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The amount of electrical power required for future aircraft is increasing significantly. In this paper, a comprehensive model of a drive shaft with multiple degrees of freedom was developed and integrated to detailed engine and electrical network models to study the impact of higher electrical loads. The overall system model is composed of the engine, shafts, gearbox, and the electric network. The Dynamic Dual Spool High Bypass JT9D engine was chosen for this study. The engine was modeled using NASA’s T-MATS (Toolbox for the Modeling and Analysis of Thermodynamic Systems) software. In the electrical side, one generator was connected to the Low Pressure (LP) shaft and the other to the High Pressure (HP) shaft. A modified model of the shafts between the engine and the accessory gearbox was created.

Small remotely piloted aircraft (10-25 kg) powered by internal combustion engines typically operate on motor gasoline, which has an anti-knock index (AKI) of >80. To comply with the single-battlefield-fuel initiative in DoD Directive 4140.25, interest has been increasing in converting the 1-10 kW power plants in the aforementioned size class to run on lower AKI fuels such as diesel and JP-8, which have AKIs of ~20. It has been speculated that the higher losses (short-circuiting, incomplete combustion, heat transfer) that cause these engines to have lower efficiencies than their conventional-scale counterparts may also relax the fuel-AKI requirements of the engines. To investigate that idea, the fuel-AKI requirement of a 3W-55i engine was mapped and compared to that of the engine on the manufacturer-recommended 98 octane number (ON) fuel.

As the cost and complexity of modern aircraft systems increases, emphasis has been placed on model-based design as a means for reducing development cost and optimizing performance. To facilitate this, an appropriate modeling environment is required that allows developers to rapidly explore a wider design space than can cost effectively be considered through hardware construction and testing. This wide design space can then yield solutions that are far more energy efficient than previous generation designs. In addition, non-intuitive cross-coupled subsystem behavior can also be explored to ensure integrated system stability prior to hardware fabrication and testing. In recent years, optimization of control strategies between coupled subsystems has necessitated the understanding of the integrated system dynamics.

As IC engines decrease in displacement, their cylinder surface area to swept volume ratio increases. Examining power output of IC engines with respect to cylinder surface area to swept volume ratio shows that there is a change in power scaling trends at approximately 1.5 cm−1. At this size, it is suggested that heat transfer from the cylinder becomes the dominant thermal loss mechanism and performance and efficiency characteristics suffer. Furthermore, small IC engines (>1 cm−1) have limited technical performance data compared to IC engines in larger size classes. Therefore, it is critical to establish accurate performance figures for a family of geometrically similar engines in the size class of approximately 1.5 cm−1 in order to better understand the thermal losses that contribute to lower efficiencies in small IC engines. The engines considered in this scaling study were manufactured by 3W Modellmotoren, GmbH.

Numerous previous studies have highlighted the potential efficiency improvements which can be provided to aircraft thermal management systems by the incorporation of vapor cycle systems (VCS), either in place of, or in conjunction with, standard air cycle systems, for providing the needed thermal management for aircraft equipment and crews. This paper summarizes the results of a cycle-based VCS control architecture as tested using the Vapor Cycle System Research Facility (VCSRF) in the Aerospace Systems Directorate of the Air Force Research Laboratory at Wright-Patterson Air Force Base. VCSRF is a flexible, dynamic, multi-evaporator VCS which incorporates electronic expansion valves and a variable speed compressor allowing the flexibility to test both components and control schemes. The goal of this facility is to reduce the risk of incorporating VCS into the thermal management systems (TMS) of future advanced aircraft.

As the cost and complexity of modern aircraft systems advance, emphasis has been placed on model-based design as a means for cost effective subsystem optimization. The success of the model-based design process is contingent on accurate prediction of the system response prior to hardware fabrication, but the level of fidelity necessary to achieve this objective is often called into question. Identifying the key benefits and limitations of model fidelity along with the key parameters that drive model accuracy will help improve the model-based design process enabling low cost, optimized solutions for current and future programs. In this effort, the accuracy and capability of a vapor cycle system (VCS) model were considered from a model fidelity and parameter accuracy standpoint. A range of model fidelity was evaluated in terms of accuracy, capability, simulation speed, and development time.

Two compact intercoolers are designed for the Rotax 914 aircraft engine to increase engine power and avoid engine knock. A study is performed to investigate the effects of unsteady airflow on intercooler performance. Both intercoolers use air-to-liquid cross flow heat exchangers with staggered fins. The intercoolers are first tested by connecting the four air outlets of the intercooler to a common restricted exit creating a constant back pressure which allows for steady airflow. The intercoolers are then tested by connecting the four air outlets to a 2.4 liter, 4 cylinder engine head and varying the engine speed from 6000 to 1200 RPM corresponding to decreasing flow steadiness. The test is performed under average flight conditions with air entering the intercooler at 180°F and about 5 psig. Results from the experiment indicate that airflow unsteadiness has a significant effect on the intercooler's performance.

Vapor compression systems (VCS) offer significant benefits as the backbone for next generation aircraft thermal management systems (TMS). For a comparable lift, VCS offer higher system efficiencies, improved load temperature control, and lower transport losses than conventional air cycle systems. However, broad proliferation of VCS for many aircraft applications has been limited primarily due to maintenance and reliability concerns. In an attempt to address these and other VCS system control issues, the Air Force Research Laboratory has established a Vapor Cycle System Research Facility (VCSRF) to explore the practical application of dynamic VCS control methods for next-generation, military aircraft TMS. The total refrigerant mass contained within the closed refrigeration system (refrigerant charge) is a critical parameter to VCS operational readiness. Too much or too little refrigerant can be detrimental to system performance.

An Electromechanical Actuation System (EMAS) are an important component for an all electric Aircraft. EMAS would be lighter and require less system maintenance and operational costs than hydraulic actuators, typically used in aircraft systems. Also, hydraulic actuation systems require a constant power load to maintain hydraulic pressure, whereas EMAS only use power when actuation is needed. The technical challenges facing EMAS for aircraft primary flight control includes jam tolerance, thermal management, wide temperature range, high peak electric power draw, regenerative power, installation volume limit for thin wings, etc. This paper focuses on a laboratory test setup to simulate EMAS flight control environment to test and evaluate three important performance parameters of EMAS; thermal management, transient peak power draw, and regenerative power.

The Air Force Research Laboratory (AFRL), in cooperation with the University of Dayton Research Institute (UDRI) and Fairchild Controls Corporation, is building a test facility to study the use of advanced vapor cycle systems (VCS) in an expanded role in aircraft thermal management systems (TMS). It is dedicated to the study and development of VCS control and operation in support of the Integrated Vehicle ENergy Technology (INVENT) initiative. The Two Phase Thermal Energy Management System (ToTEMS1) architecture has been shown through studies to offer potential weight, cost, volume and performance advantages over traditional thermal management approaches based on Air Cycle Systems (ACS). The ToTEMS rig will be used to develop and demonstrate a control system that manages the system capacity over both large amplitude and fast transient changes in the system loads.

This paper presents the concept of a dual latent heat sink for thermal management of pulse heat generating electronic systems. The focus of this work is to verify the effectiveness of the concept during charging through experimentation. Accordingly, custom components were built and a prototype version of the heat sink was fabricated. Experiments were performed to investigate the implementation feasibility and heat transfer performance. It is shown that this heat sink is practicable and helps in arresting the system temperature rise during charging (period of pulse heat load).

The two-phase flow modeling is done using the level set method to identify the interface of vapor and liquid. The modifications to the incompressible Navier-Stokes equations to consider surface tension, viscosity, gravity and phase change are discussed in detail. The governing equations are solved using finite difference method. In the present work, investigations on the effect of thermal conductivity and latent heat of vaporization of liquid on heat transfer in a 44 µm thick liquid film containing vapor bubble with droplet impact is investigated. The importance of thermal conductivity and latent heat of vaporization of liquid on heat transfer is identified. The variation of heat flux with thermal conductivity and latent heat is plotted. The computed liquid and vapor interface, velocity vector and temperature distributions at different time instants are also visualized for better understanding of the heat removal.

Advances in the past decade of the energy and power densities of lithium-ion based batteries for hybrid electric vehicles and various consumer applications have been substantial. Rechargeable high rate lithium-ion batteries are now exceeding 6 kW/kg for short discharge times (<15 seconds). Rechargeable lithium-ion polymer batteries, for applications such as remote-control aircraft, are achieving simultaneously high energy density and high power density (>160 Whr/kg at >1.0 kW/kg). Some preliminary test data on a rechargeable lithium-ion polymer battery is presented. The use of high rate rechargeable lithium-ion batteries as a function of onboard power, electric laser power level, laser duty cycle, and total mission time is presented. A number of thermal management system configurations were examined to determine system level weight impacts. Lightweight configurations would need a regenerative thermal energy storage subsystem.

The detrimental effects of prolonged sitting during long-duration flights include deep vein thrombosis, pressure sores, and decreased awareness and performance. However, the cushion is often the only component of the ejection seat system that can be modified to mitigate these effects. This study investigated the long-duration effects of sitting in four ejection seat cushions over eight hours. Subjective comfort survey data and cognitive performance data were gathered along with comparative objective data, including seated pressures, muscular fatigue levels, and lower extremity oxygen saturation. Peak seated pressures ranged from 1.22–3.22 psi. Oxygen saturation in the lower extremities decreased over the eight hours. Cognitive performance increased over time regardless of cushion with the exception of the dynamic cushion, which induced a decrease in performance for females.

Rotating Heat Pipe (RHP) technolog y is being developed for high speed (>20 krpm) regimes of electric motor/generator cooling. The motivation for this research is the potential application of the high speed RHPs for the thermal management of advanced rotating electrical machines. The passive nature and relatively simple features of this device are attractive for the removal of waste heat from the rotors of electric machines. Interesting air-cooling experimental results of two high speed RHPs designed, fabricated and tested at AFRL are presented here. Emphasis is made on external heat removal concepts useful for cooling the RHP condenser in order to be successful in promoting this technology to real world problems.