CASE STUDIES
Delivering mission-critical thermal management and motion control solutions across diverse industry
Customer Challenge:
The customer required an effective demisting solution for both the ‘A’ panel and the ‘B’ panels on an eVTOL aircraft, ensuring clear visibility and operational safety under varying environmental conditions.
Our Solution:
We collaborated closely with the customer to determine the optimal placement of the fan heater, ensuring minimal temperature loss from the supply air. In addition, we provided expert guidance on the design of the air distribution system to achieve a uniform demist airflow across all window panels, enhancing visibility and overall system efficiency.
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Customer Challenge:
The customer needed a substantial increase in static pressure at very low airflow rates to ensure reliable and efficient cooling within a high-density rack system. This requirement was critical to maintaining thermal performance in a confined space.
Our Solution:
Using Ansys flow development tools, we engineered a mixed-flow impeller design incorporating additional half blades to deliver a more centrifugal performance. This approach enabled us to achieve — and even exceed — the required static pressure rise at lower flow rates. Furthermore, precise trimming of the impeller’s trailing edge was applied to fine-tune the design, ensuring compliance with the customer’s power limitations.
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Customer Challenge:
The customer encountered significant design constraints due to a highly restrictive space envelope for the engine cooling system. The available depth was extremely shallow, which posed challenges for airflow management and component integration. Ballistic louvres were incorporated on both the inlet and outlet top covers, adding additional limitations on geometry and airflow paths. These factors required innovative solutions to ensure optimal cooling performance within the confined space.
Our Solution:
Leveraging our Ansys thermal design tools and extensive industry experience, we optimised the system layout to achieve uniform airflow across the entire stack of heat exchanger faces. This approach minimised acoustic noise and effectively mitigated recirculation issues caused by the close proximity of the inlet and outlet louvres. During testing, system performance demonstrated strong correlation with our predictive models, validating the design approach. Despite the constraints of the restricted space envelope, the flexibility offered by the mixed-flow fan solution ensured that cooling requirements were fully met within the specified ambient limits.
Read More About Engine Cooling System
Customer Challenge:
The customer required a vapour-cycle cooling system to regulate the temperature of an avionics cabinet in a civil aircraft application. This solution needed to deliver reliable thermal management under varying flight conditions while meeting stringent weight, space, and efficiency constraints typical of aerospace environments.
Our Solution:
The vapour-cycle system was originally developed for a rack-mounted configuration and later re-engineered for integral installation at the rear of an avionics console. Operating in a recirculation mode, it effectively cooled the electronics within the enclosure while directing waste heat to the base of the unit. From there, the heat was transferred to the cabin environmental control system (ECS), which routed it under the floor to the aircraft discharge valves. The system also featured a straightforward remote interface for fault annunciation and control, ensuring ease of monitoring and operational reliability.
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Customer Challenge:
The customer required a pair of precision actuators to control and guide the nozzle of a launch thruster on a payload-carrying rocket. These actuators needed to deliver accurate positioning under extreme conditions, ensuring reliable thrust vector control during ascent and maintaining structural integrity within the demanding environment of space launch operations.
Our Solution:
Working in close collaboration with the customer and exchanging detailed CAD models, we engineered the actuator body to fit within a highly constrained envelope while meeting demanding operational requirements. The design incorporated a brushless DC motor and an integral high-integrity ballscrew, both housed within the limited space. Extensive finite element analysis (FEA) was performed to validate structural integrity under severe launch and flight loads, while motor performance was optimised to maximise efficiency within these challenging conditions.
Read More About Actuators