AI America Preview 2008 10/7/08 10:09 Page 16
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FIGHTING THE
COST OF FUEL
Innovations in interconnection technology help decrease weight and increase fuel
efficiency in commercial aircraft
With fuel prices having increased 40% over the optimize the composite shells for long-term weight levels.
last year, the Aerospace industry is looking ever reliability in conditions of shock and vibration, The challenge in aircraft data networks is to
more intensely for ways to shave off pounds to extreme temperature cycling, aircraft fluid harden proven land-based network systems to
increase fuel efficiency. immersion, and similar factors. work in the harsh environment on board the
aircraft. Such hardening also ensures all the
Cable insulations grow thinner various electrical interconnection components
Innovative cable designs are also a fruitful area work together to maintain signal integrity. High-
for saving weight. With as much as 350 km of speed coaxial Quadrax connectors and contacts
cable on a commercial aircraft, even the cable and various fibre-optic connector technologies
insulation adds considerable weight. Newer meet the needs of providing high data rates in a
insulation systems are as thin as one or two high-density connector.
sheets of paper. Reducing the insulation’s wall While Tyco Electronics has several connector
thickness even by an additional one-half sheet of packaging options available, rectangular
paper can save up to 20 pounds in wiring connectors remain popular because of the
harnesses. When measured against the long- industry’s familiarity with the form factor.
term fuel costs to run an aircraft, this weight Fibre-based interconnections are growing in
reduction is considered significant. popularity because of their unmatched high
As more of the aircraft’s systems move away bandwidth, inherent noise immunity, and light
from traditional hydraulic systems to “Fly by Wire” weight. Most aircraft use a combination of
systems, these weight savings become even copper and fibre for data networks. As new
more pronounced. Tyco technologies are applied, close collaboration
Electronics has reduced the insulation’s wall between aircraft manufacturers and suppliers of
thickness by 25% from the aerospace industry subsystems ensure smooth migration.
standards of today, but maintained the
mechanical and electrical performance that the Every ounce saved makes aircraft
Lightweight composites replace metal OEM aircraft manufactures need to maintain more efficient
Electrical interconnections are one area where the aircraft safety. The commercial aircraft industry combines a
airline industry is closely evaluating the potential tendency to use older, proven technology with a
for weight savings. New connector designs from Data networks increase bandwidth in high- desire for innovation to make planes more
Tyco Electronics are replacing the traditional density footprints efficient, capable, and reliable. Given that the
heavy metal shells with lightweight composite As with most networks, aircraft data networks lifespan of an aircraft can exceed 20 years,
materials, yielding weight savings of 20% to 30%. require higher speeds and higher interconnection decisions to change are not taken lightly. But
Composite shells can be plated in applications densities. The need to accommodate increasing suppliers like Tyco Electronics, by working closely
requiring protection from EMI and lightning strikes, amounts of data at high rates is driven by the with the entire supply chain, are creating the
while still offering significant weight savings over needs of In-Flight Entertainment Systems, by space- and weight-saving interconnection
their metal-shell counterparts. Electronic Flight technologies to lower operating costs and
The new composites have been tailored to Bags in the cockpit, and by advanced increase performance for the airline industry.
meet the stringent mechanical, environmental, computers and avionics throughout the aircraft.
and performance requirements of modern Higher bandwidths and interconnections
aircraft. Tapping their expertise in material densities allow higher throughput within the
science, Tyco Electronics has been able to existing footprint-while decreasing or maintaining Visit Tyco Electronics Booth 435
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