Fuel Pump Thermal Bypass for Low-Power Oil Temperature Control

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Solution Overview

Problem

Modern aircraft face challenges in achieving efficient fuel system thermal management at low power conditions due to the inefficiency of centrifugal main pumps, which are difficult to replace despite their high reliability, and this affects overall thrust specific fuel consumption (TSFC) and gearbox performance.

Innovation Solution

Incorporating a fuel oil cooler bypass pathway with a bypass valve to selectively direct fuel flow, allowing temperature control of lubricating oil within the fuel delivery system, thereby preventing overcooling and maintaining optimal oil temperature for improved pump and gearbox performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If centrifugal main pumps are used for fuel delivery, then reliability is improved, but thermal management capability deteriorates at low power conditions

Engineering Contradiction:
Improvepump reliabilityVSAvoidfuel system thermal management
Core Design Contradiction:
ReliabilityVSTemperature

Solution Approach 1:

The patent implements a dynamic thermal management system with a temperature sensor and control valve that adjusts the fuel flow path based on real-time temperature conditions. At low power conditions, the system dynamically switches between cooling the fuel through the oil cooler or bypassing it, optimizing thermal management while maintaining pump reliability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes the thermal parameters of the fuel by selectively routing it through the oil cooler or bypass pathway based on temperature sensor feedback. This parameter change allows the fuel to either absorb heat from the pump oil or remain at ambient temperature, resolving the thermal management issue while keeping the centrifugal pump.

Inventive Principle:
Principle #35Parameter changes

2Temperature

If fuel is cooled through the oil cooler, then thermal management is improved, but pump performance deteriorates due to overcooling

Engineering Contradiction:
Improveoil temperature controlVSAvoidpump performance
Core Design Contradiction:
TemperatureVSPower

Solution Approach 1:

The patent employs a feedback control mechanism where a temperature sensor continuously monitors the fuel temperature and adjusts the control valve position accordingly. This feedback loop prevents overcooling by closing the bypass valve when fuel temperature is adequate and opening it when the fuel becomes too cold, thereby maintaining optimal pump performance.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The fuel system serves its own thermal management needs by using the fuel itself as the cooling medium for the pump oil. The fuel absorbs excess heat from the oil cooler when needed, and the system self-regulates to prevent the fuel from becoming too cold, which would harm pump performance.

Inventive Principle:
Principle #25Self-service

3Loss of energy

If gearbox horsepower extraction is reduced, then fuel system efficiency is improved, but thermal management capability worsens

Engineering Contradiction:
Improvegearbox horsepower extractionVSAvoidthermal management
Core Design Contradiction:
Loss of energyVSTemperature

Solution Approach 1:

The fuel serving dual purposes: it is both the working fluid for combustion and the cooling medium for the pump oil. This multi-functionality allows the system to improve fuel efficiency by reducing gearbox horsepower extraction while maintaining thermal management capabilities through the existing fuel flow path.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 solution enhances fuel system efficiency by maintaining optimal oil temperature, improving pump and gearbox performance, and reducing fuel system gearbox horsepower extraction.

Implementation Method 1

A fuel oil cooler is positioned fluidly between the main fuel pump and the combustor assembly configured to cool oil utilized by the fuel delivery system

Methodology Applied
Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

A fuel oil cooler bypass valve is positioned along the fuel oil cooler bypass pathway to control the first flow of fuel along the fuel oil cooler bypass pathway

Methodology Applied
Scientific EffectFluid flow control: Valve

Data Source

PatentUS20250270957A1Fuel pump system with built-in thermal bypass
Publication Date: 2025.08.28 HAMILTON SUNDSTRAND CORP
  • US20250270957A1 patent drawing
  • US20250270957A1 patent drawing
  • US20250270957A1 patent drawing

AI summary

A fuel delivery system for a gas turbine engine includes a fuel source, and a main fuel pump configured to deliver a first flow of fuel to a combustor assembly of the gas turbine engine. A fuel oil cooler is positioned fluidly between the main fuel pump and the combustor assembly configured to cool oil utilized by the fuel delivery system, and a fuel oil cooler bypass pathway is configured to selectably direct the first flow of fuel to bypass the fuel oil cooler.