PROJECT DETAILS
FADEC is a computer-managed aircraft ignition and engine control system used in modern commercial and military aircraft to control all aspects of engine performance digitally. Our client is a Government of India-approved Aerospace and Defense R&D unit. The client is developing FADEC for Defence Research and Development Organization (DRDO), Ministry of Defence, Government of India. We collaborated with the client from the initial stages of the design process. Our domain expertise leveraged with Computational Fluid Dynamics simulation (CFD analysis) technology has accelerated our clients Innovation process and enabled our client to explore more design options and make well-informed decisions at the appropriate stages in the product development cycle
The 3D CAD model provided by the client has been simplified to meet the requirements of the CFD analysis. This simplification takes into account the pertinent physics and the quality of the mesh.
The CFD mesh has been created based on the simplified CAD model discussed previously. This mesh is composed of polyhedral hex core elements, ensuring adequate resolution in areas with high gradients. The total cell count of the mesh is 8 million, achieving optimal quality metrics in accordance with established CFD analysis standards.
CFD analysis is performed at ambient temperatures of 40 degrees Celsius and 75 degrees Celsius. Various operational sequences of ECU units are evaluated in the CFD analysis to comprehensively assess the effectiveness of the thermal design. All heat-dissipating components are represented as 3D models with volumetric heat dissipation characteristics. Junction contact resistances are incorporated according to the specifications provided by the manufacturers data sheets. The enclosures radiation is modeled using a surface-to-surface radiation approach. Overall, the CFD analysis is conducted with great attention to detail, adhering to the best practices in electronic cooling CFD analysis. Our rigorous CFD methodologies have produced results that align 98% with the measured values.
CFD analysis has been conducted for the entire operational sequence of ECU units. The results of the CFD analysis indicate that the junction temperature of all dissipating equipment remains within the limits specified by the manufacturer, and there is an adequate operational margin. Additionally, no thermal hot spots have been detected, suggesting that the overall thermal configuration is highly effective.
The results of the CFD analysis indicate that the thermal design of the FADEC unit is highly effective. This design promotes safer operating temperatures for all electronic components housed within the enclosure, thereby enhancing overall reliability.
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