THERMOCOAX presents the results of its NIPSE work presented at the TRA show coming in last week and will also be shown at ILA Berlin from Thursday, April 26, 2018.
THERMOCOAX has reached a major milestone this year. The company is celebrating its 60th anniversary.
60 years of service to our customers, 60 years of innovation in the nuclear, aerospace, semicon, and industrial markets meeting the expectations of these sectors through their constantly evolving applications.
To celebrate this event, the teams undertook the crossing of the bay of Mont Saint-Michel last month. Braving the cold, the mud, and the rivers (sometimes full), we managed to chase the clouds and together we reached the finish line of this jewel of architecture, The Mont Saint-Michel, also called the “Wonder of the West”. It was a very beautiful day revealing the mutual effort, team spirit, strong human values of THERMOCOAX.
THERMOCOAX is a worldwide key player and has been designing, developing and manufacturing heating solutions for aeronautic market for 20 years.
Based on the 60 years homemade Mineral Insulated Cable, we provide our customers with solutions for:
- Ground applications:
- R&D programs with institutes
- Ground aero test equipment
- Flying models:
- Anti-icing system for pitot tube, Angle of Attack, Total Air Temperature Sensor
- Wire Cutter (WSPS) on helicopter equipped with electrical anti-icing devices.
- Anti-icing screen for helicopter engine air inlet.
- Specific Application:
- Shower Heating system for VIP business Jet
Technical Application of Grey water drain mast
To save weight, the grey water from the washbasins is ejected to the outside of the plane.
Function of the configuration, most planes are equipped with two drain masts, one at the front and one at the rear where the washbasins are.
The major risk with a drain mast is the production of ice at the tip and risking a potential impact with the fuselage or it getting sucked into the engines.
Technical Description of Drain Mast Anti-Icing
In accordance with the specification, the drain is equipped with one or two water pipes.
The shell is made using the resin-moulded method.
For optimal efficiency of the anti-icing system, THERMOCOAX technology warms up the water pipes instead of the shell.
Heating cable technology available:
- Self-regulated cable
- Or fixed power cable coupled with switches
- Inconel or nickel sheath cable
- Ø 5 up to 3mm
- Power supply 28 or 115Vac 400hz
- Dissipated power from 20 to 250 Watts
- Pipe Temperature up to >40°C at -55°C environmental conditions
Each heating cable is produced with cold ends.
The cable is then wrapped onto the tube.
The cable is flexible enough to increase the volume of cable and get more heat for areas exposed to coldest conditions.
Cable is brazed on the tube for:
- Conduction pipe/heater for more thermal efficiency
- Production repeatability
Thermocoax Drain Mast Final Assembly
Drain masts are developed, produced and checked in Thermocoax facilities
Acceptance Test Criteria of Drain Masts:
- Line resistance
- Insulated resistance under 500Vcc
- Dielectric 1mn 1500Vac
Test for Qualification Program of Drain Mast
THERMOCOAX conducts the qualification test program in accordance with our customers’ specifications.
Our engineers write the QTP for customer approval prior to running the tests.
Most of the tests (thermal, humidity, electrical etc.) on the drain mast are performed in THERMOCOAX’s test lab facilities.
These require heavy equipment (vibration, acceleration, impact etc.) and are sub-contracted to external laboratories or provided by our customers with the complete water system.
-Typical Qualification Test Schedule for Drain Mast
- Impact & Crash Safety
- Pyrotechnic Shock
- Load Test
- Temperature & Altitude
- Temperature Variation
- Explosive Atmosphere
- Sun & Dust
- Fluid Susceptibility
- Audio, induced signal, radio frequency
- HIRF, ERFE
- Fire and Flammability
- Combined Temperature, Altitude, Humidity
- Dielectric Test
- Engine Blade Out
- X-Ray Examination
- Thermal Cycling Test
THERMOCOAX supplies the following platforms:
- Dassault Falcon Jet
- Bombardier C Series
- Embraer EJet 1 & 2
THERMOCOAX is a key player for anti-icing systems on board aircraft platforms and is proud to participate in challenging international aero programs.
THERMOCOAX focuses on high quality heating products for the best stability and repeatability in operation. For 15 years, we have witnessed the challenges faced by our customers to manufacture aircraft and to improve the safety and comfort of passengers.
New large programs are taking shape, THERMOCOAX is ready for production ramp up and supporting the market with cost-effective drain masts.
Thermocoax Pedigree :
THERMOCOAX has been a worldwide key player for 20 years in designing, developing and manufacturing with thermocouple sensors for the aeronautical market.
Based on the 60 years Mineral Insulated Cable produced in-house, we are providing our customers with solutions for:
– Ground applications:
R&D programs with institutes
Ground aero test equipment
– Flying models:
Thermocouples and RTDs for air cabin management system.
Thermocouples for helicopter engines with 15 000 units installed
Alternator Bearing temperature measurement on twin aisle and double deck platforms
– Scientific tasks:
Skin temperature on supersonic frame
Engine Space launcher
Technical Applications of the Brake Temperature Sensor :
New technologies are rapidly developing and the brake industry is working hard to make aircraft operations safer and offer passengers more comfortable travelling conditions.
A new generation of brakes has been installed on modern aircraft. Carbon brakes developed by key brake manufacturers is the result of a long and costly program of investment in research and development.
The new carbon disk generation provides more power braking during landing but also during braking in an emergency.
Firstly, the brake thermocouple gives the brake temperature in real time and can be transformed in a “hot brake” alert to the pilot when the value goes over a predetermined temperature threshold.
It gives valuable information to the cockpit on the temperature of the right and left brakes. If these differ too much, an asymmetric friction on the brakes can cause difficulties when maintaining heading and keeping speed under control.
Thanks to this system, the pilot receives a “Go/No Go” clear message for takeoff authorization. The brake thermocouple indicates that in case of a braking emergency event during takeoff, the brake will have his full capacity to stop the aircraft on time for the safety of all passengers.
Secondly, during takeoff in hot climates, this temperature monitoring avoids a too early landing gear retraction. This avoids a risk of tyre explosion in the wheel compartment.
The brake thermocouple is now a key piece of equipment that airlines use to reduce turnaround times (TAT) in short-haul operations to around 30 minutes.
This new generation of carbon brakes replaces the old metallic brake.
Each brake manufacturer develops their own carbon technology. Specialists agreed to give carbon technology products a longer life, more braking cycles and much higher efficiency of braking especially for heavy airliners.
But carbon brake technology produces high amounts of heat energy during braking and the temperature can get very hot if the dissipation of kinetic energy is not optimum. This temperature rises to nearly 1000°C during normal braking. In case of emergency braking at full power during takeoff at full weight, the friction off the carbon disks is so powerful that the energy produced causes the temperature to rise to 2000°C.
Temperature monitoring is implemented on every aircraft platform, commercial and military. One thermocouple per brake/wheel is the rule. A typical single-aisle aircraft is equipped with 4 thermocouples, a twin-aisle aircraft 8 to 12 thermocouples, double-deck aircraft 16 thermocouples and military fighter 2.
This is an opportunity for THERMOCOAX to contribute to this program and improve the safety of the airframe and passengers every day around the world.
Technical description of brake thermocouple
When measured at nominal temperature, the thermocouple typically has the following properties:
- K type thermocouple
- Single-circuit, 2 wires
- Class 1 in accordance with IEC and ASME
- Ceramic insulator
- Dielectric under 500V
- Insulation resistance:
- 1011Ω.m at room °T
- 107 Ω.m at 600°C
- Inconel 600 sheath
- Ø 2.5 to 4.75mm
- Hermetic connector EN2997
- Hermetic connector D38999
- 2 compensated pins
- Oval base or mesh for easy removal from the torque tube when replacing
- Mass: <100g
- Environmental and safety of flight tests
- Impact: RTCA/DO160 Sect 7 cat B, D
- Cat B
- Cat D
- Vibration: RTCA/DO160 Sect 8
- Cat R curve W
- Cat T curve E
- 2000 hz, 200G
- HALT Tests
Acceptance Test Criteria of the Brake Thermocouple :
- Temperature calibration
- Helium leak test
- XRay by sampling
- Time constant
- Visual and mechanical inspection
- Line resistance
- Insulation resistance
- Dielectric 500Vac, 60Hz/60s
- Final manufacturing report
Packaging and Cleanliness :
THERMOCOAX focuses on high quality Brake thermocouple products for the best stability and repeatability while in operation.
We understand our customers’ challenges to manufacturing braking systems and to make the aeronautical industry reliable and the millions of passengers safer.
At THERMOCOAX, we are working hard to contribute to these incredibly challenging programs.
THERMOCOAX has supplied many commercial programs and military platforms.
THERMOCOAX designs, develops, qualifies and produces in accordance with aircraft specifications such as :
- Airbus 350
- Embraer EJet
- Mitsubishi Regional Jet
- Irkut MC21
- Sukhoi Super Jet100
- COMAC C919
THERMOCOAX is the major player for brake thermocouples and is a proud contributor to great aeronautic programs.
26 November, 2015
The challenges of equipment integration on future aircraft engines – particularly next-generation Ultra-High Bypass Ratio (UHBR) powerplants – is the focus of a three-year European Union-funded technology project now underway with 10 companies and organisations.
Called nipse (Novel Integration of Powerplant System Equipment), this programme addresses installation limitations expected in such future engines, including the thinner nacelles and larger fan modules ; along with architectures that require more functionality and provide extra thermal constraints through lower ventilation capability and reduced volume availability.
In this context, the NIPSE project seeks to find better placement options for equipment, using locations in the engine, the nacelle and the aircraft itself. NIPSE also addresses the need to improve thermal management of integrated powerplant systems (IPPS).
NIPSE is targeting potential engine fuel savings of up to 2-3 percent, gained through a 15-percent reduction of equipment volume for the UHBR engine, along with weight savings and improved thermal management on the more integrated powerplant systems. Additionally, a reduction of development time for the installation of powerplant systems is anticipated.
We, THERMOCOAX, participates to improve fire detection technology and the implementation of these sensors on the engine or nacelle.
Established within the European Commission’s Horizon 2020 Programme, NIPSE is funded at 6.2 million euros and has a three-year duration from its formal kickoff last June. It is managed by the Commission’s INEA (Innovation and Networks Executive Agency), with Aircelle (Safran) as the programme leader in its role as industrial coordinator.
Iain Minton, NIPSE project coordinator
The NIPSE consortium :
Safran Aircelle (France) ; ARTTIC (France) ; Thermocoax SAS (France) ; Stichting Nationaal Lucht- En Ruimtevaartlaboratorium (The Netherlands) ; Compañía Española De Sistemas Aeronáuticos (Spain) ; BAE Systems (Operations) Limited (UK) ; Meggitt Aerospace Ltd. (UK) ; Safran Snecma (France) ; Safran Labinal Power Systems (France), Archimedes Center for Innovation and Creation (Greece).
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 636218
The THERMOCOAX Bleed Air detector is designed to detect leaks in an aircraft’s pneumatic duct system by sensing the temperature of the overheated air surrounding the leaking duct.
The NEGACOAX technology gives the location of the overheat condition, annunciates the overheat to the aircraft’s crew warning system.
The NEGACOAX consists in a homemade Mineral Insulated Cable, doped with eutectic salts. When the NEGACOAX detects an overheat (air leakage) the cable Impedance value will drop down and the capacitance value will increase very fast.
Example of curve with NEGACOAX NG124 :
The THERMOCOAX’s current technology uses the Binary compound within Eutectic as described below, in others words, liquidus and solidus will melt entirely at the same temperature.
This specificity gives the high accuracy of this technology :
Insulated Cable homemade manufacturing, this technology offers a high reliability and nearly no maintenance.
The maximum length of each NEGACOAX detector is 5 meters. We have no length limitation regarding the number of detector connected together to make a complete loop.
THERMOCOAX’s NEGACOAX detectors are typically installed at heat critical points throughout the aircraft structure. Typically, these are located in the wings, engine pylon, fuselage, empennage and tail cone (APU compartment).
This technology can be applied to military, commercial transport and general aviation aircraft.
The electronic control system associated will get 2 separated electrical parameters :
By connecting both ends of the NEGACOAX loop with the electronic system, the leakage location can be determined by current ratio.
NEGACOAX Detector Characteristics
- Nickel Sheath
- Insulant: Al2O3 + eutectic salts
- Constantan conductor
- Line resistance at 20°C: 2,15±0,05Ω/m
- Diameter Ø2,2mm +0,2/-0,4
- Length L<300cm ±6mm
- Length 300cm<L<460cm +19/-0
- Max detector Length 460cm
- Mass=25gr+(27*L)gr with L= length in meter
- Service Life: 20 years
- MIL and RTDO 160 standard
- 100 000 Flight hours
- MTBF > 300*106 hours
- FMEA 1.954*10-7 Failures/FH
NEGACOAX Product Ranges :
Thermocoax has a large experience on aircraft platform with :
- McDonnel Douglas MD90
- Airbus A340
- Dassault Falcon F5X
- Embraer KC390
- Bombardier Global Express
- Airbus Helicopter
Thermocoax supplies a large range of accessories to fix the detectors on the aircraft structures
Mechanical System for :
1 or 2 loops :
NEGACOAX is compatible with any electronic system with the following characteristic :
Thermocoax is working in partnership with aircraft industry electronic specialist.
Thermocoax offers as option an upgrade of the detector with integrated shunt resistor in the connector. This shunt (>30KΩ) is connected between the core and the sheath.
from August 25th to 30th, 2015.
ZEHR Aero, our partner and we, look forward to welcoming you in Hall F3, Stand C6.