Aircraft EWIS high voltage testing considerations

March 21, 2014 Michael Traskos

There are two factors that need to be considered when using aerospace wires/cables for higher voltage systems: (1) Determining the long-term insulation life impacts of high voltage utilization, and (2) the impact that high voltage testers may have through repeat high potential testing. In this article we will focus on the second factor. Read more

High voltage systems on aircraft

May 24, 2013 Michael Traskos

Aerospace Information Report (AIR) 6127 currently being developed by the SAE AE-7 committee provides a framework for designing high voltage subsystems utilized for More Electric Aircraft (MEA). The AIR identifies design risks, mitigation techniques, and testing methods for MEA. Electrical discharges on MEA are a potential risk that should be mitigated through careful design and […] Read more

RF High Potential Withstanding Voltage

This test measures the ability of a high frequency connector to withstand a specified RF voltage and frequency. The connector is mated to the appropriate receptacle and connected to the test circuit. A specified RF voltage and frequency are applied between the center contact and the connector body, stabilized, and maintained for one (1) minute. […] Read more

Developments in High-Voltage

May 10, 2017 Michael Traskos

The first meeting of the 8A and 8D committees for 2017 was held in Kissimmee Florida in April 2017. There were several topics discussed and voted upon that will have an impact on future wire component and system designs (previous article on SAE 8A/8D committee meeting available here). One common theme in the meeting was […] Read more

Voltage, Current, and Thermally Rating Connectors

September 13, 2023 Michael Traskos

While electrical component qualification is nothing new to the aerospace industry, the emerging trend toward full aircraft electrification requires every component to be electrically connected; for most equipment, this means incorporation of electrical connectors. Weight, cost, reliability, and performance are the four most common elements initially considered in connector selection, but the finer details of electrical connectors use must also be considered. Here, we discuss how one might go about qualifying an electrical connector, specifically, to address its voltage, current, and thermal limitations. Read more

Determining Voltage Drop

October 11, 2019 Michael Traskos

If voltage is applied to a circuit and the attached equipment does not turn on, then there is an issue with either the circuit or the applied voltage (assuming the device is fully functioning). Sometimes glossed over in circuit design, the length and gauge of a wire can impact the voltage to the load; this is known as “voltage drop”. Just as the current carrying capacity of a wire/wire harness is impacted by the system and environment, so too is the voltage drop.

In this article, we go over the idea of voltage drop, guidance on its application in design, and an example of quantifying the voltage drop on a wire/cable.

Dielectric Withstand Voltage

The dielectric withstand voltage (DWV), sometimes referred to as the “Voltage Proof Test” or “Wet Dielectric Test”, is perhaps one of the most referenced tests when examining wires. The reason is that the test performs the most important part in wire insulation assessment: it determines if the wire insulation is free of breaches (or has […] Read more

Dielectric Withstand Voltage – Connectors

The connector is among the most vulnerable parts of the electrical system to the dielectric breakdown. The repeat mating and demating of connectors can wear couplings and pins and can introduce damage to the protective insulating inserts as well as contaminates. This test examines a connector’s dielectric strength at a given voltage level. In particular, […] Read more

Corona Extinction Voltage

High voltage spikes onto wires/cables can progressively degrade the insulation performance and lead to an insulation breach and/or create conductive paths through the insulation. Wires/cables with consistent insulation systems and without air gaps or voids in the insulation will typically have a higher corona inception voltage and a higher extinction voltage. The higher the voltage […] Read more

Creepage and Clearance

October 13, 2023 Chris Wollbrink

High voltage systems on aircraft will be more commonplace as the eVTOL market “takes-off.” One safety aspect that often comes up is the separation of the high voltage; often, this comes down to creepage and clearance distance of these systems. Read more

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