NIPSE

Novel Integration of www.nipse.eu

Powerplant System
Equipment

Electrical interconnections
Flat Cable Derating Test & Evaluation

Roel van BENTHEM

Edwin BLOEM
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018

This project has received funding from the European Union’s Horizon 2020 research and
innovation programme under grant agreement No 636218
Outline Workshop Presentation

1. Introduction/NIPSE context
2. Wire rating & derating versus harness weight
3. Flat Cables versus Round cables
4. Flat Cable Samples
5. Test Facility & Test Results
6. Derating Analysis
7. Thermal Modeling & Results
8. Conclusions and further work
9. References

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
1. Introduction/FLat Cables within NIPSE
context

 With the development of new turbofan aero engines,

such as the Ultra-High Bypass Ratio (UHBR) engine and
open-rotor solutions, advances in propulsion and fuel
efficiency can be made through increasing fan
diameters and higher bypass -ratios.
 This will provide less space for the engine systems and
introduces limits on ventilation.
 Higher operating temperatures are being expected.
 Less derating is expected for innovative flat-cable
designs for the extreme environmental conditions that
occur in nacelles.
 Less derating = weight reduction of cable harnesses
designs.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
3
2. Wire Rating (1)

 Conductor sizing of a wire when carrying a

current is based on a thermal balance
between:
▪ Internal heating by Ohms law due to the conductor
resistance
▪ External cooling by natural convection and radiation
which is improved for flat cables w.r.t round cables
Qnatural cooling ~ ΔT
ΔT

22 20 18 AWG
4L  2 ΔT ΔT~I2R
Di R = e M D =  Di L I
Di 2 4

Qheating=I2R
I2 ->
L

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
4
2. Wire Rating (2)

SAE-AS 508816

ΔT=50oC

I=7.5 Amps (AWG 24)

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
5
2. Wire Derating (3) – I design = 7.5Amps

SAE- AS50881
Wire specifications Free Wire Current [Amp]
(120oC wire in 70oC environment)
Wire Gauge Core diameter Wire weight Ambient Air 60.000 feet Wire in a bundle
(AWG) mm kg/km @ 1 Bar @ 0.072 Bar 22 wires

24 0.59 2.7 7.5 6 2.0

Δ=-4
20 Δ=-12 0.97 +151% 6.8 +441% 13.5 10.8 3.5
16 1.45 14.6 20 16 5.2
12 2.18 31.3 36 28.8 9.4
8 3.85 90.0 75 60 19.5
4 6.35 215.0 132 106 34.3
Current derating = > =1 =0.8 =0.325

Current derating = mass increase

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
6
3. Flat Cables versus Round cables (n=22)

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
7
4. Sample Instrumentation

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
8
5. Test Facility
View A
Thermal vacuum test facility

Samples
Tripple layer flat Double layer flat Single layer flat
cable C cable D cable E

Infrared Camera
Mirror IR camera

~500 mm View angle

Flat metallic mirror plate 24°x18°

IR window
-45° +45
° Frame

References Round bundle B Single wire A (not visible)

Horizontal sample setup View A Vertical sample setup View A

~350 mm
Shrouds of the thermal Shroud ~350 mm
Shroud
vacuum test facility Single layer flat cable E Double layer flat cable D Tripple layer flat cable C

Single layer flat cable E Double layer flat cable D Tripple layer flat cable C

Flat metallic mirror plate

Flat metallic mirror plate ~500 mm -45°
~500 mm
+45° Horizontal sample setup

Horizontal 90o Rotated

Horizontal
Round bundle B sample setup Single wire A
Frame
Frame

Round bundle B Single wire A

Round bundle B Single wire A

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
9
5. Facility and Tested Flat Cable Samples

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
10
5. Test Results: IR temperature imaging

E -1 layer D -2 layers C -3 layers

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
11
6. Test Results & Derating Analysis

B-Round cable

Sample Measured Relative Theoretical

C-Flat 3 layers derating derating d/d0 weight
(d=Ix/IA) w.r.t reduction *
w.r.t. AS50881
D-Flat 2 layers Sample A (d0=0.325)
B
0.376 116% 20%
ΔT

E-Flat 1 layer C
0.426 131% 34%

D
0.473 146% 44%

E
A-Single wire 0.583 179% 60%

*neglecting fixation, tyraps, connectors,

shields and braiding

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
12
7. Thermal Modeling (1) – cable geometry

 A flat cable is modelled as a vertical stack of horizontal

layers of wires inside a box shaped virtual braid

A
C

B
D

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
13
7. Thermal Modeling (2) – nodal network

 Flat cable thermal network

▪ contact conduction
▪ air conduction
▪ radiation
▪ convection

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
14
5. Thermal modeling(3) - convection

 Flat cable convection model

▪ Flat plate approximation, box shape model
▪ horizontal
▪ vertical
▪ Typical dimension scaling for area “effectively” exposed to
convection
▪ “effective width”
▪ “effective thickness”
▪ Linear correction factor for round surface of wires
▪ horizontal correlation factor
▪ vertical correlation factor

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
15
7. Modeling (4) - Results after correlation

 Statistics of the difference between the predicted and

measured cable temperature
Horizontal case
A-Single Wire B-Round C-3 Layers D-2 layers E-1 layer
|T| Min 0.00 0.47 0.57 0.09 0.25
|T| Max 1.44 3.20 4.12 5.95 4.12
T Mean 0.62 1.00 1.28 -0.72 1.10
T Standard dev 0.35 1.50 2.39 2.80 2.04

Vertical rotated case

A-Single Wire B-Round C-3 Layers D-2 layers E-1 layer
|T| Min 0.03 0.90 1.20 1.56 0.81
|T| Max 1.61 4.57 5.31 4.65 4.70
T Mean 0.22 2.67 3.92 3.50 3.07
T Standard dev 0.40 1.06 1.27 0.89 1.05

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
16
8. Conclusions and further work

Thanks to the work done in the frame of the NIPSE Project :

 The development of a innovativ e derating test facility
demons trated an improved performance of horizontal and rotated
flat cable samples with respect to the references sampl es (a singl e
wire and round cabl e) and with respect to the aerospace derating
standard AS5088 1.
 I ntroducti on of IR camera prov ed to be a valuable tool for
improv ed understanding of the test results
 The thermal modeling accuracy after correl ati on is ±6 o C.
 The derating of flat cables can be rel ated to the number of layers .
 For a 1 layer Flat Cable up to a 1.8 times higher current was found
in ambient air whi ch leads to a theoretical weight reduction of 60%.
 I t should be v erified with use cases how much of the predicted mass
reduction is achievable in practice.
 A n update of the aerospace derating standards to promote the use
of flat harnesses designs is recommended.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
17
9. References

Papers
1. Thermal analysis of wiring bundles for weight reduction and improved safety , AIAA
2011-5111, 41st I nternational Conference on Environmental Systems (I CES), 17 - 21
July 2011, Portl and, Oregon, USA, Roel van Benthem, Wubbo de Grave, and
Fennanda Doctor, Simon Tayl or, Kees Nuyten , Pierre-Alexis Jacques Dit Routier\
2. Derating Standards and Thermal Modelling Tools for Space Harness Designs, 45th
I nternational Conference on Environmental Systems (I CES ), 12-16 July 2015,
Bellevue, Washington, Seattl e, USA , Benthem, R.C. van; Doctor, F.; Malagoli, M;
Bonnafous, B

Upcoming papers (pending final acceptance )

1. Flat Cable Derating Tests and Thermal Modelling for Weight Reduction of Aircraft
Engine Harness Designs , Aegats ’18, Toulouse, 23 -25 October 2018, Roel. C. van
Benthem, Edwin. A Bl oem, Franck Al bero, Laurent Azemard
2. Improvement of the Wire Rating Standards based on TV Testing and Thermal
Modeling, 48th I nternational Conference on Environmental Systems, I CES -2018-162,
8-12 July 2018, Albuquerque, New Mexico, Marc Malagoli, Yoann, Allewaert , Roel
C. van Benthem , Wubbo de Grave , Adry van Vl iet, Denis Lacombe , Leo Farhat

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under
grant agreement No 636218
NIPSE Public Workshop, ILA Berlin, 26-27 April 2018
18
 NIPSE Project Coordinator
Iain Minton
Safran Nacelles
T +44 (0)1282 419362
iain.minton@safrangroup.com

NIPSE Project Office

Emmanuelle Da Silva
ARTTIC
nipse-arttic@eurtd.com

www.nipse.eu

This project has received funding from the European Union’s

Horizon 2020 research and innovation programme under
grant agreement No 636218 19