Periodic Reporting for period 2 - HARP ((Harmonised Amphenol Radiall Project) - A next generation high density modular electrical interconnect solution.)
Berichtszeitraum: 2019-09-01 bis 2021-12-31
Within the avionics eco-system, current federated architectures use specific hardware called Line Replaceable Units (LRU) defined into the ARINC standards and look like exemples shown in Figure 1-1.
These LRU units are usually large, heavy, bulky since they are self-contained in terms of connection, power and cooling functions. These units are racked into a chassis and to do so use large and robust connectors (ARINC 600 standard) to ensure they are correctly installed and connected.
Today there is a move towards Integrated Modular Avionics (IMA) which are comprised of Line Replaceable Modules (LRM) allowing sharing and increase of functionalities across several electronic boards leading to a better optimized rationalisation of hardware ressources. These LRMs in the form factor of a ‘blade’ are light weight and contain only one Printed Circuit Board (See Figure 1-2).
LRMs take up less space and weight, and represent a huge improvement in terms of maintainability and scalability by allowing blade hot swap, easy modification as well as direct connection to the Electrical Wiring Interconnect System (EWIS) compared to the legacy ARINC 600 approach. Furthermore, these new IMA architectures provide the means for a better distribution of the systems or sub-systems across the airframe closer to where the functions are installed.
Overall objective of HARP project is to address and provide solutions to the following issues :
• a fully compatible set of physical interface solutions (connectors) based on the installation constraints
• high density of connections combined with modularity of signals (copper, fiber)
• -easy access ergonomics : a harnessing approach that can support simplified installation and maintenance of both the avionics systems and the aircraft wirings
• low insertion and extraction forces of electronic boards (blades)
The proposed HARP new connector range will be :
• Modular: to host different types of interfaces (power, frequency) within a constant installation dimensional envelop.
• Standard : based on industry proven building blocks and multi source
• Designed to cost: targeted production costs of the new connection solution is 50% below current equivalent solutions
• Ergonomic: easy connectors installation operation during electronic boards production. easy installation of connectors on aircraft harness side, as well as system structure. It shall be possible to rack/unrack without using any tool.
• Compatible with High connection points density
• Durable : connectors will allow for the blades to be mated / unmated at least 500 times
As detailed in the technical report, the results done on Cleasnky demonstrator connectors, allow to reach a TRL 6. Technical validation was share with the end user. For the moment, no business has been implemented.
These LRU units are usually large, heavy, bulky since they are self-contained in terms of connection, power and cooling functions. These units are racked into a chassis and to do so use large and robust connectors (ARINC 600 standard) to ensure they are correctly installed and connected.
Today there is a move towards Integrated Modular Avionics (IMA) which are comprised of Line Replaceable Modules (LRM) allowing sharing and increase of functionalities across several electronic boards leading to a better optimized rationalisation of hardware ressources. These LRMs in the form factor of a ‘blade’ are light weight and contain only one Printed Circuit Board (See Figure 1-2).
LRMs take up less space and weight, and represent a huge improvement in terms of maintainability and scalability by allowing blade hot swap, easy modification as well as direct connection to the Electrical Wiring Interconnect System (EWIS) compared to the legacy ARINC 600 approach. Furthermore, these new IMA architectures provide the means for a better distribution of the systems or sub-systems across the airframe closer to where the functions are installed.
Overall objective of HARP project is to address and provide solutions to the following issues :
• a fully compatible set of physical interface solutions (connectors) based on the installation constraints
• high density of connections combined with modularity of signals (copper, fiber)
• -easy access ergonomics : a harnessing approach that can support simplified installation and maintenance of both the avionics systems and the aircraft wirings
• low insertion and extraction forces of electronic boards (blades)
The proposed HARP new connector range will be :
• Modular: to host different types of interfaces (power, frequency) within a constant installation dimensional envelop.
• Standard : based on industry proven building blocks and multi source
• Designed to cost: targeted production costs of the new connection solution is 50% below current equivalent solutions
• Ergonomic: easy connectors installation operation during electronic boards production. easy installation of connectors on aircraft harness side, as well as system structure. It shall be possible to rack/unrack without using any tool.
• Compatible with High connection points density
• Durable : connectors will allow for the blades to be mated / unmated at least 500 times
As detailed in the technical report, the results done on Cleasnky demonstrator connectors, allow to reach a TRL 6. Technical validation was share with the end user. For the moment, no business has been implemented.
1 « State of the art » analysis has been performed, during Period 1
This constitutes the key design features of the HARP connectors and provide risks mitigation for UBBICK demonstrator.
2 A technical specification report has been produced which includes :
• Challenge of installation constraints and required performances from the Topic Manager in order to make a trade-off between cabinet & blade design on one hand and connector design on the other hand
• Definition of connector & insert envelops and connectors interfaces
• Definition of performances at connector level (compliance matrix)
• Definition of connectors for UBBICK demonstrator
• Adaptation and completion for the evolutive connector range beyond UBBICK needs.
• Budgetary prices for UBBICK volumes and for the market in general
• Risks analysis update and risks mitigation plan
3- Technology derisking activities have been performed in parallel of activities 1 and 2.
In order to meet economical and technical targeted performances, HARP has to solve several technological challenges, dealing with manufacturing process technologies like molding, overmolding, plating on plastics, stamped and formed of special shapes contacts and with quick mount and quick mate connector design as well.
• Activities performed as of today were typicaly :
• Characterization of composite material parameters for simulation software
• Rheological simulations
• Mechanical simulation
• Prototype manufacturing
4- Tests on prototypes have been done to reach TRL6
• production of representative connectors based on indsutrial processes
• assembly of the connectors and integration on end user equipment
• Tests on connectors based on the qualification test plan shared in deliverable 3.1
• cross results with end user equipment tests to confirm the TRL 6
Final results are compliant with the targeted performances. Some minor adjustments have to be done for a product launch. These adjustements are linked to the differences between the prototype processes and the final processes for series.
Technology for right angle PCB connection has been validated and will be re-used for other product.
The heritage coming from the "high dimension" shell molding will be used for new product development
This constitutes the key design features of the HARP connectors and provide risks mitigation for UBBICK demonstrator.
2 A technical specification report has been produced which includes :
• Challenge of installation constraints and required performances from the Topic Manager in order to make a trade-off between cabinet & blade design on one hand and connector design on the other hand
• Definition of connector & insert envelops and connectors interfaces
• Definition of performances at connector level (compliance matrix)
• Definition of connectors for UBBICK demonstrator
• Adaptation and completion for the evolutive connector range beyond UBBICK needs.
• Budgetary prices for UBBICK volumes and for the market in general
• Risks analysis update and risks mitigation plan
3- Technology derisking activities have been performed in parallel of activities 1 and 2.
In order to meet economical and technical targeted performances, HARP has to solve several technological challenges, dealing with manufacturing process technologies like molding, overmolding, plating on plastics, stamped and formed of special shapes contacts and with quick mount and quick mate connector design as well.
• Activities performed as of today were typicaly :
• Characterization of composite material parameters for simulation software
• Rheological simulations
• Mechanical simulation
• Prototype manufacturing
4- Tests on prototypes have been done to reach TRL6
• production of representative connectors based on indsutrial processes
• assembly of the connectors and integration on end user equipment
• Tests on connectors based on the qualification test plan shared in deliverable 3.1
• cross results with end user equipment tests to confirm the TRL 6
Final results are compliant with the targeted performances. Some minor adjustments have to be done for a product launch. These adjustements are linked to the differences between the prototype processes and the final processes for series.
Technology for right angle PCB connection has been validated and will be re-used for other product.
The heritage coming from the "high dimension" shell molding will be used for new product development
Key expected results until the end of the project are :
• Manufacture demonstrator based on UBBICK requirements and test it (mechanical, environmental and electrical tests) in a complete functionnal cabinet.
• Perform connectors evaluations (at connector level )
• Get TRL 6 maturity on the targeted technological bricks
• Meet cost objectives (-50% versus current Arinc technology )
• Define potential improvements for HARP family beyond UBBICK needs
Impacts
The HARP connector family will provide a variety of solutions for LRM cabinet solutions that will be applicable to several aircraft types:
• Business jet segment with a low volume/high mixture of different configurations with very reduced space behind the cabinet, potentially reduced quantities of connection points and a wide variety of connection point patterns
• Large aircraft segment with high volume/low mixture of configurations and requiring highly competitive low costs solutions.
• Rotorcraft segment, which represent a small share of the market but also use avionics systems of the same type than what is found on business jets or large aircraft.
From a technical / functional perspective, benefits for equipments and aircraft manufacturers (depending on the limit of supply) will include:
• LRM assembly time saving and more operational reliability
• LRM cabinet assembly and different assembly sequencing using the tool less quick harness connectors which use low insertion forces (one handed) and time saving during equipment validation.
• No need for additional torque inspection tests, no risk of incorrect mounting, no risk of FOD by tooling or screws being left in the cabinets and potentially causing faults.
• These benefits are also applicable to the airlines providing them in turn with more operational reliability and inspection, fault finding and maintenance time savings.
• Light weight connectors allowing to reduce the fuel consumption of the aircrafts.
• A lighter, cost effective connector with a reduced number of components will optimize transports and inventory costs all along the supply chain.
Avionic connectors activity represents a significant parts of commercial aerospace connectors revenues of both companies. HARP connectors will allow Radiall & Amphenol Air LB to develop their market share and generate manufacturing activities particularly in their sites located in France.
• Manufacture demonstrator based on UBBICK requirements and test it (mechanical, environmental and electrical tests) in a complete functionnal cabinet.
• Perform connectors evaluations (at connector level )
• Get TRL 6 maturity on the targeted technological bricks
• Meet cost objectives (-50% versus current Arinc technology )
• Define potential improvements for HARP family beyond UBBICK needs
Impacts
The HARP connector family will provide a variety of solutions for LRM cabinet solutions that will be applicable to several aircraft types:
• Business jet segment with a low volume/high mixture of different configurations with very reduced space behind the cabinet, potentially reduced quantities of connection points and a wide variety of connection point patterns
• Large aircraft segment with high volume/low mixture of configurations and requiring highly competitive low costs solutions.
• Rotorcraft segment, which represent a small share of the market but also use avionics systems of the same type than what is found on business jets or large aircraft.
From a technical / functional perspective, benefits for equipments and aircraft manufacturers (depending on the limit of supply) will include:
• LRM assembly time saving and more operational reliability
• LRM cabinet assembly and different assembly sequencing using the tool less quick harness connectors which use low insertion forces (one handed) and time saving during equipment validation.
• No need for additional torque inspection tests, no risk of incorrect mounting, no risk of FOD by tooling or screws being left in the cabinets and potentially causing faults.
• These benefits are also applicable to the airlines providing them in turn with more operational reliability and inspection, fault finding and maintenance time savings.
• Light weight connectors allowing to reduce the fuel consumption of the aircrafts.
• A lighter, cost effective connector with a reduced number of components will optimize transports and inventory costs all along the supply chain.
Avionic connectors activity represents a significant parts of commercial aerospace connectors revenues of both companies. HARP connectors will allow Radiall & Amphenol Air LB to develop their market share and generate manufacturing activities particularly in their sites located in France.