Thermal Management of Electrical Actuation System via Enhanced Air Circulation and Thermal Energy Storage

ABSTRACT: In the proposed Phase I program, we will validate and optimize a thermal management (TM) concept for High Performance Electric Actuation System (HPEAS). The TM system does not interfere with the Environment Control System (ECS) nor the Power and Thermal Management System (PTMS). The concept is based on enhanced forced convection and thermal energy storage (TES). It is expected this approach can address essentially all scenarios encountered in electrical actuation of flight control surfaces. The TM system can function in a wide range of environmental temperature and pressure, and under a variable gravity situation. During most of the flight time, forced convection and radiation are sufficient to transport the waste heat from the HPEAS to the bay wall or wing skin for rejection to ambient air. Phase change material (PCM) will absorb heat during periods of peak power and/or when the ambient condition is not suitable for heat sinking. The feasibility and effectiveness of the proposed concept will be demonstrated by performing experiments with a full-scale lab prototype simulating an electromechanical actuator (EMA). The experimental data can also be used to validate a numerical model which is essential for design and optimization of TM systems. In the Phase II program, TM systems will be designed, fabricated and applied to flight quality EMA hardware in collaboration with a prime aerospace company. BENEFIT: The primary benefit of the proposed technique is to greatly increase the heat transfer effectiveness from EMAs to ambient air under various flight conditions and body force. By significantly enhancing air circulation in bays, EMAs located there can operate at much higher power without overheating. The numerical model developed in this program can be used to optimize heat removal by air surrounding complex-shaped heat sources. It is anticipated the proposed TM system can find application in the cooling of electric motors and generators in hybrid and electric vehicles. The technology developed can also be applied to many types of portable systems such as personal cooling systems, etc.