Aircraft Controller Cooling Boot for Integrated Air-Liquid Heat Removal
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Solution Overview
Problem
Existing heat dissipation systems for aircraft powerplants are in need of improvement to more effectively cool electronic components, particularly electric machine controllers, which generate significant heat during operation.
Innovation Solution
An air cooling circuit and a liquid cooling circuit are integrated into the aircraft propulsion system to cool electronic controllers, utilizing air cooling boots that direct air from external or internal sources to impinge and convectively cool the controllers, while a liquid cooling circuit further enhances cooling using a liquid working fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling is used for electronic controllers, then cooling effectiveness is improved, but device complexity increases due to additional cooling circuits and components
Solution Approach 1:
The cooling system is segmented into multiple independent cooling circuits (air cooling circuit and liquid cooling circuit), each handling specific cooling tasks. The air cooling circuit includes separate components for air intake, distribution, and exhaust, allowing modular design and maintenance while achieving effective cooling of electronic controllers.
Solution Approach 2:
A heat exchanger is introduced as an intermediary component between the electronic controllers and the cooling circuits. The heat exchanger facilitates efficient thermal transfer from the controllers to the cooling fluid, enabling effective cooling while simplifying the direct coupling between controllers and cooling systems.
2Volume of moving object
If cooling circuits are integrated into the propulsion system, then space utilization is improved, but reliability decreases due to increased system integration complexity
Solution Approach 1:
The integrated propulsion system is divided into distinct functional modules including separate air cooling circuits, liquid cooling circuits, and heat exchanger assemblies. This modular segmentation allows for independent testing, maintenance, and replacement of components, thereby maintaining reliability while achieving compact integration.
Solution Approach 2:
Redundant cooling pathways and backup components are incorporated into the integrated system design. The system includes multiple cooling circuits that can operate independently, providing fail-safe capabilities that maintain reliability despite the complex integrated architecture.
3Temperature
If multiple cooling circuits are used, then cooling effectiveness is improved, but device complexity increases due to additional components and control systems
Solution Approach 1:
The air cooling circuit and liquid cooling circuit are merged into a coordinated system that shares common components such as heat exchangers and control systems. This merging allows the multiple cooling circuits to work synergistically, achieving superior cooling effectiveness while reducing overall system complexity through shared infrastructure.
Solution Approach 2:
The cooling system is designed with multi-functional components that can serve multiple purposes. For example, the heat exchanger serves as both a thermal transfer device and a flow distribution manifold, while the control system manages both air and liquid cooling circuits, reducing the need for separate dedicated components.
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 combined air and liquid cooling systems effectively manage heat dissipation from electronic controllers, ensuring efficient operation and longevity of these critical components.
Implementation Method 1
The cooling boot is configured to direct the air through the air outlets and into the air plenum to air cool the electric machine controller
Implementation Method 2
The cooling boot may be configured such that the air directed into the air plenum convectively cools the electric machine controller
Implementation Method 3
The liquid cooling circuit is configured to cool the electronic controller using a liquid working fluid
Data Source
AI summary
An apparatus is provided for an aircraft. This apparatus includes an electric machine controller and an air cooling circuit. The electric machine controller includes controller circuitry and a controller housing. The controller circuitry is disposed within an interior of the controller housing. The air cooling circuit includes a cooling boot. The air cooling circuit is configured to direct air from an air source into the cooling boot. The cooling boot forms an air plenum with the electric machine controller. The cooling boot includes a plurality of air outlets. The cooling boot is configured to direct the air through the air outlets and into the air plenum to air cool the electric machine controller.