Adaptive Plate-Fin Heat Exchanger With Parallel-to-Series Switching
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Solution Overview
Problem
Existing environmental control systems (ECS) in aircraft waste pressure by throttling down the bleed flow control valve, leading to inefficiencies and increased fuel burn, particularly when operating conditions require less pressure/flow.
Innovation Solution
Implementing a valve array that allows for configuration of the heat exchanger assembly into either a simple cross-flow or a triple-pass cross-flow configuration, adjusting valves to optimize airflow through multiple heat exchanger cores for efficient pressure management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If the bleed flow control valve is throttled down to reduce pressure/flow demand, then the pressure and flow are reduced to match demand, but pressure is wasted and fuel burn increases
Solution Approach 1:
The heat exchanger assembly dynamically changes its flow configuration from parallel to serial based on operating conditions. The valve array can switch between connecting all heat exchanger cores in parallel (for high flow demand) or in series (for low flow demand), allowing the system to adapt its pressure drop characteristics to match demand without wasting energy through valve throttling
2Productivity
If the bleed flow control valve is fully open at design point, then maximum pressure and flow are available, but the system cannot adapt to lower demand conditions efficiently
Solution Approach 1:
The system transitions from a static valve control approach to a dynamic configuration approach. The valve array enables the heat exchanger assembly to reconfigure its internal flow paths, switching between parallel connection (maximum productivity) and serial connection (energy efficient adaptation to lower demand), providing both high productivity at design point and adaptability to varying conditions
Solution Approach 2:
The heat exchanger assembly is divided into multiple independent heat exchanger cores (first, second, and third cores) that can be connected in different configurations. This segmentation allows the system to selectively engage cores in parallel or series based on demand, enabling both high productivity when all cores are engaged in parallel and efficient adaptation when fewer cores are engaged in series
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Achieves lower fuel burn and reduced pressure drop across the ECS pack by allowing flexible configuration of the heat exchanger assembly, enhancing operational efficiency.
Implementation Method 1
The plurality of heat exchanger cores is disposed between the system inlet and the system outlet
Implementation Method 2
The valve array fluidly connects the system inlet to the system outlet via parallel flow through all of the plurality of heat exchanger cores
Data Source
Figure 1
Figure 2
AI summary
An environmental control system (10) includes a cross-flow heat exchanger, a first valve (132), and a second valve (134). The heat exchanger includes three cores each with their own respective inlet, outlet, and cold air passage. The first inlet is fluidly connected with a hot air source. The second outlet is fluidly connected to the first outlet. The third inlet is fluidly connected to the second inlet and to a hot air destination. The first valve is fluidly connected with the hot air source, the second inlet, and the third inlet. The first valve is positioned in-line between the hot air source and the second and third inlets. The second valve is fluidly connected to the hot air destination, to the first outlet, and to the second outlet. The second valve is positioned in-line between the hot air destination and the first and second outlets.