Aviation wiring solution overcomes space limitations
The aviation industry is in the midst of a transformative era, committed to reducing environmental footprints by embracing more electric aircraft (MEA). This shift entails replacing conventional mechanical, hydraulic and pneumatic systems with advanced electrical counterparts. However this presents challenges, particularly spatial limitations. Addressing these challenges head-on, the EU-funded ICEPASS project has emerged as a pioneering endeavour aimed at developing ground-breaking wire harnesses tailored to organise the power and monitoring systems of hybrid laminar flow control (HLFC). The project's primary focus is on the leading edge – where the HLFC system operates, and where space constraints are most acute.
Revolutionising aircraft efficiency
With aircraft manufacturers prioritising reductions in CO2 emissions and enhancing flight efficiency, drag reduction remains a key area of exploration. Laminar flow control (LFC) systems, including HLFC, are at the forefront of these innovations. ICEPASS acknowledges that classic systems must coexist with HLFC in a significantly reduced space allocation. “Traditional electrical harnesses have been challenged, and where they put bundle of cables hanging from supports, the ICEPASS project has placed flat raceways directly joined to the structure, in which the wires run neatly and there is no need to provide slack at connection points at movable parts,” says Félix Ramón López Martínez, project manager. The project faced dual challenges in the development of an electrical harness for HLFC's power and monitoring systems and in the creation of an innovative electrical pathway within aircraft structures to accommodate the space limitations of the HLFC operating area. To counter these challenges, ICEPASS proposed a detailed study of new routing methodologies, component selection and additive manufacturing technologies for brackets. “One of the biggest challenges faced during the development of the ICEPASS project was to cope with the moment required to move the Krüger flap, keeping the size of the actuation system small enough to fit within the leading edge and not overrun the available budget and time framework in the attempt,” adds López Martínez.
Fewer cables, more power
After the project ended in July 2023, ICEPASS implemented flat raceways directly integrated into the aircraft structure, eliminating the need for hanging cable bundles and ensuring a neat and efficient distribution of power and data. The flat harness concept realised by the project revolutionises traditional electrical installations by replacing hanging cable bundles with raceways, optimising space utilisation and facilitating easier maintenance and inspections. “We want to push forward the use of the flat harness concept in our projects for the aeronautical and space industry. We acknowledge there are still some certification issues to address but at the same time, we recognise the potential of the solution and this is something we want to share with our customers and partners in the industry in order to find new application cases,” comments López Martínez.
An eco-friendly aerospace future
Beyond ICEPASS, Adática, the entity spearheading the project, has made significant contributions to the HLFC demonstrator through other Clean Sky 2 projects. The ADDPATTA Seals project resulted in a European Patent application for aerodynamic seals, crucially enhancing the HLFC system's performance. In conclusion, ICEPASS’s pioneering efforts in resolving space constraints through innovative wiring systems and its broader contributions within the Clean Sky 2 initiatives mark a significant stride toward greener, more efficient aviation.
Keywords
ICEPASS, laminar flow control, wire harnesses, Clean Sky 2, wiring solution, hybrid-laminar-flow-control, green aviation
