Aircraft Blower Controller Eliminates Pressure Valves

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Solution Overview

Problem

Existing aircraft environmental control systems (ECS) suffer from inefficiencies due to the use of pressure regulating and flow control valves, leading to increased engine power offtake and fuel consumption.

Innovation Solution

A blower controller that eliminates the need for these valves by adjusting the blower's operating parameters based on intake airflow conditions and pack flow demand, using a control schedule with transfer functions to optimize airflow delivery and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If pressure regulating valves and flow control valves are used to manage bleed air flow, then airflow control and pressure maintenance are achieved, but energy dissipation increases and fuel consumption rises

Engineering Contradiction:

Improveenergy dissipationVSAvoidairflow control capability

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The patent replaces mechanical flow control valves and pressure regulating valves with an electrically driven compressor system controlled by a controller. The controller receives signals from sensors monitoring cabin conditions and adjusts the compressor's airflow output accordingly, eliminating the need for traditional mechanical valves that caused energy dissipation through pressure drops and flow restrictions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system dynamically adjusts the compressor's operating parameters (such as rotational speed and airflow rate) based on real-time feedback from sensors monitoring cabin temperature, pressure, and airflow demands. This allows the system to optimize energy efficiency by matching the compressor output precisely to actual cabin requirements, avoiding the energy waste associated with fixed mechanical valve configurations.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If traditional valve systems are used for bleed air management, then airflow regulation is achieved, but engine power offtake increases

Engineering Contradiction:

Improveairflow delivery efficiencyVSAvoidengine power offtake

Core Design Contradiction:

ProductivityVSPower

Solution Approach 1:

The patent substitutes the traditional mechanical valve-based airflow regulation system with an electrically controlled compressor system. The controller electronically regulates airflow to the air conditioning pack based on cabin demands, eliminating the need for engine-powered mechanical valves that consumed additional engine power and increased fuel consumption.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system introduces an intermediary electric compressor and controller between the engine bleed air source and the air conditioning pack. This intermediary system efficiently regulates and delivers airflow to the cabin without directly taxing engine power, as the electric compressor can be optimized to match exact airflow requirements rather than relying on engine bleed air pressure fluctuations managed by mechanical valves.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stress or pressure

If pressure regulating valves are used to maintain bleed pressure, then pressure stability is achieved, but energy dissipation increases

Engineering Contradiction:

Improvebleed pressure stabilityVSAvoidenergy dissipation

Core Design Contradiction:

Stress or pressureVSLoss of energy

Solution Approach 1:

The patent replaces mechanical pressure regulating valves with an electronically controlled compressor system. The controller monitors cabin pressure and airflow requirements, adjusting the compressor's output to maintain stable pressure without the energy dissipation inherent in mechanical valve systems that create pressure drops through flow restrictions and turbulence.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements feedback control by continuously monitoring cabin pressure and airflow conditions through sensors and adjusting the compressor's operating parameters in real-time. This closed-loop control maintains stable bleed pressure and optimizes energy efficiency by matching compressor output to actual cabin demands, eliminating the energy waste associated with mechanical pressure regulating valves that operate independently of real-time conditions.

Inventive Principle:

Principle #23Feedback

Data Source

PatentEP3835558B1Environmental control system

Publication Date: 2023.01.04 ROLLS ROYCE PLC

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AI summary

Disclosed is a blower controller (25) for controlling a blower (11) that supplies a pressurised airflow (12) to an air conditioning pack (13) of an aircraft. The blower controller comprises a pack flow demand adjustment module configured to receive a pack flow demand signal (28) representative of a desired mass flow rate of an airflow supplied by the air conditioning pack, and a blower condition signal (41) indicative of a condition of an intake airflow received by the blower, and determine an corrected pack flow demand based on the pack flow demand and the blower condition signal. The controller also includes a first control signal generator (50) configured to receive the corrected pack flow demand (49) and generate a first control signal (26) to control a first operating parameter of the blower in response to the corrected pack flow demand (49). Also disclosed is an environmental control system for an aircraft, including the blower controller.