Thermal Management System with Oxygen Reduction and Heat Sink
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Solution Overview
Problem
Current thermal management systems in gas turbine engines face challenges in safely and efficiently transferring heat to the fuel flow without risking damage to the engine, particularly due to the risk of fuel heating leading to coking and system damage.
Innovation Solution
A thermal management system integrated with a fuel delivery system, including an oxygen reduction unit and a heat sink heat exchanger, along with a control system that monitors the oxygen reduction unit's operability and adjusts fuel and heat exchange fluid flows to prevent excessive heat transfer, using bypass valves to divert flows when the oxygen reduction unit is not operating within desired parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heat is transferred to the fuel flow using the thermal management system, then the thermal management efficiency is improved, but the risk of fuel overheating and coking increases
Solution Approach 1:
The control system continuously monitors oxygen reduction unit operability and adjusts heat transfer accordingly. When the oxygen reduction unit is not operating within desired parameters, the control system reduces or bypasses heat transfer to the fuel flow, preventing overheating and coking while maintaining thermal management efficiency when conditions are appropriate.
Solution Approach 2:
The system dynamically adjusts the heat transfer process based on real-time operability conditions of the oxygen reduction unit. The control system modulates heat exchange fluid flow and fuel flow through bypass valves to optimize thermal management while preventing harmful effects, transitioning between different operational states based on monitored parameters.
2Reliability
If the oxygen reduction unit is monitored and control actions are initiated, then the reliability of the thermal management system is improved, but the device complexity increases
Solution Approach 1:
A sensor monitors the operability of the oxygen reduction unit and provides feedback to the control system. The control system processes this information and initiates appropriate corrective actions, such as adjusting heat transfer or bypassing fuel flow, thereby improving reliability through automated monitoring and response while managing complexity through structured control logic.
Solution Approach 2:
The control system automatically monitors oxygen reduction unit operability and initiates corrective actions without external intervention. The system self-regulates heat transfer to the fuel flow based on monitored conditions, reducing the need for manual operation and improving reliability through continuous automated oversight.
3Reliability
If bypass valves are used to divert fuel and heat exchange fluid flows, then the safety of the system is improved, but the device complexity increases
Solution Approach 1:
Bypass valves serve as intermediary components that divert fuel and heat exchange fluid flows away from the heat exchanger when the oxygen reduction unit is not operating properly. This intermediate flow path prevents direct heat transfer that could cause overheating and coking, enhancing safety while adding controlled complexity through the bypass mechanism.
4Loss of energy
If heat exchangers are integrated into components exposed to the bypass airflow passage, then the thermal management efficiency is improved, but the airflow through the bypass passage is adversely affected
Solution Approach 1:
Heat exchangers are integrated into specific components (such as struts) that are exposed to the bypass airflow passage. The heat exchangers are positioned to utilize the bypass airflow for heat rejection while minimizing disruption to the overall airflow pattern. This localized integration allows thermal management to benefit from the bypass air cooling effect while maintaining relatively efficient airflow through the passage.
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 solution enables reliable and safe heat transfer to the fuel flow, reducing the risk of engine damage by ensuring the fuel does not overheat and coking occurs, while maintaining efficient engine operation.
Implementation Method 1
a heat sink heat exchanger, the heat sink heat exchanger in thermal communication with the fuel delivery system
Implementation Method 2
an oxygen reduction unit for reducing an oxygen content of the fuel flow
Implementation Method 3
a control system including a sensor operable with the fuel delivery system for sensing data indicative of an operability of the oxygen reduction unit and a controller operable with the sensor, the controller configured to initiate a corrective action based on the data sensed by the sensor
Data Source
AI summary
A combustion engine includes a combustion section; a fuel delivery system for providing a fuel flow to the combustion section, the fuel delivery system including an oxygen reduction unit for reducing an oxygen content of the fuel flow; a thermal management system including a heat sink heat exchanger, the heat sink heat exchanger in thermal communication with the fuel delivery system at a location downstream of the oxygen reduction unit; and a control system including a sensor operable with the fuel delivery system for sensing data indicative of an operability of the oxygen reduction unit and a controller operable with the sensor, the controller configured to initiate a corrective action based on the data sensed by the sensor indicative of the operability of the oxygen reduction unit.