Multi-port compressor manifold with integral bypass valve
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current air generation units for aircraft require significant energy and fuel to pressurize and condition outside air for cabin ventilation, especially at low ambient pressures during cruise, due to the need for compressor systems to elevate air pressures beyond cabin needs.
Innovation Solution
A multi-port compressor manifold with an integral bypass valve that allows cooled bleed air to be directed directly from a primary heat exchanger to a secondary heat exchanger, bypassing the compressors, thereby reducing energy consumption by minimizing pressure drops and allowing pressure draw from a lower engine stage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If the compressor system elevates air to high pressures to meet cabin needs, then the air pressure requirement is satisfied, but energy consumption and fuel usage increase significantly
Solution Approach 1:
The manifold is divided into multiple sections (first section receiving air from primary heat exchanger, second section receiving compressed air from compressors) with a bypass valve connecting them. This segmentation allows selective routing of air through different paths based on pressure requirements, enabling energy-efficient operation by bypassing compressors when ambient pressure is sufficient.
Solution Approach 2:
The bypass valve dynamically switches between closed and open positions based on real-time pressure conditions. When the bypass valve is closed, compressors operate to elevate air pressure. When the bypass valve is open, air flows directly from the first section to the second section, bypassing compressors and reducing energy consumption during cruise at low ambient pressures.
2Stress or pressure
If compressors are used to elevate outside air pressure during cruise at low ambient pressures, then cabin pressure requirements are met, but fuel consumption increases
Solution Approach 1:
The bypass valve dynamically adjusts system operation based on ambient pressure conditions. During cruise at high altitudes where ambient pressure is low, the bypass valve opens to allow air to flow directly from the primary heat exchanger through the manifold to the secondary heat exchanger, bypassing the compressors entirely. This dynamic switching eliminates unnecessary compression work and associated fuel consumption while still meeting cabin pressure requirements.
3Use of energy by moving object
If a bypass system is added to reduce energy consumption, then fuel efficiency improves, but device complexity increases
Solution Approach 1:
The bypass valve is integrated directly into the manifold structure, merging the bypass function with the existing air distribution system. The manifold includes a first section connected to the primary heat exchanger, a second section connected to the secondary heat exchanger, and the bypass valve positioned between these sections. This integration eliminates the need for separate bypass piping and reduces overall system complexity compared to adding a standalone bypass system.
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 enhances the efficiency and performance of air generation units by reducing fuel consumption and energy usage, particularly at high altitudes where ambient pressures are low, by minimizing pressure drops and optimizing air pressure management.
Implementation Method 1
a heat exchanger having a primary heat exchanger and a secondary heat exchanger, the heat exchanger configured to receive and cool a fluid
Implementation Method 2
the bypass valve fluidly couples the primary section and the secondary section to bypass the two compressors
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A compressor manifold (100) includes a primary section (104) having a primary inlet port (110), a first primary outlet port (112), and a second primary outlet port (114), the primary section (104) configured to receive a fluid from a primary heat exchanger (22) through the primary inlet port (110) and direct the fluid to at least one compressor (42) through the first and second primary outlet ports (112, 114). A secondary section (106) includes a first secondary inlet port (116), a second secondary inlet port (118), and a secondary outlet port (120), the secondary section (106) configured to receive the fluid from the at least one compressor (42) through the first and second secondary inlet ports (116, 118) and direct the fluid to a secondary heat exchanger (26) through the secondary outlet port (120). A bypass valve (102) is positioned between the primary section (104) and the secondary section (106) to fluidly couple the primary section (104) and the secondary section (106) to bypass the at least one compressor (42).