Thermal management concepts: Application examples using a convective heat transfer measurement sensor

The shift toward more electric aircraft has intensified thermal management challenges due to increased heat load from electrical actuators, power electronics and energy storage systems concentrated within confined fuselage bays. A Conventional Environmental Control System (ECS) alone is not sufficient to dissipate such high localized heat loads. This creates the need for innovative heat dissipation and heat reuse strategies. This paper presents two thermal management concepts evaluated at the Fraunhofer Flight Test Facility. The first, developed in the ORCHESTRA project, integrates a bilge skin heat exchanger with modified ventilation to dissipate elevated heat loads. The second, under investigation in the TheMa4HERA project, focuses on reusing avionics heat to warm the FWD cargo hold, thereby reducing ECS power demand. Both concepts depend on convective heat exchange, characterized using Fraunhofer’s Convective Heat Transfer Meter (CHM) to determine key heat transfer coefficients. In parallel, an aircraft-level thermal model was developed, validated against experimental data and subsequently used for virtual demonstration of a ground test scenario.