Rotron Thermal Management Systems

Transcription

1 Rotron Thermal Management Systems Systems Information AMETEK Rotron has been a supplier of airmoving and cooling systems since Since 2003, the expertise has been expanded to include a diverse collection of Vapor Cycle Environmental Control Systems for commercial as well as Military applications. The Ametek Rotron systems are used on various airborne, shipboard, Military vehicle and land based applications. Currently we design and build systems in three distinct categories: Value Added - Engineered product to integrate customer-defined components into a finished subsystem Passive System AMETEK engineered to a Performance Specification. Non-refrigerant based cooling, heating and humidity control Active System AMETEK engineered to a Performance Specification. Refrigerant based cooling, heating and humidity control The AMETEK Rotron systems are designed to meet the customer s unique requirements for size, weight, shock, vibration, EMI, acoustic noise, performance, materials, etc. Many of the systems are designed to meet Mil-S-901 shock, Mil-Std-167 vibration, Mil-Std- 461 EMI, etc. Temperature ranges from -54F up to 131F or higher are typical. The AMETEK Rotron systems can be designed to operate on various power sources including 28VDC, 48VDC, 270VDC, or 600VDC as well as 50/60 Hz, 400 Hz or variable frequency AC. The passive and active system cooling capacities range from a few hundred watts to tens of Kilowatts. Heat exchanger designs can be optimized for the specific applications using plate fin or finned tube designs. In many cases the systems use AMETEK Rotron fans and/or AMETEK Hughes Treitler heat exchangers to provide the customer with the best solution for the application. Our architecture options are very diverse and vary based on the application. We will work with the customer to provide the best architecture configuration customized for the application whether that means using ambient air as the heat sink, or ship s chilled water or active cooling with a sub-ambient cycle. Active applications are both direct expansion, or DX, with cooled air provided to the personnel and/or electrical loads or designed to utilize a secondary cooling circuit, routing chilled liquid (such as Water-Ethylene-Glycol) to the load. Products shown are representative of what we have built to answer customers thermal management needs; all designs are readily adaptable to meet specific requirements of other applications

2 Value Added Systems Shown at right are several typical value-added assembly AMETEK builds. These range from a simple mating of a fan with a wiring harness, to adapting a fan assembly to incorporate a silicon-rubber flapper type check valve to a fan, up to a fabricated assembly consisting of an anodized aluminum tray, multiple fans and a control module. Value Added Systems can include working to customer provided drawings, specifications and processes. We incorporate these as our own and use customer sources of supplies as required. Providing the complete assembly allows our customers to write a single purchase orders versus multiple purchase orders for the components. The customer s incoming inspection load is decreased as well as shop labor and required floor space. The units arrive fully assembled and tested. Shown at left is an air to water cooling system used onboard US Navy submarines. This compact heat exchanger cools 6kW of electronics through the chilled water system provided by the boat. Units are designed for handling high shock, vibration and other tough environmental requirements in the smallest form factor possible. AMETEK Rotron can also provide superbalanced assemblies to conform to some of the most rigorous structureborne noise requirements typically found on submarines. Shown to the right is an example of a compact heat exchanger used in a US Army mobile radar application. The unit cools high power components via forced air convection and high efficiency heat sinks. The use of high capacity AMETEK Rotron fans provides the required airflow in the confined space allocation. AMETEK Hughes Trietler provides the compact heat exchanger to provide this total system solution

3 Passive Cooling Systems Rotron produces a multitude of passive cooling systems. (Note that in this context we use the term passive to designate any system that does not have sub-ambient cooling within the system. Therefore a shipboard system, utilizing the ships chilled water as a heat sink is passive within this definition as the subambient chilling is external to the system discussed.) The system shown on the left is an example of a shipboard passive system (chilled water to air). The system dissipates 60 kw of heat from power transformers and transfers it to the ships chilled water supply. This system is designed to withstand the high shock, vibration, humidity and salt associated with shipboard installations. The system shown at the left is another example of a radar cooling system. The eight cooling fans and two scavenge fans are all controlled by a common fan controller that can vary the speed to the fans based on temperature inputs. The use of high speed AMETEK Rotron vaneaxial fans allows the customer to achieve extremely efficient cooling in a very small package

4 Active Cooling Systems Many of the threats faced by coalition forces in Iraq and Afghanistan are countered by an array of computation and communication electronics and sensors. Many of these systems are mounted in transit cases and can be operated from multiple platforms. The severe ambient temperatures associated with operation in Iraq or Afghanistan (with temperatures exceeding 130o F) can cause operational and reliability problems with the electronics. The unit shown here is one of systems AMETEK has fielded. The upper photo shows the Environmental Control Unit (ECU) as a stand-alone assembly; the same unit is installed within the transit case cover in the photo on the left. Rotron builds several variants of transit case coolers, ranging in capacity from approximately 1 kw (3,500 Btu/hr) to 3 kw (10,500 Btu/hr) These cooling systems are designed for typical Army environmental applications incorporating various techniques to withstand the harsh environments. A 3 kw transit case Environmental Control Unit attached to the transit case appears in the photo on the left. The system again includes AMETEK Rotron fans to provide airflow for both the condenser and the evaporator. AMETEK Rotron is providing an Environmental Control Unit (ECU) in response to the US Army s Tactical Idling Reduction Initiative for Heavy Tactical Vehicles. The unit is shown on the right. The system architecture provides for dual refrigerant circuits. In most cases a single circuit will provide cooling in all but the most severe ambient condition thereby saving fuel and increasing system reliability

5 Active Cooling Systems Continued The system shown on the left is an active refrigerant (R134A) based cooling system. The system cools an electronics chassis on an Military aircraft. The system includes various AMETEK Rotron cooling fans as well as an AMETE Rotron designed compressor to provide an optimized low weight solution for the application. The photo on the right shows part of a distributed Water-Ethylene-Glycol (WEG) system. Utilizing distributed liquid provides several potential benefits including a greater capability to localize cooling and an ability to save power by direct chilling of the fluid when the system is operated at low ambient conditions. The system shown is part of a 10 kw WEG system, where the WEG loops bring cooling to a total of eight separate zones. Both cooling and heating (via electric resistance heaters) control critical electronic modules to a precise temperature. Shown on the left is another example of a refrigerant based active cooling system designed and produced by AMETEK Rotron. The particular unit is integrated into an ATR chassis to provide closed loop active cooling to the chassis electronics. This type of cooling solution provides the customer with a fully enclosed subambient cooling solution allowing for more electronics to be packaged within a given space. These racks are environmentally sealed making them ideal candidates for use in vertical lift applications The photo on the left shows a typical chassis that this type of system is installed in. The cooling unit is integrated into the bottom 3.5 of the chassis. Cold air is circulated through the electronics. The heat is then exhausted to the atmosphere thru the holes shown on the side the chassis. The unit provides approximately 1,000 watts of net Other variants of different physical cooling. configuration and thermal capacities are available

6 NOTES: 15-07

7 Airscrew Vehicle Systems General Vehicle Systems Information Airscrew is a recognized expert in the design and manufacture of Environmental Control Systems for integration into aerospace and military platforms, which enable personnel and equipment to operate effectively in the most hostile environments. Airscrew is dedicated to further consolidation of its role as a major supplier of specialist equipment on a worldwide basis, continuing to provide professional service and support to its customers, basing its designs on sound engineering principles encapsulating the latest relevant technological developments. Regenerative CBRN Filtration Systems To provide the highest level of CBRN protection that is not life dependant on the concentration and nature of the challenge. Auxiliary Power Units (APU s) To provide a source of electrical power and the use of the environmental control system to operate when the main engine is not required. CBRN Filtration System Using Traditional activated carbon filters to supply either over pressure collective protection or supply individual facemask systems. Air-Conditioning Systems To provide operationally acceptable conditions within an occupied space for crew and equipment, through total space environmental control or spot cooling/heating. Engine Cooling Systems To provide a complete engine-cooling group including radiators, charge coolers, hydraulics oil coolers and Air-Conditioning Condensers in a single package 15-21

8 Vehicle Engine Cooling Systems Today s power pack designers face an everincreasing demand for cooling air through a variety of high-density radiators. In addition to the engine radiators, charge coolers, transmission and hydraulic oil coolers compete with environmental control system condenser coils for space in the engine bay. The Airscrew range of open discharge mixed flow fan units has been developed for the congested environment of the military vehicle engine bay. Aerodynamically designed, these powerful highspeed fan units have proved themselves to be durable and efficient in active service conditions. Available as hydraulic, belt or shaft driven units, designed to meet demanding environments. Airscrew is able to not only supply the fans designed for this congested environment but is also able to design complete engine cooling groups to carefully manage the total air side cooling system. Experienced consideration is given to louvre/cooler losses and distribution factors, fan inlet and discharge conditions, avoidance of hot air recirculation etc. Vehicle Engine Cooling Capabilities Typically Cooling for Engines from 200 to 1500HP Incorporation of Fan(s) Radiators Charge Air Coolers Transmission Oil Cooler Hydraulic Oil Cooler Hydraulic Pipes and Pump Manifold Assemblies Expansion Tanks Frame Application flexibility with various discharge configurations possible enabling layout versatility 15-22

9 Vehicle Air-Conditioning Airscrew has developed a particular expertise in the design of air-conditioning systems to provide habitability for the crews of armoured vehicles. Modern military vehicles require the crew to operate complex equipment while under the stress in a closed down vehicle, the temperature of which will be considerably higher than the outside air temperature due to the wild heat being generated inside the vehicle by equipment and the engine, as well as the effect of solar radiation. As a result, a closed down vehicle in the sun can be assumed to be uninhabitable even in a European climate, unless an active cooling system is fitted. The requirement for an efficient heating system for vehicles designed for operation in cold climate must also be addressed to prevent the loss of manual dexterity and possible frostbite. Typical Vehicle Air-Conditioning System Total crew space air-conditioning systems, although effective in a well insulated vehicle and with the crew in normal dress, are much less effective when the crew are wearing CBRN suits and are excessively power hungry in vehicles with little thermal insulation fitted. To meet these conditions Airscrew has developed crew temperature control systems using the principle of spot cooling and heating, by blowing cooled air over the upper body of the crew in a hot environment and warmed air over their hands and toes under cold conditions, enabling the crew to maintain their correct deep body temperature. Such systems require significantly less power than an equivalent total crew space air-conditioning system. Airscrew systems are fitted to a wide range of tracked and wheeled vehicles operating in temperatures from +55 C to 46 C. Vehicle Air-Conditioning Capabilities Split or Single Packaged Systems Space or Spot Cooling/Heating Typical Cooling Capacity: 6 to 15kW Variants incorporated with CBRN Filtration Systems Condenser incorporated with Engine Cooling System, or Self Contained Typical Heating Capacity: 9 to 20kW Variants incorporated with Auxiliary Power Units AC/DC/Hydraulic & Mechanical Drive Compressor Options Heating by Electrical Elements, Diesel Fueled Heaters or Vehicle Engine Coolant 15-23

10 Chemical Biological Radiological and Nuclear (CBRN) Filtration Systems Providing a safe environment for personnel operating under the threat of CBRN attack is best achieved by collective protection (Colpro). This creates a clean environment within the operating space with filtered agent free air. Under Colpro conditions the occupied area and all equipment within it remains clean enabling personnel to operate without the encumbrance of wearing protective gloves and respirators. Airscrew are experts in packaging CBRN systems to achieve the most effective arrangement suited to the space constraints and interface details of individual vehicle installations. In a typical CBRN filtration system, air is drawn into a cyclonic pre-filter to remove heavy dust particles which are discharged to atmosphere by a scavenge fan. The air then passes into a two-stage CBRN filter, the first stage of which removes remaining dust particles and biological agents. The second stage is a bed of impregnated activated carbon, which removes chemical contamination. Not all Vehicles are suitable for Colpro systems, in order to provide CBRN protection for in these instances Airscrew are able to provide filtration systems that interface with personal facemasks to enable un-labored breathing by the crew. Typical CBRN Filtration System CBRN Filtration Capabilities Draw Through/Blow Through Systems Bypass Systems Pressure Relief Valves Variants integrated with vehicle AC system Typically 150 to 200m³/h Airflow High Efficiency Cyclonic Pre-filters Double Ended Fan available to Provide Ventilation and Scavenge airflows Pressure/Flow Gauges Analogue/Digital Pressure and Flow Gauges Peace Time Filters Composite CBRN Filters Stand alone controls or integrated with drivers/commanders instrument panel 15-24

11 Auxillary Power Units (APU s) Airscrew designs and manufactures combined APU and environmental control systems, which provide a source of electrical power and crew cooling/heating from a single prime mover. These systems are typically fitted to vehicles that are required to operate for significant periods without their main engine running, or for transportable systems where other power systems are not available. The prime mover is usually a diesel engine that drives a generator to provide the required electrical power to the vehicle systems and the refrigerant compressor of the air-conditioning system. The engine driven fan is designed to provide the required airflow through an integrated condenser and also, if a water-cooled engine is used, though the engine radiator. These assemblies are packaged with the necessary ancillary equipment to meet the requirements of the available space envelope. Separate evaporator assemblies and control boxes are supplied for mounting in the crew compartment. Typical APU System APU Capabilities Provide Electrical Power Generation and Air-conditioning Sound proofing for silent watch requirements Automatic switch off when main engine starts Remote Starting Operation 15-25

12 Regenerative CBRN Filtration System Although providing a high level of protection, impregnated activated carbon filters are not regenerative, they must be discarded and replaced following an attack the filter effectiveness and life is also dependant on the concentration and nature of the challenge. This limits the vehicle s operation on a battlefield where chemical weapons are deployed, and creates high operational costs due to the logistics chain required to provide a regular supply of new filters to forward areas to support the vehicle fleet, and removal and disposal of contaminated filters. Regenerative System as fitted to the Terrier Vehicle As a leading authority in the design and integration of CBRN filtration and Environmental Control Systems for armoured vehicles, Airscrew has teamed with PALL Aerospace, experts in the design of specialist filters, and have jointly developed Pressure Swing Adsorbtion (PSA) regenerative filtration and environmental control systems for collective protection. This technological advance offers enhanced levels of protection against a much wider range of chemicals, including toxic industrial gasses, and can be readily applied to fighting vehicles, naval platforms and ground based shelter applications. Airflow sufficient for 2 Crew Members 4.1kW Cooling Capacity 5.7kW Heating Capacity The TERRIER word mark is a registered trademark of the Secretary of State for Defence Regenerative Filtration System Capabilities Regenerative CBRN protection No Anti-Vapor Filter Changing Combined with Environmental Control System Improved protection from toxic industrial gases and all traditional warfare agents Tested by UK & US CBRN Authorities 15-26