Cooling of high temperature zones of missile control actuation system with peltier modules

With this study, cooling of the electronics of the Control Actuation System affected by high objects emitted from turbojet missiles. The cooling process is quite difficult due to the limited design areas and high temperature exposure in this mentioned region. After the literature research, there are different examples for products and cooling in the world. It is cooling with a closed loop system where a special liquid is circulated and through some thermal mobile vendors. It is a cooling complex and supplement made with liquid, while achieving the desired cooling values ​​in cooling made with thermal pads. At the same time, many subsystem design changes outside the region where cooling is made cause the emergence of prices. When we consider all these, the need to use a simple and more reliable product for cooling is obvious. It was decided to use Peltier modules, which have proven themselves in other sectors, for the cooling of this ability. It was predicted that cooling could be provided with the use of Peltier modules and this prediction will be supported with the design and analysis to be made in the CAD environment. This study aims to cool the high temperature areas exposed to missile control drive systems with Peltier modules. With this design study, the cooling system developed to minimize the effect of the high temperatures produced by the KTS Turbojet body and the Turbojet engine on the KTS body and subassemblies has been defined. After high temperatures, the operation of the 50x150 mm driver card is negatively affected and it is aimed to reduce the temperature on the driver card with the cooling system. This cooling process will be provided by Peltier modules. Within the scope of this thesis, the basic schemes of missile control tests will be focused on, especially the energy transfer with turbojet engines will be examined and the effect of these processes on missile performance will be discussed in detail. In this context, the role that technological developments and research in the defense industry can play in security and balance opportunities will be analyzed and current potential application areas will be discussed. This thesis will be a step towards understanding and optimizing the complex communications between missile control propulsion systems and turbojet engines. The scientific contributions of this system will shed light on the improvement of defense products by helping engineers and academicians in the defense industry. With this design study, the Control Actuation System (CAS), Turbojet body and the cooling system developed to minimize the effect of the high temperatures produced by the Turbojet engine on the CAS body and subassemblies were defined. The cooling system is designed to protect the CAS from the high temperatures that occur after the operation of the turbojet. This system integrated on CAS can be considered as a major technological step after optimization. The Turkish defense industry has evolved rapidly with the development of missile systems led by the ROKETSAN company. These systems, which are indispensable for the Turkish Armed Forces, are of vital importance in various mission profiles. The structure of a missile must be lightweight, robust and aerodynamic to meet the challenges during launch, flight and interaction. Composite materials and lightweight alloys are often used to achieve these design goals. Another critical aspect of the missile structure is its ability to protect sensitive electronics and internal components from harsh environmental conditions in flight. Thermal protection systems such as ablation materials are frequently used to block heat from sensitive internal parts. Missile control propulsion systems are complex mechanisms that enable missiles to follow complex flight paths and hit their targets with precision. These systems are responsible for translating guidance commands from onboard sensors into precise movements of the missile's control surfaces, allowing the missile to follow the desired trajectory. Missiles are complex weapons and require a wide range of materials to produce. The specific materials used depend on the missile type and purpose. However, some of the most commonly used materials are Aluminum, titanium, Maraging steel, composites, etc. Missile production, a complex process involving complex engineering, precision manufacturing and meticulous quality control, requires careful consideration of various aspects for the development and deployment of effective and reliable weapon systems. Various factors, from material selection to manufacturing processes and testing protocols, play a significant role in shaping the success of missile production efforts. Among the numerous components that contribute to the effectiveness of a missile, the Control Actuation System (CAS) stands out as a critical element. CAS improves the overall performance of the missile by providing precise control and maneuverability. Turbojets revolutionized the missile industry and provided a number of features that made them an indispensable weapon system for militaries around the world. These features have significantly increased the range, speed, payload and operational flexibility of the missiles. It is possible to further expand the capabilities that turbojets provide to missiles. For example, turbojets can be made more efficient, allowing missiles to reach longer ranges. Additionally, turbojets can be made capable of reaching higher speeds, allowing missiles to hit targets faster. However, the cost and complexity of these improvements may increase. In order to develop the study and base it on numerical data, a CAD model was designed and supported by analyses. The CAD model generally consists of CAS Mechanical Unit, TJ Engine Body, Peltier Cooler Plates. The boundary conditions for CFD analyses were defined as follows; It was assumed that the missile flies at Mach number of 0.7. The ambient temperature was assumed to be 40°C. It was assumed that there was no gas flow inside the CAS Body. The flight duration was assumed to be 600 seconds. The surface temperature of the Turbojet engine insulation was assumed to be 250°C. The size of the electronic card inside the CAS that needs to be cooled was assumed to be 50x150 mm. The properties of the materials used in CFD analyses were defined as follows: Heat conduction coefficient of the CAS body material (Aluminum 7075) is 145 W/mK Heat conduction coefficient of the Termoelectric Cooler Material (Alumina 99%) is 49 W/mK Heat conduction coefficient of the Electrical Component- PCB material FR4 is 0.29 W/mk Analyses were performed using the Steady-State Thermal Modüle. Flunet and Thermal-Electric will be used together in the following stages for a more comprehensive study. Then, three-dimensional analysis model and mesh model were created and the cooling system was simulated in the ANSYS environment. As a result, the following data was obtained. When the PCB material in the CAS body is 70x170 mm in size, it was seen that the desired cooling was provided on the 50x150 mm driver card. This corresponds to 2 peltier Modüles per CAS channel. If 2 peltier Modüles are used for each CAS compartment, only 70x170 mm^2 area can be cooled. This amount of cooling is sufficient for us. A total of 8 peltiers provide cooling with a power of approximately P = ixVxN = 10x2.5x8= 200 watts from 10 amps 2.5 volts. System cooling was provided by using 8 peltier Modüles, each costing 90 dollars.