Airborne Liquid Cooling System with Integrated Heat Exchanger - ALCS

In high-performance systems such as fighter jets, the onboard radar electronics operate under extremely demanding conditions. The radar systems generate substantial heat, which can compromise the reliability and efficiency of electronic components if not adequately dissipated. Traditional cooling solutions such as air cooling are often insufficient for these advanced electronics due to the high heat flux and compact form factor of avionics systems.

SANPAR has developed Airborne Liquid Cooling System (ALCS) provides an efficient, reliable, and lightweight cooling solution designed specifically for radar and other avionics systems in fighter aircraft.

Radar systems in fighter jets, such as active electronically scanned arrays (AESAs), generate significant amounts of heat due to their high-power output and rapid operation. Effective cooling is essential to maintain the radar.

This unit is fully qualified unit certified for airborne application as it has undergone Full Qualification Testing (QT), a comprehensive suite of tests designed to ensure the system meets the rigorous performance, durability, and reliability standards required for military applications. Key tests include:

1. Electromagnetic Interference (EMI) Testing:
   
   

   - Given the sensitive nature of airborne radars and other avionics, EMI testing ensures that the liquid circulating system does not emit electromagnetic radiation that could interfere with the aircraft’s other systems.

   - The system is tested for both susceptibility to external electromagnetic fields and its own emissions, ensuring it can operate without being affected by or causing interference in a high-EMI environment, such as in a fighter jet's cockpit or radar suite.

2. Environmental Stress Screening (ESS):
   
   

   - ESS involves subjecting the liquid circulating system to various environmental conditions to simulate the stresses it will face during real-world operations. This includes temperature cycling, thermal shock, vibration, and mechanical shock tests.

   - ESS ensures the system can withstand the extreme operating environments encountered by fighter jets, such as rapid altitude changes, extreme temperatures, and high levels of vibration during combat manoeuvres.

3. Thermal Cycling and Shock:
   
   

   - The liquid circulating system is subjected to thermal cycling and thermal shock tests to ensure it can handle rapid temperature changes without compromising performance. This is critical for airborne radars, which may experience significant temperature variations during takeoff, flight, and landing.

   - The coolant must remain effective without freezing at low temperatures or boiling at high temperatures.

4. Altitude Testing:
   
   

   - Fighter jets operate at varying altitudes, and the liquid circulating system must function reliably under reduced atmospheric pressure. Altitude testing ensures the system can maintain coolant flow and heat dissipation even in low-pressure environments typical of high-altitude flight.

5. Vibration and Mechanical Shock Testing:
   
   

   - Fighter jets are exposed to intense vibrations and mechanical shocks during flight, particularly during high-speed manoeuvres or combat situations. The circulating system is tested to ensure that components like pumps, heat exchangers, and piping can withstand these stresses without failure.

   - The system is also tested to ensure the integrity of seals, joints, and connections under continuous vibration and mechanical shock.

SANPAR’s ALCS is engineered for applications that demand precise temperature control in a compact and rugged form factor, making it ideal for use in fighter jets. The unit includes the Pump, Expansion reservoir, Heat Exchanger and Electronic Control Module and other important components. Key features of the system include:

1. High-Efficiency Liquid Cooling:
   
   

   Unlike air cooling, liquid cooling provides superior thermal management by using a circulating liquid (typically a dielectric coolant or water-based glycol mixtures) to absorb and transfer heat away from heat-dense electronics, ensuring efficient cooling even in extreme operational conditions.

2. Compact and Lightweight Design:
   
   

   The ALCS is designed to fit into the limited space available in a fighter jet. Its lightweight materials and compact structure ensure that it does not add unnecessary bulk or weight to the aircraft, a critical factor for aviation applications.

3. High Reliability in Extreme Environments:
   
   

   Fighter jets operate in extreme temperatures and altitudes. SANPAR’s system is robust, capable of withstanding high G-forces, extreme temperatures, and vibrations without loss of performance, ensuring the consistent functionality of radar systems.

4. Advanced Temperature Control:
   
   

   The ALCS uses sophisticated sensors and controllers to maintain the temperature of the electronics within optimal operating ranges. This ensures the radar system's performance is unaffected by thermal stress, extending the life of electronic components.

5. Minimal Maintenance Requirements:
   
   

   SANPAR's design philosophy emphasizes ease of maintenance. The ALCS is designed for long operational periods with minimal intervention, crucial for military applications where systems must be operational for extended durations between maintenance cycles.