Intercooler Actuator Range Check via Thermal Parameters
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Solution Overview
Problem
Existing aircraft propulsion systems face challenges in efficiently controlling the intercooler's operation to regulate engine intake air temperature, particularly due to the complexity and cost associated with actuator position sensors.
Innovation Solution
The system includes an intercooler assembly with a flow control assembly featuring an actuator and flaps, controlled by a processor that determines the hot-side heat transfer effectiveness and mass flow rate, and uses these parameters to identify the actuator's position and perform a range check without the need for an actuator position sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an actuator position sensor is installed to verify actuator position, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system uses the intercooler assembly itself to generate position information through performance parameters. The controller determines actuator position indirectly by measuring heat transfer effectiveness and mass flow rate, which are naturally produced by the system operation, eliminating the need for external position sensors
Solution Approach 2:
The patent replaces the mechanical/electrical position sensor system with a thermal measurement system. Instead of using sensors to detect actuator position mechanically, the system uses thermal performance measurements (heat transfer effectiveness and mass flow rate) to infer position, substituting a complex sensing mechanism with simpler thermal measurements
2Reliability
If an actuator position sensor is installed to verify actuator position, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The system uses the intercooler assembly itself to generate position information through performance parameters. The controller determines actuator position indirectly by measuring heat transfer effectiveness and mass flow rate, which are naturally produced by the system operation, eliminating the need for external position sensors
Solution Approach 2:
The patent replaces expensive, complex position sensors with simpler, more cost-effective thermal measurement components. The solution uses standard temperature and pressure sensors to infer actuator position, significantly reducing manufacturing costs while maintaining verification capability
3Temperature
If traditional intercooler control systems are used, then temperature regulation is achieved, but system complexity increases
Solution Approach 1:
The system implements a feedback mechanism where the controller continuously monitors heat transfer effectiveness and mass flow rate, compares actual performance with expected performance, and uses this information to determine actuator position and verify system operation, enabling intelligent control without additional sensors
Solution Approach 2:
The controller performs multiple functions: it manages temperature regulation, determines actuator position, verifies actuator operation through range checks, and monitors system health. This multi-functionality is achieved by processing thermal performance data for multiple control objectives, reducing the need for separate dedicated components
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 solution enables efficient and reliable control of the intercooler, reducing system complexity and cost while maintaining effective temperature regulation, thus improving the overall performance and reliability of the aircraft propulsion system.
Implementation Method 1
an intercooler configured to cool the compressed air that is supplied from the compressor to an air intake of the engine
Implementation Method 2
The actuator is operably connected to the at least one flap to position the at least one flap in an open position, a closed position, and intermediate positions between the open position and the closed position to control an ambient air flow through the cold side
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An assembly for an aircraft propulsion system includes an intercooler assembly (32) and a controller (26). The intercooler assembly (32) includes an intercooler (66) and a flow control assembly (68). The intercooler (66) includes a primary air inlet (70), a primary air outlet (72), a secondary air inlet (74), and a secondary air outlet (76). The flow control assembly (68) is disposed at the secondary air outlet (76). The flow control assembly (68) includes an actuator (82) and at least one flap (80). The actuator (82) is configured to position the at least one flap (80) in an open position, a closed position, and intermediate positions. The controller (26) is configured to control the actuator (82) to position the at least one flap (80) in the open position, determine a hot-side heat transfer effectiveness of the intercooler (66) and a hot-side mass flow rate for the intercooler (66), determine a cold-side mass flow rate of the intercooler (66), identify a position of the actuator (82), and identify a successful or an unsuccessful actuator range check for the actuator (82).