Rotor Brake Cooling Disk with Integrated Impeller
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Solution Overview
Problem
Conventional rotorcraft braking systems with solid braking disks suffer from overheating, leading to permanent warping, vibrations, and reduced operational efficiency due to inadequate heat dissipation, limiting braking frequency and performance.
Innovation Solution
A rotor brake system incorporating a braking disk with a built-in impeller for active cooling, combined with a rotor brake control system that manages operation based on temperature and yaw rate to optimize braking performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a solid braking disk is used for rotorcraft braking, then the braking system is simple in structure, but the braking disk overheats leading to warping and reduced performance
Solution Approach 1:
The braking disk is segmented into multiple cooling channels and passages that divide the heat dissipation function across multiple pathways, allowing heat to be removed more efficiently from different regions of the disk simultaneously
Solution Approach 2:
A fluid cooling system is introduced where coolant flows through channels and passages in the braking disk to actively remove heat, transitioning from passive air cooling to active fluid-based thermal management
2Productivity
If braking operations are performed frequently with a solid braking disk, then operational efficiency improves, but overheating causes permanent warping and vibrations
Solution Approach 1:
Temperature sensors monitor the braking disk temperature in real-time and provide feedback to the control system, which adjusts braking force or activates cooling systems when temperature thresholds are approached, preventing thermal damage
Solution Approach 2:
The cooling channels and passages are pre-designed into the braking disk structure, and coolant flow is prepared in advance, enabling proactive heat removal before critical temperatures are reached during frequent braking operations
3Temperature
If a braking disk with built-in impeller and cooling channels is used, then heat dissipation improves, but device complexity increases
Solution Approach 1:
The cooling channels, passages, and impeller are integrated directly into the braking disk structure itself, combining the thermal management system with the braking component to avoid adding separate external cooling apparatus
Solution Approach 2:
The braking disk serves multiple functions simultaneously: it provides mechanical braking through friction surfaces while also acting as a heat exchanger with integrated cooling channels and passages, eliminating the need for separate cooling components
4Productivity
If temperature and yaw rate control systems are implemented, then braking performance is optimized, but control system complexity increases
Solution Approach 1:
Temperature sensors and yaw rate sensors provide continuous feedback to the control system, which automatically adjusts braking force and cooling activation based on real-time conditions, optimizing braking performance without manual intervention
Solution Approach 2:
The control system automatically manages braking force application and cooling system activation based on sensor inputs, enabling the braking system to self-regulate and optimize performance without requiring external control input
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 impeller-enhanced rotor brake system effectively cools the braking disk, allowing for more frequent and efficient braking operations, reducing the risk of overheating and extending maintenance intervals, while the temperature and yaw rate-controlled system ensures optimal braking force application.
Implementation Method 1
an impeller operably connected to the braking disk and configured to rotate with the braking disk. The rotor brake system also includes a source of cooling fluid and a controller. The cooling fluid is supplied to the rotor brake and the impeller is configured to move the cooling fluid across the rotor brake during rotation of the rotor brake.
Implementation Method 2
a first brake pad and a second brake pad positioned on opposite sides of the braking disk and configured to slow rotation of the rotor brake when pressed against the braking disk
Data Source
AI summary
According to one embodiment, a rotor brake control system includes a temperature sensor operable to measure an operating temperature of a rotor brake and a rotor brake control unit operable to instruct a caliper to adjust, based on the measured operating temperature, an amount of friction generated between a brake pad and the rotor brake.