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Refrigeration Based Forced Air-Cooling System

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In modern military, aerospace, and industrial applications, Line Replaceable Units (LRUs) are critical electronic modules designed for easy replacement and maintenance in the field. LRUs are used in radar systems, avionics, communication devices, and other mission-critical electronic systems. To ensure these high-performance electronics function reliably in demanding environments, efficient thermal management is required. Forced air cooling systems are a widely adopted solution for cooling electronics within LRUs, providing effective heat dissipation to maintain optimal operating temperatures.


  1. Principles of Forced Air Cooling:

    Forced air cooling involves the use of blowers to circulate chilled air across the surface of electronic components, dissipating heat generated during operation. The air absorbs heat and transfers it away from the components, ensuring that the LRU operates within safe temperature limits.


  2. Active Cooling:

    Forced air cooling is considered an active cooling method, as it involves mechanical components like blowers that actively move air overheat sources to enhance heat dissipation.


  3. Airflow Management:

    Proper airflow is key to the system's effectiveness. Air is directed in a controlled manner, typically from the intake side, over the heat-generating components, and then expelled through exhaust vents, carrying the heat away from the system.


  4. Airflow Management:

    Proper airflow is key to the system's effectiveness. Air is directed in a controlled manner, typically from the intake side, over the heat-generating components, and then expelled through exhaust vents, carrying the heat away from the system.


SANPAR specializes in designing and manufacturing advanced refrigeration-based forced air-cooling systems, engineered specifically for cooling ground-based Line Replaceable Units (LRUs) in laboratory and field environments. These systems are optimized to deliver highly controlled and consistent air cooling for sensitive equipment, ensuring operational stability and long-term performance.

Key to the system’s performance is the use of efficient blowers combined with state-of-the-art refrigeration units that incorporate evaporators to precisely regulate air temperature. The system is designed to consistently maintain air output at (+10°C - (+)15°C and low Relative humidity ensuring that LRUs can operate in ideal thermal conditions, even during extended testing or operational periods.

The forced air-cooling mechanism ensures that chilled air is evenly distributed over the LRUs, preventing localized hotspots and reducing thermal stress on the components. SANPAR’s systems are also built to run reliably for long durations, providing robust cooling solutions for labs and fields where sensitive equipment demands strict temperature regulation.

In addition to their precise cooling capabilities, these systems are energy-efficient and can be customized to meet specific user requirements. SANPAR’s expertise in refrigeration technology ensures that each unit is engineered for durability, operational efficiency, and ease of maintenance, making them a trusted solution for laboratory cooling needs.


Key Components of the Forced Air-Cooling System / Chiller:

  1. Refrigeration Unit:

    - The heart of the system, it uses advanced compressors to create the necessary cooling effect. The refrigeration cycle ensures precise temperature control, allowing the system to maintain consistent air delivery at (+)10°C – (+) 15°C with close tolerance.

  2. Evaporator:

    - The evaporator plays a critical role by absorbing heat from the surrounding air and reducing the temperature. The chilled air is then forced through the system to cool the LRUs efficiently.

  3. Blowers:

    - High-performance blowers are used to force cooled air across the surface of the LRUs. These blowers ensure an even distribution of air, preventing temperature fluctuations and ensuring effective cooling of all parts of the equipment.

  4. Thermostat and Control System:

    - A sophisticated control system monitors the temperature of the air and adjusts the refrigeration cycle and blower speed accordingly. This ensures that the desired air temperature is maintained consistently over long periods of time.

  5. Air Filters:

    - Air filters ensure that only clean, dust-free air is circulated over the LRUs, preventing contamination or damage to sensitive components.

  6. Condensers:

    - Condensers are used to expel the heat extracted from the LRUs, facilitating the efficient cooling process. They are integral in maintaining system balance and ensuring long-term operational efficiency.

  7. Insulated Air Ducting:

    - Insulated ducts are used to deliver the cold air from the refrigeration unit to the LRUs without any temperature loss, ensuring that the cooling process is as efficient as possible.

  8. Instrumentation:

    - Mass flow meters, Pressure sensors, sensors to measure relative humidity of the air to measure and record these measurements into the PLC and HMI faciltitates the user to monitor the performance of the SANPAR Forced Air-Cooling unit which is also known as Forced Air Chillers.

Applications of SANPAR Forced Air-Cooling Systems / Chillers:

  1. Laboratory Testing of Electronic LRUs:

    Ideal for cooling ground-based LRUs used in various industries, such as aerospace, defence, and telecommunications, during lab testing procedures.

  2. Data Centers:

    The units can be adapted for cooling servers, storage devices, and network equipment where precise thermal management is essential.

  3. Automotive Component Testing:

    Useful in the automotive industry to simulate environmental conditions and maintain optimal temperatures for testing electrical components like control units, sensors, and inverters.

  4. Defence and Aerospace Laboratories:

    Critical for the performance testing of avionics, radar systems, and other ground-based LRUs used in defence and aerospace applications.

Advantages of SANPAR Refrigeration-Based Forced Air Cooling Systems:

  1. Multiple outlets:

    SANPAR designs the unit with single or multiple outlets with equal or different flowrates at each outlet as the air demand for different LRUs could differ in the same laboratory. Air flow rates at each outlet is controlled and monitored with precision.

  2. Precise Temperature Control:

    The system can consistently maintain the output air temperature at (+)10°C - (+)15°C ensuring optimal cooling conditions for sensitive LRUs during prolonged operations.

  3. Long-Term Durability:

    Designed for extended usage, these units can provide reliable cooling for long durations without compromising performance, making them ideal for critical and sensitive laboratory testing.

  4. Energy Efficiency:

    The system is optimized for low energy consumption, ensuring that operational costs are minimized while maintaining maximum cooling efficiency.

  5. Even Air Distribution:

    The forced air mechanism ensures uniform distribution of cool air, eliminating localized hotspots and reducing the risk of thermal damage to equipment.

  6. Customizable Solutions:

    SANPAR’s systems can be customized to meet the specific cooling needs of different industries and applications, providing a versatile and adaptable solution.

  7. Reduced Equipment Stress:

    By maintaining a stable temperature environment, the system minimizes thermal stress on LRUs, extending their operational life and reliability.

  8. Low Maintenance:

    Built with durability and ease of use in mind, the systems require minimal maintenance, ensuring continuous operation with minimal downtime.