CAC Motor Water Cooling with Predictive Drag-Free Thermal Control
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Solution Overview
Problem
Existing cooling solutions for cabin air compressor (CAC) motors in aircraft create undesirable drag and fail to provide sufficient cooling, necessitating more efficient methods.
Innovation Solution
A system utilizing a turbine outlet connected to a water separator that collects cooling water, which is directed through cooling channels within the CAC motor, with the resulting steam being repurposed for cabin utilities or turbine enthalpy, and a predictive model to activate cooling when temperature thresholds are exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ram air cooling is used for the CAC motor, then cooling is provided, but undesirable drag is created and sufficient cooling is not achieved
Solution Approach 1:
The patent transitions from air-based cooling (ram air) to water-based cooling by directing cooling water from the turbine through cooling channels in the CAC motor. This hydraulic cooling method provides superior heat transfer efficiency while eliminating the drag penalties associated with air intake systems.
Solution Approach 2:
The cooling water from the turbine serves multiple functions: it cools the CAC motor through the cooling channels, and the heated water/steam is then utilized for cabin heating or other thermal requirements. This multi-functional approach maximizes the utility of the turbine's cooling output while solving the CAC motor cooling problem.
2Temperature
If additional cooling systems are added to the CAC motor, then cooling efficiency is improved, but system complexity increases
Solution Approach 1:
The patent merges the CAC motor cooling system with the existing turbine water cooling system. The cooling water infrastructure, cooling channels integrated into the motor housing, and thermal management controls are combined into a unified system, eliminating the need for separate cooling components and reducing overall system complexity.
Solution Approach 2:
The system utilizes the turbine's own cooling water output to cool the CAC motor, creating a self-sufficient thermal management solution. The heated water then feeds back into the cabin heating system or other thermal requirements, making the system self-regulating and reducing the need for external cooling resources.
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 system effectively cools the CAC motor with minimal drag, repurposing airflow and water for multiple uses, and conserves water by activating cooling only when necessary, achieving enhanced cooling efficiency.
Implementation Method 1
The first CAC outlet is fluidly connected to the plurality of first cooling channels, such that the cooling water that is evaporated into steam within the first cooling channels exits through the first CAC outlet
Implementation Method 2
The CAC motor housing includes a plurality of first cooling channels fluidly connected to the first CAC inlet such that the cooling water can flow from the first CAC inlet through the plurality of first cooling channels
Data Source
AI summary
A system for cooling a cabin air compressor (CAC) motor includes a water separator which extracts water from airflow through a turbine and/or a fuel cell, and a CAC motor including cooling channels connected to an inlet and an outlet. The inlet of the CAC motor receives water from the water separator. The steam at the outlet of the CAC motor can be repurposed for warming utilities in an aircraft cabin, or for de-icing or increasing enthalpy of the turbine. The cooling water flow can be directed to the CAC motor in response to a predicted temperature of the CAC motor exceeding a threshold. The predicted temperature can be generated by feeding inputs including CAC motor input power measured by a power sensor, differential pressure measured by a pressure sensor, and a temperature at an air cooling inlet measured by a temperature sensor to a processor which generates a map model.