real-time temperature deviation, realizing closed-loop temperature control and keeping the airflow temperature within ±0.5℃ of the target value. High-precision platinum resistance temperature sensors are installed at the inlet and outlet of the electric heating module. The sensors use a three-wire connection to eliminate wire resistance errors, achieving a measurement accuracy of ±0.1℃. The unit has a built-in signal conditioning circuit that amplifies, filters, and linearizes the weak signal output from the sensors, converting the temperature signal into a standard 0-5V analog signal. The temperature acquisition unit communicates with the system control module to ensure the real-time performance and reliability of the temperature data.

[0024] The PTC ceramic heating unit includes a power regulation subunit. Based on instructions from the system control module, this subunit dynamically adjusts the output power of the PTC ceramic heating unit using pulse width modulation (PWM) to achieve precise control of the airflow temperature. The power regulation subunit consists of an IGBT power switch, a drive circuit, and a protection circuit. By adjusting the IGBT's duty cycle, it converts the power supply voltage into a high-frequency pulse voltage, controlling the average input power of the PTC ceramic heating unit with a power regulation accuracy of 0.1kW. The power regulation subunit incorporates overcurrent, overvoltage, and overheat protection circuits. When the current or voltage of the PTC ceramic heating unit exceeds the rated threshold, it automatically cuts off the power supply to prevent damage to the PTC ceramic heating unit. The power regulation subunit uses an isolated drive circuit to achieve electrical isolation between the control circuit and the power circuit, improving the system's anti-interference capability and reliability.

[0025] The system control module stores test data for historical models and the corresponding environmental control modules for each model. Based on the model under test, the system control module calls up the test data of historical models and coordinates the operation of the high-pressure fan module, the two-stage refrigeration module, and the electric heating module to achieve precise control of airflow pressure, temperature, and flow rate. Example 2:

[0026] Based on the above embodiments, this embodiment further defines the system control module as follows: The data storage unit stores test parameter packages, historical test data, and operating condition matching rules for the environmental control modules of mainstream civil aviation aircraft models, providing data support for system operation. The data storage unit includes a local storage subunit and a cloud storage subunit. The local storage subunit stores test data for commonly used aircraft models. The cloud storage subunit uses object storage services, enabling long-term backup and off-site storage of test data, with storage capacity flexibly expandable as needed. The data storage unit incorporates a data encryption subunit to ensure data security and integrity. It supports data synchronization, enabling real-time data synchronization between the local and cloud storage subunits. In the event of a local storage subunit failure, it automatically switches to the cloud storage subunit, ensuring continuous system operation. The data storage unit also features data backup and recovery capabilities, periodically backing up test data. Backup data is stored on independent storage media, allowing for rapid recovery in case of data loss or corruption.

[0027] The data storage unit also includes an aircraft type identification subunit. This subunit supports identifying the aircraft type under test by searching for the aircraft type number, scanning the fuselage QR code, or importing the aircraft type configuration file. It can also automatically match the corresponding environmental control module test parameter library for the aircraft type. The aircraft type identification subunit has a built-in aircraft type feature database that stores identification information such as aircraft type codes, fuselage QR code features, and configuration file formats for mainstream civil aviation aircraft types, including narrow-body aircraft, wide-body aircraft, regional jets, and general aviation aircraft. The aircraft type identification subunit supports multi-modal recognition fusion. When a single recognition method cannot accurately identify the aircraft type, the results of multiple recognition methods can be combined for a comprehensive judgment.

[0028] The intelligent scheduling unit coordinates and controls the operation of the high-pressure fan module, the two-stage refrigeration module, and the electric heating module based on the preset parameters of the data storage unit or user input commands, so as to achieve precise regulation of airflow pressure, temperature, and flow rate.

[0029] The intelligent scheduling unit includes a status monitoring subunit, which collects real-time operating status data from each module and feeds the collected data back to the intelligent scheduling unit. The operating status data includes airflow parameters, equipment temperature, and operating power. Multiple monitoring points are deployed at key nodes in the high-pressure fan module, the two-stage refrigeration module, and the electric heating module, including airflow parameter monitoring, equipment temperature monitoring, and operating power monitoring.

[0030] The status monitoring subunit eliminates environmental electromagnetic interference through digital filtering technology and sends the monitoring data to the intelligent scheduling unit. It can automatically adjust the alarm thresholds of each parameter by analyzing historical operating data. When the monitoring data exceeds the threshold by ±10%, it immediately sends an early warning signal to the intelligent scheduling unit and simultaneously triggers the audible and visual alarm device.

[0031] The intelligent scheduling unit includes an early warning subunit, which is equipped with an anomaly warning algorithm. When data exceeds a set threshold, it can automatically trigger an audible and visual alarm and adjust operating parameters. The early warning subunit employs a multi-dimensional anomaly warning algorithm, setting three warning thresholds for steady-state parameters such as airflow pressure, temperature, and flow rate: ±5% of the normal threshold triggers a warning, ±10% triggers an alarm, and ±15% triggers an emergency shutdown. The early warning subunit has a built-in audible and visual alarm system, including a high-decibel buzzer and a three-color warning light, with different audible and visual combinations corresponding to different warning levels. The multi-dimensional anomaly warning algorithm is a commonly used algorithm in the field of industrial equipment condition monitoring. Its core lies in integrating data features from multiple dimensions to construct an anomaly detection model covering the entire scenario. It can effectively identify complex anomaly patterns that traditional single-dimensional algorithms cannot detect, making it suitable for the detection and early warning of air-cooled systems.

[0032] The intelligent scheduling unit includes a user interaction subunit, which provides a touch-screen interface and an API remote control interface. It supports users in pre-setting test parameters, customizing test procedures, and exporting test data reports. The unit has a built-in test template library, allowing users to directly call templates from the library and modify parameters based on templates. The user interaction subunit supports seamless switching between local touch operation and remote API control. Other parts of this embodiment are the same as those in the above embodiments and will not be repeated here.

[0033] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. An intelligent air cooling system for aircraft environmental control module testing, characterized in that, include: A high-pressure blower module is used to provide a stable high-pressure airflow for testing aircraft parts. The high-pressure blower module can be infinitely adjusted according to different test conditions. A two-stage refrigeration module is used to perform segmented refrigeration on the airflow output by the high-pressure blower module; An electric heating module is used to compensate the temperature of the airflow after it has been processed by a two-stage cooling module, so that the airflow temperature matches the target temperature value for testing aircraft parts, and the temperature control accuracy reaches ±0.5℃. The system control module stores test data of historical models and corresponding environmental control modules for each model. The system control module calls up the test data of historical models according to the model under test, and coordinates and controls the operation status of the high-pressure fan module, the two-stage refrigeration module, and the electric heating module to achieve precise control of airflow pressure, temperature, and flow rate.

2. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 1, characterized in that, The high-pressure blower module includes at least one set of blower units, which are used to provide continuous and stable high-pressure airflow output for multi-system testing of aircraft. Each set of blower units is equipped with an independent variable frequency speed control subunit, which can achieve stepless pressure and speed regulation according to the test conditions. The blower unit is connected to a two-stage cooling module.

3. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 1, characterized in that, The two-stage refrigeration module includes a first refrigeration unit and a second refrigeration unit. The system control module combines fuzzy control algorithm or neural network algorithm to control the first refrigeration unit and the second refrigeration unit to work together, and dynamically adjusts the operating status and capacity output of the two refrigeration units according to the real-time cooling load.

4. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 1, characterized in that, The electric heating module includes: The PTC ceramic heating unit adopts a distributed layout, which can perform segmented temperature compensation on the airflow after it has been processed by two-stage refrigeration modules. The temperature acquisition unit collects airflow temperature data before and after heating in real time and feeds it back to the system control module.

5. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 4, characterized in that, The PTC ceramic heating unit includes a power adjustment subunit, which dynamically adjusts the output power of the PTC ceramic heating unit using pulse width modulation according to the instructions of the system control module, thereby achieving precise control of the airflow temperature.

6. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 1, characterized in that, The system control module includes: The data storage unit is used to store the test parameter package, historical test data and operating condition matching rules of the environmental control module of mainstream civil aviation aircraft models, so as to provide data support for system operation. The intelligent scheduling unit coordinates and controls the operation of the high-pressure fan module, the two-stage refrigeration module, and the electric heating module based on preset parameters of the data storage unit or user input commands, so as to achieve precise regulation of airflow pressure, temperature, and flow rate.

7. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 6, characterized in that, The data storage unit includes a model identification subunit, which supports identifying the model to be tested by searching the model number, scanning the QR code on the machine body, or importing the model configuration file, and can automatically match the environmental control module test parameter library of the corresponding model.

8. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 6, characterized in that, The intelligent scheduling unit includes a status monitoring subunit, which collects the operating status data of each module in real time and feeds the collected data back to the intelligent scheduling unit. The operating status data includes airflow parameters, equipment temperature, and operating power.

9. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 6, characterized in that, The intelligent scheduling unit includes an early warning subunit, which is equipped with an anomaly early warning algorithm. When the data exceeds a set threshold, it can automatically trigger an audible and visual alarm and adjust the operating parameters.

10. The intelligent air-cooling system for testing aircraft environmental control modules as described in claim 6, characterized in that, The intelligent scheduling unit includes a user interaction subunit, which provides a touch-screen operation interface and an API remote control interface. It supports users to preset test condition parameters, customize test processes, and export test data reports. The unit has a built-in test template library, which allows users to directly call templates in the template library and modify parameters based on the templates.

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