Unleashing the potential of power electronics
New semiconducting materials such as silicon carbide (SiC) are an ideal response to the needs of future applications requiring high-frequencies and high power density, making it possible to design robust power conversion systems, for example, that are both highly efficient and optimised for use in the aerospace sector.
Silicon carbide MOSFETs offer a particularly interesting alternative to silicon IGBT technology for developing power modules of all kinds. Cooling systems can be more compact because of the higher junction temperatures of these new components, and higher switching speeds make it possible to increase power density and voltages.
In the race to develop power electronics solutions with a better power-to-weight ratio (kW/kg), these are very significant benefits.
Another big advantage of SiC technology is that is tailor-made for the voltage and current demands of the equipment and systems installed on board aircraft — especially with the relentless rise in bus voltages and onboard power requirements, which typically now reach around 540VDC and 1MW or more.
Aerospace engineers face three main challenges when designing new power equipment and new energy generation, distribution or conversion systems embedded in the electrical chain.
# 1 Mature materials
The limited availability of robust, reliable power components that have proven their performance in harsh environments (altitude, temperature, radiation) restricts the flexibility to design new systems architectures.
# 2 Standardised, cost-competitive components
Likewise, the low level of standardisation in the field of power electronics for harsh environments generally leads to custom developments, with long and costly development cycles, to meet the compatibility requirements of onboard systems.
# 3 Qualified components
Very few of the COTS power components available on the market today are certified or qualified to aerospace standards (DO-160). As a result, aircraft manufacturers and OEMs need to include qualification cycles in their development roadmaps, pushing up the total cost of ownership of their onboard equipment and systems.
The COTS Aero power module from Thales addresses all these issues, providing aircraft manufacturers and OEMs with a DO-160 compatible, off-the-shelf power electronics solution that is not only robust and reliable but also offers designers the flexibility they need to develop new architectures.
To offer competitive solutions with higher energy efficiency and lower emissions, aircraft manufacturers and OEMs are harnessing the latest technologies to develop electrical power supplies that perform better, consume less and offer just the right combination of size, weight and power (SwaP), cost and maintainability. More onboard power and higher energy efficiency are the watchwords in the relentless march to electrification.
Power electronics technologies are used to control and convert electrical energy, and an aircraft's onboard systems cannot operate without them. Today, disruptive innovation in the field of power electronics and power modules is one of the driving forces behind this electric revolution.
Power electronics and power modules need to operate in harsh environments, in both pressurised and non-pressurised zone, and are key components of the power converters, actuators, electric motors and other devices that perform critical functions on board an aircraft.
Thales is playing a leadership role in the industry's efforts to step up to the electrical challenges of green aviation. With our advanced power electronics solutions, we are helping the aviation industry to navigate this technological transformation by improving energy efficiency, incorporating new energy sources and optimising the weight of onboard systems.
More on: Electrical Systems | Thales Group
Thales has developed a dedicated power module to meet the specific needs of More Electric Aircraft (MEA) and Urban Air Mobility (UAM), more notably flying taxis.
Our COTS Aero power module is a full-SiC phase leg power module suitable for all DC/AC power conversion applications up to 260kW in non-pressurised zone and at altitudes of up to 44,000 feet depending on the mission profile.
This COTS solution is compatible with DO-160 standards and combines a small form factor with robust mechanical design and high performance, in particular thanks to the use of Silicon Carbide MOSFET chips.
Its innovative packaging allows engineers to design high-performance systems that are smaller, lighter and more economical thanks to their higher power density, lower switching losses and the ability to operate at high temperatures.
Thales's COTS Aero power module offers a fast track to fully qualified and reliable onboard equipment solutions that make it possible to optimise system architecture from the earliest phases in the design process.
This new power module brings significant benefits for onboard equipment providers, lowering total cost of ownership thanks to shorter development cycles and offering greater flexibility in electrical architecture design.
Key benefits
-
Compatible with DO-160 standards
-
COTS module available in 1200V and 1700 V versions
-
Energy efficiency: optimised SWaP-C (Size, Weight and Power and Cost)
-
Performance: high temperature operation (maximum junction temperature: 175°C)
-
Supply chain reliability: immediate availability, obsolescence management
-
Silicon carbide (SiC) technology for optimal performance
-
Flexibility and ease of integration:
-
single packaging with different current options
-
easy parallel configuration of multiple modules
-
bus integration or mounted on power PCB
-
Use cases and target functions
The COTS Aero power module from Thales is designed for electrical power generation, conversion and distribution systems as well as electrical actuators for all the following onboard systems:
- ATA 21 Air conditioning and pressurisation
- ATA 24 Electric power generation, distribution and conversion
- ATA 27 Flight controls
- ATA 30 Ice and rain protection
- ATA 32 Landing gear
- ATA 49 Auxiliary Power Unit
- ATA 65 Tail rotor drive
- ATA 67 Rotors flight control