Micro-Chiller Power Control for Compact Thermo-Electric Cooling
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Solution Overview
Problem
Existing micro-chiller systems are not feasible for compact installations in aircraft mini-bars, galleys, or in-seat compartments due to size constraints and power limitations, making it difficult to provide chilled refreshments to premium passengers effectively.
Innovation Solution
A micro-chiller unit with a controller that adjusts power based on available aircraft power and sensor data to maintain a set-point temperature using thermo-electric elements, with safety features to prevent overheating and efficient operation, integrated with sensors for Prognostic and Health Management (PHM) to ensure reliable performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional refrigeration systems are installed in aircraft mini-bars or in-seat compartments, then cooling capacity is sufficient, but the system size and weight exceed available space constraints
Solution Approach 1:
The refrigeration system is divided into multiple independent thermo-electric cooling modules, each capable of providing partial cooling capacity. This segmentation allows the system to fit within compact aircraft spaces while maintaining reliable cooling through distributed thermal management zones
Solution Approach 2:
Conventional mechanical compression refrigeration systems are replaced with thermo-electric (Peltier) cooling elements that use electrical current to generate cooling effects directly. This substitution eliminates complex mechanical components, reducing system volume and weight while improving reliability through fewer moving parts
2Speed
If maximum power is supplied to thermo-electric elements to achieve rapid cooling, then cooling speed increases, but power consumption exceeds aircraft local power availability
Solution Approach 1:
The power supply to thermo-electric elements is made dynamic and adjustable rather than fixed at maximum. The controller modulates power levels based on real-time temperature sensor feedback, allowing rapid cooling when needed while reducing power consumption during maintenance phases, adapting to aircraft power availability
Solution Approach 2:
The cooling system operates in periodic cycles with alternating high-power and low-power phases. During high-power phases, rapid cooling is achieved; during low-power phases, the system maintains temperature within acceptable ranges, optimizing the balance between cooling speed and power consumption
3Measurement precision
If multiple sensors are integrated for comprehensive monitoring, then system control precision improves, but device complexity increases
Solution Approach 1:
The controller is designed as a multi-functional integrated unit that performs temperature monitoring, power management, safety control, and diagnostic functions through a single device. This universal controller consolidates what would otherwise require multiple separate components, reducing system complexity while maintaining comprehensive monitoring precision
Solution Approach 2:
Temperature sensor data is fed back to the controller which automatically adjusts power to thermo-electric elements to maintain set-point temperatures. This closed-loop feedback system achieves precise temperature control through simple on/off or modulated power adjustment rather than complex multi-sensor processing
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
Enables efficient and safe cooling of compact spaces within aircraft, ensuring passenger comfort by maintaining set-point temperatures while optimizing power usage and preventing overheating, thus addressing the feasibility and efficiency issues of previous systems.
Implementation Method 1
supplying current to a set of components of the micro-chiller unit comprising at least a set of thermo-electric elements to cool the interior cavity of the micro-chiller unit to a set-point temperature
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2D
AI summary
A controller assembly, apparatus, and method of manufacture for a micro-chiller unit is provided. The control assembly includes a controller (450,600) coupled to a plurality of sensors (400) configured within a micro-chiller unit wherein the controller (450,600) is configured to receive sensed data from at least one sensor of the plurality of sensors (400) comprising at least temperature data of an interior cavity disposed in the micro-chiller unit, wherein in response to receiving at least temperature data, the controller (450,600) is configured to adjust an amount of power to the micro-chiller unit in accordance with a maximum level of power from a supply locally available, wherein the amount of power is further adjusted in accordance with a mode of operation of the micro-chiller unit for supplying current to at least a set of thermo-electric elements to cool the interior cavity of the micro-chiller unit to a set-point temperature.