This presentation discussed the practical implementation of a HVDC electrical system for aircraft operating on more electric systems. For complete details about Astronics' offerings for more electric aircraft, visit Astronics.com.

1. MEA Conference
Seattle
Aug 20-23, 2018
astronics.com
Michael Ballas
Practical Implementation of HVDC Electrical System

2. Astronics at a Glance
Proven Innovators, 50 Years of Success
astronics.com 2
Global reach and collaboration
Subsidiaries, partners, and customers worldwide
Strength and stability
~$1B market cap
NASDAQ
ATRO
Solution breadth
Aerospace, defense, semiconductor, and others

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Serving Global Customers
Representative List
230+ Airlines
Airbus
AMAC Aerospace
Bell Helicopter
Boeing
Bombardier
Carson Helicopters
Cirrus Aircraft
Comlux
Daher
Dassault Aviation
Embraer
General Dynamics
Gogo
Gulfstream
Hondajet
Ratheon Company
Rockwell Collins
Sikorsky
Textron
Thales
Thompson Aero Seating
U.S. Army/Navy/Air Force/
Marines
Zodiac Aerospace
Hughes
Intel
Jet Aviation
L3 Technologies
Leonardo
Lockheed Martin
NASA
Panasonic Avionics
Pilatus

4. Astronics Expertise Connectivity & Data
Aircraft Data Systems
IFC Antennas and Radome Systems
Inflight Entertainment System
Hardware
VIP IFEC & CMS Systems
Lighting & Safety
Aircraft Lighting Systems - Cabin, Cockpit, Interior,
Exterior
Airfield Lighting Systems
Emergency Systems
Enhanced Vision Systems
VIP Lighting Systems
Services & Structures
Custom Design and Manufacturing
Fuel Access Doors
Custom Product Design
Systems Certification
Interiors
Environmental Control Systems
Passenger Service Units
SmartTray
Test & Simulation
Simulation & Training Systems
Test & Measurement
Power & Motion
Power for Passengers and Crew
Power Distribution, Conversion, Control
Seat Motion Systems

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Electrical Power Generation
Distribution
Conversion
Cabin Power Management
About Astronics Advanced Electronic Systems
Power System Integrator
COREPOWER® Products
System Architect
Safety Analysis
Flight Critical Software
Avionics Integration
Certification Experience

6. Key Challenges
Weight/cost optimization
System autonomy
Managing HVDC distribution?
Variable power demand
Efficient power conversion
System safety/health mgmt
Battery efficiency and safety
Solution Enablers
Solid state distribution and
conversion elements
Advanced switching
Distributed power
Advanced system control
System integration
Key Electrical System Challenges for eVTOL, MEA
Two Story Lines
» Optimized high power switching, coordination and distribution
» Efficient—self-aware electrical power system

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Power System Functions
CONTROL
Utility LogicAvionics
Display
Interface
Electronic Circuit
Breaker Unit
Motor
Control
PRIMARY POWER
Power
Conversion
Generator
Control
Power
Distribution
Unit
BatteryStarter
Generator
Modular Systems Based Approach

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Power Distribution
Flexible, Modular Architecture
1000V Electronic
Contactors
270V DC Electronic
Power Distribution
270VDC Electronic
Contactors
Data Concentration &
Control for distribution
28V DC Electronic
Power Distribution
115V AC Electronic
Power Distribution
RS-485/422/232
Mil-Std-1553
A429
Ethernet

9. Function Integration Case Study
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The Value of Functional Integration: $33,000 and 27 lbs Saved
One System,
Many Functions….
Strobe Power Supply
Instrument Light Dimming LRU
Taxi Light Dimming LRU
Taxi Light Control Relay
Landing Light Dimming LRU
Landing Light Control Relay
Taxi/Landing Light Flashing System
Inertial Separator Monitoring LRU
Prop de-ice Control Relay
Prop de-ice Timer LRU
Airframe de-ice Power Control LRU
Windshield Heat Power Control LRU
Airframe de-ice Timer LRU
Pitot Heat Power supply LRU
Pitot Heat Power relay
Pitot Heat Control Relay
Hour meter
Air Conditioning Control LRU
Fuel Boost Pump Auto-management LRU
Fuel Boost Pump Control relay
Tank Sequencer LRU
LDG gear retraction, extraction relay
How
» PWM Control
» Discrete Control
» Decision Logic
» Analog Control
» Data Bus Control
» Runtime Totalizer
» Load Current
» Load Voltage
Existing LRUs Removed

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High Voltage Contactors
Mechanical Switching High DC Voltages
Limited switching life cycles
with electromechanical devices
as voltage increases beyond
28VDC.

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Solid-state devices switch much faster and more precisely than electromechanical
devices, but there are penalties that grow increasingly severe with current rating:
1. Conduction loss heat (device voltage drop)
Tradeoff between semiconductor device size/quantity/cost and heat generation
2. Heat sinking weight
SiC mosfets manage additional heat but other associated components must be cooled
3. Switching component cost
High semiconductor cost
above 200V.
4. No galvanic isolation
Low leakage, but no true isolation
5. No dissimilar technology
High Power Contactors – Solid State Challenges

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Load Rating
» 270VDC (up to 10A)
Solid State ECB
» 270VDC (15-25A)
Hybrid w/micro relay ECB
» 270VDC (50-400A)
Contactor w/separate CCA
Control Board
› Higher voltages possible
HVDC Contactors – Product Family Solution
Specifications
» Single pole single throw
normally open
» 200-400VDC operation
» 50A-400A continuous current
» 4000A fault clearing
» 3mS nominal switching time
» -40°C to +71°C
» Unpressurized environments
Safety Benefits
» True galvanic isolation
» Redundant over-voltage
protection
» Over-current protection
» I2t overload protection
» Back up fusible element
ELECTRONIC
SWITCH
ELECTRONIC
SWITCH
ELECTRONIC
SWITCH
ELECTRONIC
SWITCH
ELECTRONIC
SWITCH
RELAY
CNTR
CNTR
CNTR
CNTR
Contractor LRU
Packaging Flexibility
PDP LRU

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Optimized Power Source Switching – Fault Clearing
Hybrid Source
Contactor
Hybrid Load
Contactor
Electronic
Circuit
Breaker
Fault clearing coordination
» Enables faster coordination between different layers of wire protective
devices
» I2t curves (e.g. AS33201) are based on thermal circuit breaker capabilities
» Software based I2t significantly faster with less tolerance
» Various layers of wire protective devices can communicate
» 1 second fault clearing would be more than adequate to ensure proper
communication latency and proper coordination
» Shorter fault sustainment minimizes secondary fault propagation
» Contactors, ECBs, and wire gages can all benefit, and can be downsized

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Optimized System Solution – High Efficiency, Flexibility
Power Conversion
System Control
HVDC Distribution
Brushless Generation
Lightweight/Modular
User Configurable
Protection
Switching
Sensing
High Efficiency Solid State
Lightweight, Compact
AC/DC, DC/DC/ Freq Conv.
Utility Management
Power Management
Communication Gateway
I/O Extender
User Configurable
High Reliability
Power Dense
Configurable (SGU)

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Why
Enabling extended periods of unsustained (zero maintenance) operation
How
An integrated aircraft-level solution
What
An optimized balance between:
» Operationally durable integrated design approach
» Health state awareness
» Ability to tolerate or adapt (real time, autonomously) to abnormal conditions
Practical IVHM Objectives
Highly Efficient and Self-Aware Electrical Power System

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Summary: Practical HVDC Electrical System for eVTOL
September 19, 2018
Adaptive
Provide highly
adaptive system
elements to
address widely
varying platform
needs
HVDC
Solve the HVDC
switching
challenge
Switching
Provide
coordinated
switching to
improve safety
and reduce
system weight
Efficient
Provide high
efficiency
distribution and
conversion
Smart
Utility integration
(weight savings)
Dynamic power
management
(efficiencies,
autonomy)
Sensing, monitoring,
reporting and
actionable change
(IVHM)

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Astronics Advanced Electronic Systems
www.Astronics.com
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