Controller Cooling with Fuel-Cooled Cold Plate and TECs
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Solution Overview
Problem
Electronic components in starter/generator controllers for gas turbine engines face temperature management challenges, as some components operate near or below the maximum operating temperature, requiring efficient cooling to prevent failure and maintain performance, while also needing to optimize combustion efficiency by utilizing the heated fuel.
Innovation Solution
A cooling system comprising a cold plate with integrated intermediate thermoelectric coolers (TECs) for components with lower maximum operating temperatures, allowing for additional local cooling and insulation to manage heat effectively, while the cold plate itself uses fuel as a cooling fluid that absorbs heat from higher-temperature components, enhancing combustion efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electronic components are mounted directly to a cold plate, then the cooling system is simple, but components with lower maximum operating temperatures cannot be adequately cooled
Solution Approach 1:
The patent applies local quality by implementing different cooling strategies for different components based on their specific thermal requirements. Components with lower maximum operating temperatures are mounted on TECs (thermoelectric coolers) that provide active localized cooling, while other components are mounted directly on the cold plate for passive cooling. This allows each component to receive the appropriate level of cooling needed for its operating temperature constraints.
Solution Approach 2:
The patent uses TECs as intermediary devices between the cold plate and heat-generating components. The TECs act as thermal mediators that actively pump heat away from temperature-sensitive components, enabling these components to operate at lower temperatures than the cold plate itself. This intermediary layer resolves the contradiction by providing enhanced cooling capability without requiring all components to be directly coupled to the cold plate.
2Use of energy by moving object
If fuel is used to cool the cold plate, then combustion efficiency increases, but the fuel temperature becomes too high for components requiring lower operating temperatures
Solution Approach 1:
The patent segments the cooling system into multiple zones with different temperature levels. The cold plate receives cooling from fuel, creating a first temperature level suitable for most components. TECs create a second, lower temperature level for temperature-sensitive components. This segmentation allows the system to utilize the thermal energy in fuel for general cooling while providing additional active cooling where needed.
Solution Approach 2:
The patent changes the thermal parameters of the cooling system by introducing TECs that actively modify the temperature distribution. Instead of a uniform cooling approach, the system creates localized temperature gradients through the TECs, enabling different regions of the controller to operate at different temperatures optimized for their specific component requirements.
3Ease of operation
If all components are cooled to the same temperature, then the cooling system is uniform, but temperature-sensitive components cannot operate at their optimal lower temperatures
Solution Approach 1:
The patent implements local quality by providing differentiated cooling for different components based on their thermal sensitivity. Temperature-sensitive components are mounted on TECs that maintain them at lower operating temperatures, while other components are cooled by the cold plate alone. This non-uniform cooling approach optimizes reliability for each component type according to its specific requirements.
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 components with lower maximum operating temperatures using TECs, preventing performance degradation and increasing combustion efficiency by maintaining higher fuel temperatures, thus ensuring reliable operation and improved engine performance.
Implementation Method 1
at least one electronic component mounted to the cold plate by an intermediate thermoelectric cooler
Implementation Method 2
the cold plate itself uses fuel as a cooling fluid that absorbs heat from higher-temperature components
Implementation Method 3
As the fuel absorbs heat from the electronic components, the temperature of the fuel increases, which increases the efficiency of combustion in the engine
Data Source
Figure 1
Figure 2
AI summary
A controller (22) according to an exemplary aspect of the present disclosure includes, among other things, a cold plate (28) and at least one electronic component (40, 42) mounted to the cold plate (28) by an intermediate thermoelectric cooler (44, 46).