HTcoils

The aim of the Cleany Sky 2 project HTcoils and its partners (HPW High Performance Wires, PEAK Technology and coordinator LKR Leichtmetallkompetenzzentrum Ranshofen) was the development of high-temperature, high performance wires, impregnating varnishes and potting ingredients (resins) with an increased thermal index value . Besides required materials development it was further goal to manufacture sufficient wire materials for sub-assembly coils tests, final demonstration and qualification of high temperature coil systems and to test their functionality in electromagnet actuators for different applications in an aeronautic Electrical Environmental Control System (E-ECS).

The main objectives were:

• to develop specific wires, impregnating varnishes and potting ingredients (resins) to have complete solutions for high temperature coil and qualify these ingredients
• to manufacture high temperature coils with these ingredients, integrate them in the Topic Manager’s defined application and demonstrate that the solutions proposed can be industrializedall solutions have to comply with aeronautical constraints (electrical, vibration, lifetime, manufacturing process, etc.) according to RTCA/DO-160.

The main results of  HTcoils can be summarized as follows:

• HPW developed a very thin, high temperature wire (incl. varnish) with a final diameter of 0.70mm The wire material proved its durability over 20.000 hours thermal testing leading to a thermal-like index of 274°C
• Compared to the baseline TLI 240°C this is an increase of +14.6%
• PEAK realized a manufacturing route (coil winding + potting) for the novel high temperature conductor wires
• PEAK showcased coil manufacturing including final demonstrator assembly
• PEAK demonstrated the final actuator functionality on demonstrators.

Future Benefits of the novel high temperature wires (TLI 274°C):

• Use of actuators at higher environment temperatures
• Enabling the design of smaller, lighter actuators hence saving structural mass
• Realization of better trade-off for aircraft heating management hence contributing to CO₂ emission reduction
• Exploitation of actuators from aeronautics to electric car technologies
• Stay at forefront of material development (HPW), process development (PEAK) and electric actuator technologies (LTS) with the results achieved.