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Very high temperature HVDC busbar (180 - 240°) with reliable and cost effective technology

Project description

Advanced busbar technology for high-temperature applications

Power distribution systems in more electric aircraft are expected to deal with high voltages and temperatures. With EU funding of the VILB project, France-based company Auxel and the LSE Research Laboratory based in the United Kingdom will jointly design and demonstrate a technology that can effectively address these challenges. The new technology, called varnished and impregnated laminated busbar (VILB), is a real breakthrough as it is based on an entirely new strategy for insulating laminated busbars. This process is expected to make the laminated busbars resistant to higher temperatures (240 °C) and partial discharges.

Objective

More Electrical Aircraft power distribution systems are increasingly required to operate in harsh environments and increasing voltage (HVDC), including high temperature. The company Auxel (an industrial leader in laminated busbars) & the LSEE Research Laboratory (Electrotechnical Systems and Environment) will conjointly address this topic by developing a technology able to effectively address the challenges of High Voltage, high operating temperature (up to 240°) and controlled lifetime: VILB (Varnished & Impregnated Laminated Busbar) technology. Firstly, VILB is a technological breakthrough as it is based on an entirely new strategy for the insulation of laminated busbars (LBB) (one component of the power distribution systems). Indeed, VILB will replace insulating films, glue and complex assembly processes by a heating press with an impregnation technology using a dielectric resin. This process will make the LBB resistant to higher temperatures (240°) and partial discharge (tiny short circuits appearing during the insulation phase and accelerating the system ageing). Secondly, VILB is a limited risk taking technology as it is inspired by perfectly mature technologies and products widely used for the insulation of electric machines. Thirdly, the potential VILB impacts are way beyond aeronautical sector: VILB could be duplicated in many other applications such as power modules, converters, automotive Industry, etc. Finally, thanks to this simplified process, in comparison with the traditional thermally bonded insulating film on heating press process, the implementation of VILB technology for busbars will result in higher productivity (x 5), lower production costs (from - 10% to - 30%) and energy savings (- 80%). During the project, the busbar will be designed, its performance simulated, the prototypes tested to TRL6 demonstration ending with a “TRL 7 ready” prototype. AUXEL and the LSEE have already co-patented VILB with 2 patent pending applications.

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Coordinator

AUXEL
Net EU contribution
€ 398 816,25
Address
Rue de la barre zone industrielle
59147 Gondecourt
France

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Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Links
Other funding
€ 170 921,25

Participants (1)