Dual-Circuit Generator Cooling for Power Converter Heat Limits
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Solution Overview
Problem
Electric propulsion systems for aircraft face challenges in cooling power conversion electronics integrated with generators, as high coolant temperatures desirable for generator cooling are undesirable for power electronics.
Innovation Solution
A dual cooling system with separate circuits and heat exchangers for generators and power converters, where the power converter heat exchanger is positioned upstream to remove thermal energy, utilizing different cooling fluids and airflow configurations to optimize cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high temperature coolant is used for generator cooling, then generator cooling efficiency is improved, but power electronics cooling performance deteriorates
Solution Approach 1:
The cooling system is divided into two separate cooling circuits: a generator cooling circuit with high temperature coolant (80-105°C) and a power converter cooling circuit with low temperature coolant. This segmentation allows each component to be cooled at its optimal temperature, resolving the contradiction between generator cooling efficiency and power electronics cooling performance
Solution Approach 2:
The power converter cooling circuit is extracted as a separate system from the generator cooling circuit. The power converter heat exchanger is positioned upstream in the cooling system, and a separate cooling pump delivers coolant independently to the power converter, allowing it to be cooled at lower temperatures suitable for power electronics
2Reliability
If separate cooling circuits are implemented for generator and power converter, then cooling performance for both components is improved, but system complexity increases
Solution Approach 1:
While maintaining separate cooling circuits for optimal thermal management, the system merges the generator heat exchanger and power converter heat exchanger into a common duct structure. This allows both heat exchangers to share the same airflow path and structural support, reducing overall system complexity while preserving the benefits of separate cooling circuits
Solution Approach 2:
The common duct structure serves multiple functions: it houses both the generator heat exchanger and power converter heat exchanger, provides a shared airflow path for cooling both components, and reduces the number of separate structural components needed. This multi-functionality reduces system complexity while maintaining effective cooling
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 configuration effectively cools both the generator and power converter, improving system reliability and potentially reducing weight by optimizing thermal management.
Implementation Method 1
a generator heat exchanger fluidly connected to a generator of the power generation system via the generator cooling circuit to cool the generator
Implementation Method 2
a power converter heat exchanger fluidly connected to a power converter of the power generation system via the power converter cooling circuit to cool the power converter
Implementation Method 3
the generator heat exchanger and the power converter heat exchanger are located in a common duct... the airflow directed through the duct to remove thermal energy from the power converter heat exchanger and the generator heat exchanger
Data Source
AI summary
A cooling system of a power generation system includes a generator cooling circuit having a first cooling fluid circulating therethrough. The generator cooling circuit includes a generator heat exchanger fluidly connected to a generator of the power generation system via the generator cooling circuit to cool the generator. A power converter cooling circuit has a second cooling fluid different from the first cooling fluid circulating therethrough. The power converter cooling circuit includes a power converter heat exchanger fluidly connected to a power converter of the power generation system via the power converter cooling circuit to cool the power converter.