Aircraft APU Intercooler Integration for Weight Reduction
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Solution Overview
Problem
Existing aircraft auxiliary power units (APUs) are often heavy and complex, making them unsuitable for aircraft applications due to their weight and complexity, which complicates their use as efficient power sources when the main engines are shut down.
Innovation Solution
A compound engine assembly for aircraft APUs, comprising a compressor, intercooler, engine core with internal combustion engines, and a bleed conduit, which provides both compressed air and electrical power to the aircraft, with a bleed air valve controlling fluid communication between the intercooler and the pneumatic system, allowing for efficient power distribution and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If known ground-based APUs are used, then power supply capability is improved, but weight and complexity increase making them incompatible with aircraft applications
Solution Approach 1:
The patent combines the compressor and intercooler into a single integrated assembly where the intercooler is positioned within the compressor housing structure. This merging eliminates separate mounting structures, reduces overall component count, and decreases weight while maintaining the dual functionality of compression and cooling for aircraft power supply applications
2Power
If known ground-based APUs are used, then power supply capability is improved, but device complexity increases making them incompatible with aircraft applications
Solution Approach 1:
The intercooler is integrated within the compressor housing, combining two separate systems into one unified structure. This reduces the number of independent components, simplifies assembly procedures, and lowers maintenance complexity while preserving the complete power supply function needed for aircraft operations
Solution Approach 2:
The compressor housing serves multiple functions: it contains the compression mechanism, houses the intercooler structure, provides mounting points for accessories, and facilitates fluid flow paths. This multi-functionality reduces the need for separate structural components, thereby reducing overall device complexity
3Temperature
If compressed air is cooled in an intercooler, then temperature is reduced improving efficiency, but additional components and weight are added
Solution Approach 1:
The intercooler is positioned inside the compressor housing structure, utilizing the existing housing material and structure as part of the heat exchange system. This integration eliminates the need for a separate external intercooler unit, reducing weight while achieving the required temperature reduction for improved thermodynamic efficiency
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
The solution enables efficient provision of compressed air and electrical power to aircraft systems, reducing weight and complexity while maintaining operational reliability, even when main engines are shut down, by utilizing a compact and lightweight compound engine assembly.
Implementation Method 1
an intercooler including at least one first conduit in heat exchange relationship with at least one second conduit, the at least one first conduit having an inlet in fluid communication with an outlet of the compressor, the at least one second conduit being configured for circulation of a coolant therethrough
Data Source
AI summary
An auxiliary power unit for an aircraft, having a compressor, an intercooler including first conduit(s) having an inlet in fluid communication with the compressor outlet and second conduit(s) configured for circulation of a coolant therethrough, an engine core having an inlet in fluid communication with an outlet of the first conduit(s), and a bleed conduit in fluid communication with the outlet of the first conduit(s) through a bleed air valve. The auxiliary power unit may include a generator in driving engagement with the shaft of the engine core to provide electrical power for the aircraft. A method of providing compressed air and electrical power to an aircraft is also discussed.