Issue link: https://te.mouser.com/i/1477779
AEROSPACE, DEFENSE & MARINE / Addressing the Top 10 Connectivity Challenges in Developing Electric Aircraft Addressing the Top 10 Connectivity Challenges in Developing Electric Aircraft 4 Higher altitudes not only make the system more vulnerable to partial discharge, it also promotes water seepage into gaps in components and eventual corrosion. Other conditions—power switching, lightning strikes—cause surges in power cable systems that can cause cable voltage to exceed PDIV momentarily, leading to insulation erosion or catastrophic failure. The usage of appropriate dielectric materials and design constructions that eliminate air gaps will result in designs with minimal air pressure effects. 8. Handling Operating Temperatures Ranges and Thermal Management Requirements In battery charge cycles, a balance must be struck between higher energy transfer and higher temperatures. During high power charging (HPC), individual components are subjected to temperature extremes at resistance points along the HV path. Every microohm (υΩ) of resistance must be minimized. Areas to reduce resistance include cable terminations, contact interfaces (crimps and contact types), and contact materials. Liquid-cooled cables and laying cables in convective- or conductive-cooling heat sinks are also solutions. Thermal sensing and thermal modeling can be employed to design a cooling "ecosystem" for charging systems on the ground—and to detect high temperatures during power surges on landing and take-off. 9. New Cabling, Management and Crimping Techniques Sharp edges and non-smooth conductive surfaces in HV connectors can produce concentrated voltage gradients contributing to corona discharge. Electrically sealing crimp regions smooth out surfaces and the electrical geometries to reduce the likelihood of voltage stress. Any change in geometry requires analysis to determine: Is that edge going to contribute to a partial discharge or corona effect? If so, then construction must be modified to mitigate that risk. Just as HV utility power lines use circular corona rings to prevent corona losses, rounded features can be added to HV cables to control electrical stress. Even a single loose strand of wire sticking out of a shielded cable can cause problems. All components must be carefully designed, tested, and maintained to help ensure performance. 10. Accommodating High- Volume Production While not directly under a EWIS engineer's purview, designers must consider the ability of a manufacturer to handle the production, delivery, and quality of components at scale. The eVTOL market is projected to grow exponentially—and the ability to supply quality components in quantity is essential. All products should be 100% tested and inspected to help ensure performance and fitness for the application. Manufacturers who can handle the tooling, supply chain, cost control, and certifications for today's demanding aerospace and eVTOL programs can address tomorrow's innovative electric- aircraft projects. About the author: Matthew McAlonis is Technical Fellow and global leader of Engineering for the Aerospace Defense & Marine Business Unit at TE Connectivity. He can be reached at mmcaloni@te.com. For more information on TE's product solutions for the urban-air/advanced- air mobility (UAM/AAM) market, check out www.te.com/urban-air-mobility