Aircraft Cooling System Dynamic Mass Flow Control
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Solution Overview
Problem
Aircraft liquid cooling systems require complex and costly simulations to design duct systems, leading to increased installation space and weight due to the need for larger ducts at greater distances from the conveying device.
Innovation Solution
A method for operating an aircraft cooling system that controls the mass flow of cooling medium based on the thermal output of the cooling energy consumer and the temperature difference across each cooling station, eliminating the need for large ducts by optimizing cooling medium supply according to actual energy requirements, using temperature sensors and a control unit to adjust the mass flow dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the duct system is designed to supply nominal volume flow to all cooling stations regardless of distance, then sufficient cooling energy delivery is ensured, but installation space and weight increase due to larger duct cross-sectional areas
Solution Approach 1:
The patent implements dynamic control of cooling medium mass flow to each cooling station based on real-time thermal output requirements and temperature differences. Flow control devices adjust the mass flow dynamically, allowing smaller duct cross-sections while maintaining adequate cooling delivery. This resolves the contradiction by making the system adaptive rather than statically oversized for all stations.
Solution Approach 2:
The patent applies local quality by controlling mass flow individually at each cooling station according to its specific thermal output and temperature difference requirements. Instead of uniform flow distribution, each station receives customized flow based on local cooling needs, enabling optimized duct sizing that reduces overall system weight while maintaining reliable cooling delivery.
2Reliability
If the duct system is designed to supply nominal volume flow to all cooling stations regardless of distance, then sufficient cooling energy delivery is ensured, but installation space increases due to larger duct cross-sectional areas
Solution Approach 1:
The dynamic mass flow control allows the duct system to be sized for actual rather than maximum required flow at each station. By adjusting flow rates dynamically based on thermal output and temperature difference, the system achieves reliable cooling delivery with smaller duct cross-sections, reducing installation space requirements.
Solution Approach 2:
Individualized flow control at each cooling station enables local optimization of duct sizing. Each duct section can be sized according to the specific flow requirements of its associated cooling station rather than being oversized to serve all stations, thereby reducing total installation space.
3Reliability
If time-consuming simulations are used to design the duct system, then adequate cooling supply to all stations is ensured, but design time and cost increase
Solution Approach 1:
The patent employs feedback control using temperature sensors at cooling stations to monitor temperature differences between inlet and outlet. This real-time feedback enables automated adjustment of mass flow rates, ensuring adequate cooling supply without requiring time-consuming design simulations. The control system adapts to changing conditions dynamically.
Solution Approach 2:
The cooling system performs self-regulation through automated control devices that adjust mass flow based on measured thermal output and temperature difference. This self-service capability eliminates the need for extensive external simulation studies during the design phase, reducing design time while maintaining reliable cooling supply.
4Quantity of substance
If larger duct cross-sectional areas are used to supply distant cooling stations, then sufficient cooling medium flow is ensured, but the weight of the cooling system increases
Solution Approach 1:
Dynamic mass flow control allows the system to deliver adequate cooling medium quantity to distant stations without requiring permanently large duct cross-sections. Flow rates are adjusted dynamically based on actual cooling needs, enabling the use of smaller, lighter ducts that still provide sufficient flow when required.
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
This approach simplifies the design process, reduces installation space and weight, and optimizes cooling energy supply by ensuring sufficient cooling while minimizing the overall mass flow of cooling medium, thus reducing the load on the conveying device.
Implementation Method 1
a cooling medium cooled by the refrigerating machine is supplied to the cooling station
Implementation Method 2
Cooling energy can be transferred from the cooling circuit to a cooling energy consumer by means of a heat exchanger of the cooling station
Data Source
AI summary
In a method for operating an aircraft cooling system a cooling medium is guided through a cooling circuit, which is connected to a refrigerating machine and to at least one cooling station associated with a cooling energy consumer, to supply cooling medium cooled by the refrigerating to the cooling station. A temperature of the cooling medium upstream of the cooling station and a temperature of the cooling medium downstream of the cooling station are detected. The mass flow of cooling medium supplied to the cooling station is controlled in dependence on a thermal output of the cooling energy consumer and in dependence on a difference between the temperature of the cooling medium upstream of the cooling station and the temperature of the cooling medium downstream of the cooling station.