Free fall simulator cooling system
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Solution Overview
Problem
Current free fall simulators experience issues with condensate droplets causing discomfort to users, uneven temperature distribution, and noise generation due to their cooling systems, which affect user experience and maintenance efficiency.
Innovation Solution
A closed pressure chamber with a heat exchanger inside, maintaining higher pressure than atmospheric pressure, captures condensate and ensures even mixing of cooled air, reducing noise and facilitating maintenance, while also allowing for waste heat recuperation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling system with heat exchanger is used to cool circulating air in the wind tunnel system, then the air temperature is reduced, but condensate droplets are generated and carried into the flight chamber causing discomfort to users
Solution Approach 1:
The cooling system is segmented into separate functional zones: a cooling zone where condensation occurs, and a release zone where only cooled air is introduced into the flight chamber. The heat exchanger is positioned such that the condensation zone is isolated from the flight chamber, preventing droplet contamination while maintaining cooling effectiveness.
Solution Approach 2:
A carefully designed air flow path acts as an intermediary between the cooling system and the flight chamber. The system uses controlled air circulation to separate condensate droplets from the cooled air stream, allowing only the cooled air to reach users while trapping condensate within the cooling system boundaries.
2Temperature
If cooled air is released directly into the flight chamber, then temperature regulation is achieved, but uneven temperature distribution and cold air streams are created causing user discomfort
Solution Approach 1:
The cooling system implements local quality control by releasing cooled air at multiple strategic locations within the flight chamber rather than at a single point. This distributed release pattern ensures uniform temperature distribution throughout the chamber, eliminating localized cold spots and improving overall thermal comfort.
3Ease of repair
If the cooling system components are placed in easily accessible locations for maintenance, then maintenance efficiency is improved, but noise generation and interference with the air stream are increased
Solution Approach 1:
The cooling system components are nested within the wind tunnel structure, with maintenance access provided through strategically positioned access panels and service corridors. This nested arrangement allows maintenance personnel to reach critical components without requiring disassembly of the entire system, while keeping noise-generating elements isolated from the flight chamber.
4Adaptability or versatility
If a closed cooling system is used instead of open cooling, then independence from outer environment is achieved, but temperature mixing efficiency is reduced and cold air streams become more pronounced
Solution Approach 1:
The closed cooling system maintains continuous circulation and mixing of air throughout the flight chamber. The system uses persistent air movement and multiple release points to ensure that cooled air is continuously distributed and mixed with warmer air, preventing the formation of persistent cold streams while maintaining environmental independence.
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
Prevents condensate droplets from reaching users, achieves uniform temperature distribution, reduces noise, and simplifies maintenance, enhancing user comfort and operational efficiency by capturing and recycling waste heat.
Implementation Method 1
a water-air-type heat exchanger connected to a cold generator is located. The heat exchanger can be located in an outlet duct, which directs the cooled air stream directly under the flight chamber.
Implementation Method 2
Behind the inlet duct of the stream duct, an auxiliary fan is located, which supports the airflow through the cooling system.
Implementation Method 3
The air passing through the heat exchanger comes into contact with the cooling medium (e.g. water circulating in the heat exchanger), whereafter it travels back into the wind tunnel system, where it is mixed with the rest of the circulating air, thereby cooling it down.
Data Source
AI summary
A free fall simulator comprising: a wind tunnel system; a flight chamber connected to the wind tunnel allowing for a continuous flow of circulating air, and a cooling system for cooling of the air circulating in the wind tunnel system, wherein the cooling system comprises: an air inlet sucking in a part of the air circulating in the wind tunnel system; at least one heat exchanger comprising a coolant; and at least one air outlet adapted such that the cooled air leaves the cooling system through the at least one air outlet. The cooling system further comprises: a closed pressure chamber comprising a cooling area having pressure higher than atmospheric pressure, and at least one auxiliary fan. The at least one heat exchanger is located inside of the closed pressure chamber so that the cooling of the circulating air takes place in the cooling area.