Honeywell Heat Exchanger
Aircraft Environmental Control System Water Extraction System
Capstone Senior Design Project
Engineering Principles Studied:
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Software Utilized:
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Tools Utilized:
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Main Objectives:
- To design, build, and operate a testing apparatus to simulate a Honeywell Aircraft Environmental Control System (AECS) for the purposes of research and development.
- Design and fabricate a compact air/water separation device used to dry air for aircraft safety and passenger comfort.
- Conduct experiments using the test apparatus and water separation device to determine its efficiency.
Background:
The introduction of the pressurized aircraft in the mid 1900’s uncovered new obstacles for the airline industry. Modern aircraft utilize an AECS (Aircraft Environmental Control System), which treats and conditions compressed air that has been bled off of the main engines such that it may be supplied to the cabin of the aircraft. Within a typical AECS is an air to air heat exchanger, which is used to drop the temperature of the air to comfortable levels and remove excess humidity. Humidity and water droplets are removed to prevent virus transmission and to protect sensitive equipment. The device which traps and removes the condensed water from the system will for the purposes of this document be called a scupper. Specifically, Honeywell has tasked the team with designing a system which simulates in-flight conditions such that the experimental scuppers may be tested and evaluated. The team is responsible for creating an apparatus which will simulate all of the conditions of a typical AECS operating at altitude. The team will then use the apparatus to experiment with custom scupper designs in order to optimize its effectiveness.
The introduction of the pressurized aircraft in the mid 1900’s uncovered new obstacles for the airline industry. Modern aircraft utilize an AECS (Aircraft Environmental Control System), which treats and conditions compressed air that has been bled off of the main engines such that it may be supplied to the cabin of the aircraft. Within a typical AECS is an air to air heat exchanger, which is used to drop the temperature of the air to comfortable levels and remove excess humidity. Humidity and water droplets are removed to prevent virus transmission and to protect sensitive equipment. The device which traps and removes the condensed water from the system will for the purposes of this document be called a scupper. Specifically, Honeywell has tasked the team with designing a system which simulates in-flight conditions such that the experimental scuppers may be tested and evaluated. The team is responsible for creating an apparatus which will simulate all of the conditions of a typical AECS operating at altitude. The team will then use the apparatus to experiment with custom scupper designs in order to optimize its effectiveness.
Results:
- Successfully built a testing apparatus that simulates the AECS of an aircraft in flight.
- Designed and tested several iteration of the 3D printed water removal device which performed better than all previously existing solutions.
- Demonstrated the fully operational system to the engineers leading this project from Honeywell exceeding their expectations.
- Successfully designed and implemented a 55 sensor data acquisition system providing valuable insight into the thermodynamic processes occurring throughout the system.
- Completed the project under budget and ahead of schedule allowing for further exploration and experimentation to be completed.