Optimal allocation of thermodynamic irreversibility for the integrated design of propulsion and thermal management systems

More electric aircraft systems, high power avionics, and a reduction in heat sink capacity have placed a larger emphasis on correctly satisfying aircraft thermal management requirements during conceptual design. Thermal management systems must be capable of dealing with these rising heat loads, while simultaneously meeting mission performance. Since all subsystem power and cooling requirements are ultimately traced back to the engine, the growing interactions between the propulsion and thermal management systems are becoming more significant. As a result, it is necessary to consider their integrated performance during the conceptual design of the aircraft gas turbine engine cycle to ensure that thermal requirements are met.;This can be accomplished by using thermodynamic subsystem modeling and simulation while conducting the necessary design trades to establish the engine cycle. However, this approach also poses technical challenges associated with the existence of elaborate aircraft subsystem interactions. This research addresses these challenges through the creation of a parsimonious, transparent thermodynamic model of propulsion and thermal management systems performance with a focus on capturing the physics that have the largest impact on propulsion design choices. This modeling environment, known as Cycle Refinement for Aircraft Thermodynamically Optimized Subsystems (CRATOS), is capable of operating in on-design (parametric) and off-design (performance) modes and includes a system-level solver to enforce design constraints. A key aspect of this approach is the incorporation of physics-based formulations involving the concurrent usage of the first and second laws of thermodynamics, which are necessary to achieve a clearer view of the component-level losses across the propulsion and thermal management systems. This is facilitated by the direct prediction of the exergy destruction distribution throughout the system and the resulting quantification of available work losses over the time history of the mission.;The characterization of the thermodynamic irreversibility distribution helps give the propulsion systems designer an absolute and consistent view of the tradeoffs associated with the design of the entire integrated system. Consequently, this leads directly to the question of the proper allocation of irreversibility across each of the components. The process of searching for the most favorable allocation of this irreversibility is the central theme of the research and must take into account production cost and vehicle mission performance. The production cost element is accomplished by including an engine component weight and cost prediction capability within the system model. The vehicle mission performance is obtained by directly linking the propulsion and thermal management model to a vehicle performance model and flying it through a mission profile. A canonical propulsion and thermal management systems architecture is then presented to experimentally test each element of the methodology separately: first the integrated modeling and simulation, then the irreversibility, cost, and mission performance considerations, and then finally the proper technique to perform the optimal allocation.;A goal of this research is the description of the optimal allocation of system irreversibility to enable an engine cycle design with improved performance and cost at the vehicle-level. To do this, a numerical optimization was first used to minimize system-level production and operating costs by fixing the performance requirements and identifying the best settings for all of the design variables. There are two major drawbacks to this approach: It does not allow the designer to directly trade off the performance requirements and it does not allow the individual component losses to directly factor into the optimization.;An irreversibility allocation approach based on the economic concept of resource allocation is then compared to the numerical optimization. By posing the problem in economic terms, exergy destruction is treated as a true common currency to barter for improved efficiency, cost, and performance. This allows the designer to clearly see how changes in the irreversibility distribution impact the overall system. The inverse design is first performed through a filtered Monte Carlo to allow the designer to view the irreversibility design space. The designer can then directly perform the allocation using the exergy destruction, which helps to place the design choices on an even thermodynamic footing. Finally, two use cases are presented to show how the irreversibility allocation approach can assist the designer. The first describes a situation where the designer can better address competing system-level requirements; the second describes a different situation where the designer can choose from a number of options to improve a system in a manner that is more robust to future requirements.