Abstract Green aviation demands lightweight, highly efficient electro-hydraulic power system for flight-critical actuation. However, transient thermal coupling among motor, pump and oil tank can trigger hydraulic oil degradation and insulation failure, jeopardizing safety and efficiency. To close this gap, we develop a first-principles dynamic thermal system model that captures coupled electro-mechanical-thermofluidic interactions over the full flight envelope. Parametric simulations show that under extreme duty cycles, load pressure, motor speed, working fluid, and ambient temperatures can raise component temperatures by up to 42% within 60s. Aiming to decouple transient peaks from steady-state design limits, we integrate a discrete fin-coupled a compact phase change heat storage unit (PCHSU). Dynamic simulations show that the PCHSU lowers peak temperatures of the motor, pump, and oil tank by 7.7%, 13.6%, and 2.9%, respectively. It also reduces thermal swing by 30% and entropy generation by 4.1%, leading to a 3.2% drop in electrical energy consumption for the same hydraulic output. Experiments confirm that, under extreme thermal conditions, the motor temperature with and without the PCHSU can differ by up to 20°C. The PCHSU also delays the temperature peak by 600 s and maintains a stable plateau for 200 s. The optimized design method offers a lightweight, theory-driven route to enhance thermal reliability and energy efficiency of electro-hydraulic power systems, directly supporting the transition toward low-carbon, high-performance aircraft.
Zhao et al. (Thu,) studied this question.
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