AEROL-HP

"Development, construction, integration, and progress toward to two-hase device monitoring and qualification on aircrafts"

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 Obiettivo del progetto (Objective)

'The proposed project is part of the Cleansky Eco-Design activities for the all (or more) electric aircrafts. The main targets of the call are related to improved aircraft weight, improved electronic equipment life cycles & reduced maintenance thanks to the use of highly efficient passive (“green”) thermal control systems (as already used on satellite systems).

Technical objectives: The EHP proposal is part of the ECO-Design ITD and will address the development, and qualification aspects of highly efficient two-phase cooling devises such as heat pipes and loop heat pipes to be used on board of aeronautical aircrafts. The main objectives are : • Qualify two-phase heat transfer devises in accordance with specific aeronautical requirements such as : o High acceleration loads o Long duration vibration stresses • Reduce global aircraft weight at equipment and/or system level => reduce aircraft consumption and increase operating range • Lower impact on environment through the use of passive and maintenance free thermal equipments • Increase reliability of controlled equipment (power electronics) => decrease repair and maintenance aspects The Ammonia HP and LHP products are today baselined (with a TRL 9) on all Space satellites or payloads thanks to the reliable capability provided by these “isothermal” lightweight thermal management devises. Non-space applications are also more and more considered for these two-phases devises to be used on high power electronic (railway applications) or primary flight control actuators. The AeroL-HP products will be developped up to CDR level with qualification of the two-phase hardware. From a technical side, the proposed thermal link will have to provide a reliable and competitive (generic, modular and low cost) product (Rejected power/mass). The thermal link will be a scalable system able to address payload dissipations from 30W (TBC) up to 900W (or higher).'

Introduzione (Teaser)

This EU-funded project has allowed the development of a passive cooling solution in the frame of the more electric aircrafts.

Descrizione progetto (Article)

Over time, there has been a move within industry to run all (more) aircraft power systems on electricity, thus leading to considerable cost, weight and environmental savings. However, this all (more) -electric aircraft concept imposes new challenges in the field of thermal management. Electronic designers are required to meet the strictest technical specifications with regard to withdrawing payload dissipation and optimising the weight and compactness of new equipment.

Work in the EU-funded project AEROL-HP revolved around developing and monitoring on-board two-phase cooling devices to make sure that they meet specified aeronautical requirements. These include high acceleration loads and long vibration stress cycles, as well as reduced equipment weight and passive designs.

Development of (loop) heat pipes with passive design is holding promise for more reliable and less expensive aircraft thermal control. Project members decided to develop a mini-loop heat pipe concept to cope with the outlined requirements. After agreeing on the interfaces for this mini-loop heat pipe, they manufactured a breadboard that has been submitted to a thermal testing campaign to evaluate its performances.

Results from testing the breadboard were satisfying in terms of heat sharing, start-up capabilities and orientation. The monitoring procedure of the thermal device was defined. The heat sink design was also defined.

Breadboard results allowed to design the qualification model which was composed of 5 mini-loop heat pipes. After manufacturing, the qualification model device has been successfully tested in laboratory conditions and in an environment representative of aircraft.

The developed device allowed the transfer of power loads of 250W without exceeding the aircraft manufacturer equipment maximal allowable temperature.