Dual-compressor vapor cycle system
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Solution Overview
Problem
Existing aircraft environmental control systems face inefficiencies and limited operating ranges in cooling thermal loads due to single compressor systems, which affect fuel consumption and space utilization, while lacking redundancy for reliable operation.
Innovation Solution
A dual-compressor vapor cycle cooling system (VCCS) with parallel compressor systems and a system controller that dynamically adjusts operating loads to maximize efficiency and lifespan, incorporating multiple compressors, condensers, expansion devices, and evaporators for enhanced redundancy and load sharing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single compressor system is used in the vapor cycle cooling system, then the device complexity is reduced, but the operating range and efficiency are limited
Solution Approach 1:
The single compressor system is segmented into multiple compressor systems (first compressor system with first and second compressors, second compressor system with third and fourth compressors). Each compressor system can operate independently or in combination, allowing the system to adapt to various thermal loads and flight conditions, thereby expanding the operating range without excessive complexity increase.
Solution Approach 2:
The system incorporates dynamic control capabilities where the system controller selectively activates different compressor systems based on real-time thermal load requirements, flight conditions, and system efficiency considerations. This dynamic operation allows optimal performance across varying conditions while managing device complexity through intelligent control.
2Reliability
If a single compressor system operates at high load continuously, then the cooling capacity is sufficient, but the component lifespan is reduced
Solution Approach 1:
The cooling capacity is segmented across multiple compressor systems, allowing the total cooling demand to be distributed among several compressors rather than placing continuous high load on a single compressor. This segmentation enables individual compressors to operate at lower, more sustainable loads, extending their lifespan while maintaining sufficient total cooling capacity.
Solution Approach 2:
The system ensures continuous cooling capability by having multiple compressor systems that can operate simultaneously or alternately. This continuity allows the system to maintain adequate cooling output at all times while preventing any single compressor from being overworked, thus balancing productivity requirements with component reliability.
3Reliability
If multiple compressor systems are added to increase redundancy, then the system reliability is improved, but the device complexity increases
Solution Approach 1:
The system is segmented into modular compressor units (first compressor system with first and second compressors in series, second compressor system with third and fourth compressors in series). This modular segmentation provides inherent redundancy while keeping each module relatively simple, allowing the system to achieve improved reliability without excessive overall complexity.
Solution Approach 2:
The multiple compressor systems are designed with universal functionality, where each compressor system can perform the same cooling function and can be selectively activated based on system requirements. This multi-functionality approach allows redundancy to be achieved while managing complexity through standardized, interchangeable components that simplify control and maintenance.
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 dual-compressor system increases operating range and efficiency, reduces fuel consumption, and provides redundancy by allowing multiple efficient operating loads, optimizing cooling performance across varying thermal demands.
Implementation Method 1
a first compressor system including a first motor, a first motor controller, and a first compressor in series with a second compressor; a second compressor system, in parallel to the first compressor system, the second compressor system including a second motor, a second motor controller, and a third compressor in series with a fourth compressor
Implementation Method 2
a condenser fluidically coupled to the first and second compressor systems
Implementation Method 3
a first expansion device in series with, and fluidically coupled to, a flash heat exchanger, the flash heat exchanger fluidically coupled to a second expansion device
Implementation Method 4
the second expansion device fluidically coupled to a first evaporator, the first evaporator fluidically coupled to the first and second compressor systems
Implementation Method 5
a vapor cycle cooling system configured to cool one or more thermal loads for a vehicle
Implementation Method 6
a first expansion device in series with, and fluidically coupled to, a flash heat exchanger
Data Source
Figure 1
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AI summary
A vapor cycle cooling system includes first and second compressor (112B) systems in parallel with one another, each compressor system including a motor, a motor controller (180, 280, 380, 480), and a first compressor (112A, 212A) in series with a second compressor (112B); a condenser (102, 202, 302) fluidically coupled to each compressor system; a filter drier (138, 238, 338), in series with, and fluidically coupled to the condenser (102, 202, 302); a first expansion device in series with, and fluidically coupled to, a flash heat exchanger (106, 206), the flash heat exchanger (106, 206) fluidically coupled to a second expansion device, the second expansion device fluidically coupled to a first evaporator (266), the first evaporator (266) fluidically coupled to each compressor system; a system controller (180, 280, 380, 480) electrically coupled to each motor controller (180, 280, 380, 480); and a motor and motor controller (180, 280, 380, 480) cooling loop fluidically coupled to the filter drier (138, 238, 338) and each motor, wherein the vapor cycle cooling system is configured to cool one or more thermal loads (264) for a vehicle.