Mechanical design and analysis of mobile pre-conditioned air (PCA) unit for a tactical unmanned combat aerial vehicle

Unmanned aerial vehicles (UAVs), used by the air forces of many countries today, possess capabilities for reconnaissance, surveillance and precision strikes. Unmanned combat aerial vehicles (UCAVs) provide tactical advantages for air forces in almost every region of the world. However, their sensitive electronic components require appropriate thermal management for critical tasks during ground testing and maintenance activities. In general, Pre-Conditioned Air (PCA) units are responsible for cooling, heating and conditioning the desired environment and delivering conditioned air to relevant spaces such as aircraft, military or medical shelters and command centers. The FE-PCA device is a portable, economical, durable and efficient solution, designed with a special configuration where system components are integrated onto a sturdy steel chassis. This thesis consists of the establishment, design, and analysis of a climate control system utilizing an ideal vapor compression cooling cycle with a mobile PCA unit developed for an UCAV, addressing the identified needs. The designed mobile FE-PCA device aims to effectively provide cooling or if necessary, heating to the aircraft without relying on external sources. Its primary objective is to ensure the optimal ambient temperature for electronic devices within the aircraft. Additionally, when used in conjunction with a ground power unit (GPU) during ground tests and maintenance activities, it eliminates the need for the aircraft engine to run, resulting in fuel savings and ensuring the job safety of technicians. The conducted system design, mechanical design and analysis have resulted in a next-generation mobile PCA unit with a cooling capacity of 21.6 KW. With the designed unit, UCAVs will be able to reliably perform critical attacks, coordination and intelligence reconnaissance missions.