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The world of motorsport is often considered to be glamorous, not a parallel that many would draw with UAV programmes. However, both operate in environments that test man and machine to their limits. Consider the dry desert heat through to intense humidity and sub zero ice wastelands, severe vibration, long service life and a need for simple in-the-field servicing and the synergies become more apparent. The ability to consistently perform in these environments led BERU f1systems to devote Wire in Composite (WiC) to the aerospace market rather than the racetrack. With numerous contracts already commenced for both the airframe and engine, the firm is developing the concept specifically for UAVs
Superior Protection
WiC completely encloses wiring looms in a bespoke composite sleeve, protecting assemblies against damage caused by vibration and harsh environmental conditions. In addition, the technology improves packaging by laying wires securely side-by-side as opposed to a traditional bundle. In fact, WiC looms can be built to virtually any shape or form, creating a loom that exactly matches the profile of the component to which it is attached. This offers the ability to incorporate sharp bend radii without the risk of strain or
chafing found in a conventional harness. This inherently reduces vibration, decreases package size and also prevents damage by external forces or accidental human interference during installation or maintenance procedures.
Testing of prototype parts has shown that WiC will easily match the temperature and humidity performance of existing loom technologies. The testing completed to date has also highlighted an added bonus of improved EMC performance thanks to the shielding effects of the carbon.
“For composite UAVs we can offer a much lighter simpler and more robust solution,” says BERU f1systems John Bailey. “We have started a project now to produce UAV structural parts with the wiring harness embedded.”
Harsh Environment
Bailey believes that the work will result in a more durable and robust vehicle that is easier to maintain and he is quick to liken the UAV to a race car. “It's an exceptionally aggressive environment in a racing car,” continues Bailey; “hot and harsh with very little space and pretty severe serviceability requirements. There are a lot of parallels with UAVs.”
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An ongoing development contract with harsh environmentconnector specialist Souriau, is helping to solve specific issues as Bailey explains; “Resin flow during the curing process in the autoclave is critical. We have worked to optimise the connector for the highest reliability.” The firm has already completed testing of the system to satisfy the relevant aerospace requirements of EURO CAE ED-14D, and to date it has succeeded.
Reduced Package Space
March saw the first structural parts for applications in UAVs come out of BERU f1systems' five metre specialised high temperature (350ºC), pressure (200PSi) autoclave. “We have designed and manufactured parts to demonstrate WiC's suitability for use in composite UAV structures,” continues Bailey. “These prototypes demonstrate how effective WiC is for reducing package space.” The firm is already planning a “Gen II” that will highlight how the technology can assist rapid deployment. “Our second generation will show how the technology provides a robust, easy and secure connection method for wings and associated circuitry,” says lead engineer for the programme David Dowdell. “Research has shown assembly and deployment must be quick and simple to undertake in the field.”
Beyond Wiring
The technology has the potential to go beyond electrical systems. BERU f1systems' WiC can also be used to embed hydraulic and fuel lines too. “We are already embedding hydraulic lines in our Factor 001 bicycle,” adds Dowdell. “In a UAV this can protect them from damage, either from attack or accidental interference during maintenance.” The firm is also looking at Flex Rigid technology and sees all areas of aerospace benefiting from this.
Apart from the WiC, BERU f1systems also believes its force and load cell technologies could have relevance to the UAV market. “We pride ourselves on being able to measure pretty much anything on a race car,” says force measurement manager, Simon Roberts. “Some of our systems are already being used in aero applications so a transfer is very feasible.” |
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