Integrated Environmental Control Module With Coaxial Impellers
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Solution Overview
Problem
Existing environmental control systems in aircraft turrets face challenges with inefficient thermal management due to bulky components like bolt-in plate-style heat exchangers and external fins, which occupy critical space and offer limited thermal capacity in low airflow conditions.
Innovation Solution
An environmental control module (ECM) featuring a heat exchanger with coaxial impellers driven by a brushless drive coil, allowing for efficient airflow management through separate cold and hot side channels, with optional magnetic coupling for impeller synchronization, enabling modular replacement and reduced service risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bolt-in plate-style heat exchangers with blind mate connectors are used, then heat exchanger installation is simplified, but the connectors are easily damaged and reliability decreases
Solution Approach 1:
The patent merges the heat exchanger core with the impeller assembly into a single integrated unit. The heat exchanger is formed as one piece with the impeller, eliminating separate connectors and reducing failure points. This integration maintains ease of installation while dramatically improving reliability by removing the vulnerable blind mate connector interface.
2Temperature
If structural coldwalls are used for cooling, then thermal management is achieved, but critical volume within the turret is consumed
Solution Approach 1:
The impeller assembly serves multiple functions simultaneously: it drives cooling airflow through the heat exchanger, generates thrust for the turret, and structures the cooling channels. This multi-functionality eliminates the need for separate structural coldwalls, achieving thermal management while preserving critical turret volume for payload.
3Temperature
If traditional external fins are used, then heat dissipation is provided, but thermal capacity is limited in low air flow or zero airspeed conditions
Solution Approach 1:
The patent replaces passive mechanical fin structures with an active impeller-driven airflow system. The impeller generates controlled airflow through the heat exchanger channels, providing active heat dissipation that maintains thermal capacity effectiveness across all airspeed conditions, including zero airspeed operations where passive fins would be ineffective.
4Temperature
If separate motors drive fans of the heat exchanger, then cooling function is achieved, but device complexity increases
Solution Approach 1:
The patent combines the cooling fan function with the turret thrust generator into a single impeller assembly driven by a single motor. The same impeller that generates cooling airflow also produces thrust for turret movement, eliminating the need for separate motors and reducing overall device complexity while maintaining effective cooling function.
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 ECM provides efficient thermal management with reduced space occupancy and enhanced thermal capacity, facilitating modular servicing and minimizing service disruptions while maintaining system integrity.
Implementation Method 1
the drive is a brushless drive coil at least partially positioned in a drive pocket defined in the hot side impeller, and energizing of the brushless drive coil urges rotation of at least the hot side impeller about the drive axis
Implementation Method 2
the hot side impeller is operably connected to the cold side impeller via a magnetic coupling such that rotation of the hot side impeller about the drive axis urges rotation of the cold side impeller about the drive axis
Implementation Method 3
a heat exchanger having a cooling airflow inlet, a plurality of cold side channels fluidly connected to the cooling airflow inlet to direct the cooling airflow through the enclosed space
Data Source
AI summary
An environmental control module (ECM) for an enclosed space includes a heat exchanger having a cooling airflow inlet, a plurality of cold side channels fluidly connected to the cooling airflow inlet to direct the cooling airflow through the enclosed space, and a cooling airflow outlet to remove the cooling airflow from the heat exchanger. A hot side impeller is configured to rotate about a drive axis and is positioned to urge the cooling airflow out of the enclosed space and through the cooling airflow outlet. A cold side impeller is operably connected to and is coaxial with the hot side impeller and is configured to urge the cooling airflow into the heat exchanger via the cooling airflow inlet. A drive secured is to the enclosed space and is operable connected to the hot side impeller to drive rotation of the hot side impeller and the cold side impeller.