Pump Bypass Flow Split for Minimum Flow and Overheat Control
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Solution Overview
Problem
Conventional fluid pump systems in aircraft fuel systems face challenges in managing fuel capacity and heat rejection, leading to pump overheating and inefficiencies due to complex valve arrangements that increase weight and size.
Innovation Solution
A controllable pump system with a flow split mechanism, including a bypass line and a flow sense valve, utilizes sensors and actuators to maintain a minimum flow rate, preventing overheating while optimizing output flow through a flow module and shut-off valve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional valve arrangements are used to control flow, then flow control capability is achieved, but system weight and size increase
Solution Approach 1:
The patent extracts the flow control function from complex mechanical valve arrangements and implements it through a simplified system using a flow divider and electronic control. The flow divider separates total pump flow into measured and unused portions, with electronic sensors and controllers replacing heavy mechanical valves to achieve flow control capability while reducing system weight.
Solution Approach 2:
The patent replaces conventional mechanical valve arrangements with an electronic control system comprising flow sensors, position sensors, and electronic controllers. This substitution eliminates complex mechanical linkages and heavy valve components while maintaining flow control capability through electronic actuation of pump displacement.
2Ease of operation
If complex valve arrangements are used to control flow, then flow control capability is achieved, but system size increases
Solution Approach 1:
The patent extracts the flow control function from complex mechanical valve arrangements and implements it through a simplified system using a flow divider and electronic control. The flow divider separates total pump flow into measured and unused portions, with electronic sensors and controllers replacing heavy mechanical valves to achieve flow control capability while reducing system size.
Solution Approach 2:
The patent employs multi-functional components where the flow divider serves both flow control and flow measurement functions, and the electronic control system integrates multiple control tasks (flow regulation, temperature management, efficiency optimization) into a single compact unit, reducing overall system size compared to dedicated separate components.
3Productivity
If pump flow is reduced to match demand, then fuel capacity is optimized, but pump temperature increases causing overheating
Solution Approach 1:
The patent implements feedback control using flow sensors and temperature sensors that continuously monitor system conditions. The electronic controller adjusts pump displacement and bypass flow based on real-time feedback to maintain optimal operating temperature while matching flow output to actual demand, preventing overheating during low-flow conditions.
Solution Approach 2:
The patent uses variable displacement pump technology that dynamically adjusts pump output based on actual system demand. The electronic control system continuously modifies pump displacement to optimize the balance between maintaining sufficient flow for cooling and matching demand to maximize fuel capacity, enabling adaptive temperature management.
4Temperature
If minimum flow rate is maintained to prevent overheating, then pump temperature is controlled, but output flow efficiency decreases
Solution Approach 1:
The patent segments the total pump flow into two distinct paths: a measured flow portion that goes to the output and an unused flow portion that is bypassed. This segmentation allows the system to maintain minimum flow through the pump for cooling while directing only the necessary amount to the output, improving overall flow efficiency by eliminating unnecessary flow through complex valve arrangements.
Solution Approach 2:
The patent introduces a flow divider as an intermediary component that separates total pump flow into measured and unused portions. This intermediary enables precise control of output flow while maintaining adequate flow for pump cooling, improving efficiency by eliminating the need for complex valve arrangements that would otherwise be required to achieve the same flow control.
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 system effectively maintains pump temperature and output flow, reducing the risk of overheating and simplifying the system design by eliminating complex valves, thereby reducing weight and size.
Implementation Method 1
The flow split system can include a flow sense valve (FSV) comprising a piston. The piston can be biased (e.g., with a spring) against pressure on the bypass line such that the bypass flow is configured to move the piston.
Implementation Method 2
The piston position sensor can be a linear variable differential transformer (LVDT), for example.
Implementation Method 3
The piston can be biased (e.g., with a spring) against pressure on the bypass line such that the bypass flow is configured to move the piston.
Data Source
Figure 1
AI summary
A fluid pump system can include a controllable pump (101) configured to generate a pump flow through the controllable pump and to output an output flow to an output line (103). The fluid pump system can include a flow split system (105) configured to be in fluid communication with the controllable pump in a bypass state such that the flow split system is configured to divert a portion of the pump flow to maintain a desired output flow to the output line but to also allow the controllable pump to maintain a minimum pump flow through the controllable pump to maintain pump temperature below a high temperature threshold.