Aircraft IPCU Power and Thermal Management via Dynamic Mode Switching
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Solution Overview
Problem
Existing integrated power and cooling systems for aircraft are inefficient in providing peak power and cooling due to limitations in operating pressure and power balance, often requiring oversized systems to handle occasional peak power demands, leading to lower efficiency most of the time.
Innovation Solution
An open-loop system with a power summing controller and bi-directional solid-state contactors is implemented, allowing the IPCU starter/generator to generate power and control power balance throughout operation, including peak periods, by coupling power from the engine and IPCU to aircraft loads, and using energy storage devices to manage transient power needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the IPCU is oversized to handle peak power demands, then peak power capability is improved, but system efficiency deteriorates during normal operation
Solution Approach 1:
The patent implements dynamic power management by enabling the IPCU to operate flexibly across different power levels. The system can transition between combustion mode and bleed air mode dynamically, and the starter/generator can switch between motor and generator modes based on real-time power demands, allowing efficient operation at both peak and normal power levels without permanent oversizing
Solution Approach 2:
The system changes operational parameters to resolve the contradiction. By switching the IPCU between different operating modes (combustion vs. bleed air, motor vs. generator), the system adapts its power output and efficiency characteristics to match actual demand, thereby maintaining efficiency while providing peak power capability when needed
2Temperature
If the IPCU operates in closed-loop mode with high compressor pressure ratio, then cooling capacity is improved, but system adaptability deteriorates due to pressure limitations at high altitude
Solution Approach 1:
The system dynamically switches between closed-loop and open-loop configurations based on operational conditions. At high altitudes or when adaptability is needed, the system transitions to open-loop mode where the cooling turbine discharges to ambient, eliminating pressure ratio limitations and maintaining operational flexibility while still providing adequate cooling capacity
3Device complexity
If the starter/generator is used only for startup, then device complexity is reduced, but power generation capability during operation deteriorates
Solution Approach 1:
The starter/generator is designed as a multi-functional component that serves both as a starter motor during startup and as a power-generating generator during operational modes. This universal design allows a single device to perform multiple functions without requiring separate systems, thereby maintaining power generation capability while avoiding the complexity of additional dedicated power systems
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 configuration enables efficient peak power and cooling generation without over-sizing, maintaining system efficiency across a wide range of operations by utilizing the IPCU starter/generator for continuous power support and energy storage for transient loads, enhancing overall system performance.
Implementation Method 1
The air is expanded by cooling turbine 102 to generate very cold air to cool the avionics liquid cooling loop through avionics cooler 116
Implementation Method 2
heat exchangers 116 and 118 as well as pump 120. The avionics cooling system is used to provide temperature controlled air flow to the avionics equipment
Data Source
AI summary
A system and method for improved system efficiency of an integrated power and control unit (IPCU) of an aircraft is disclosed. The system uses an open-loop cooling system and turbo machine power matching to provide wide operation range without over-sizing. In order to reduce the temperature of the air flow through the cooling heat exchanger, the cooling turbine need to expand further in the same time generating power but the power could be higher than the compressor could absorb so a generator that would convert the power and used in supplying the aircraft would result in more efficient system.