High-speed data transmission

Due to an ever-increasing functionality, more and more data need to be exchanged within the avionic system. The solution to this requirement without increasing weight and cabling complexity was to evolve the avionic architecture towards the use of Ethernet to connect the flight control system together within one network. To achieve this major change, SOURIAU, along with airframe and equipment manufacturers, developed a new technology of contacts perfectly suited for this new environment. The quadrax contact, in a very small space, enables the transmission of a high-speed (100 Mbps) fullduplex (both directions) Ethernet signal, without any data loss. This superior performance also offers a 50% size reduction over conventional wiring solutions. Therefore, cost of ownership and installation are reduced.

Moreover, the ever-increasing need for services to passengers, especially video on demand, requires more and more bandwidth. In this respect, a major step forward has been accomplished: AIRBUS chose fiber optics for the backbone of the IFE (In-Flight Entertainment) network as well as for all the video applications (CMV – concentrator Multiplexer Video, CVMS – Cabin Video Monitoring System, ETACS – Enhanced Taxi Aid Camera System). SOURIAU participated in this technological revolution by developing a high performing solution of optical contacts and connectors. Currently, there are more than 700 ELIO® optical contacts on board each A380.

High-speed technologies are now commonly used for new aeronautical developments, in civil and military platforms. For that reason, the quadrax and ELIO® contact have been standardized, and are now known worldwide as Arinc 664 and Arinc 801.

High-power transmission

One of the key issues in today’s development of new aeronautical programs is weight reduction. This can be addressed by different means: the use of composite materials, the reduction of cables thanks to network technologies, … One of the paths followed in the process of designing new civil aircrafts is the replacement of the hydraulic power (hydraulic circuits managing thrust reversers, slat flaps, breaks) by electrical motorized actuators. Not only has this replacement permitted to drastically reducing weight (elimination of hydraulic pumps, pipes and fluids) but also to increase reliability. Actuators either electro-hydraulic or electro-mechanical installed directly on the equipment to control (flat slap, thrust reversers, spoilers …) have replaced the secondary hydraulic circuit.

The installation of such a type of actuator implies a huge power supply (60 to 80 Amps) within very harsh environments in terms of temperature and vibrations (wings, tails, engines). To answer this issue, SOURIAU has extended its standard aeronautical ranges to high power applications. This range extension went through the full qualification of a new concept of power contact for the standard ranges MIL DTL 38999 and EN 2997. These product lines are now qualified to withstand 80 Amps per contact at 260 °C in a high vibration environment while conforming to demanding specifications. To achieve such extreme requirements, SOURIAU worked closely with its customers in order to create new aging tests. The socalled HALT test makes it possible to guarantee excellent quality of the products throughout the life of the program. These products are now widely used on A380 systems such as thrust reversers manufactured by HISPANO SUIZA, spoilers (LIEBHERR) and flaps (GOODRICH). This trend is confirmed by projects of “full electric” engines and need for power contacts to withstand more demanding environments, higher temperature and more intense vibration.

Composite materials use

In order to decrease aircrafts operating costs, weight reduction is a key factor. Thus every new aeronautical program monitors the ratio of composite materials used in manufacturing. Composite materials are increasingly used, for external structures as well as interconnection solutions. SOURIAU has worked for several years on the subject of composite materials and now masters the suitability of the best materials with the molding and metal-plating processes. Its high quality of plating enables SOURIAU to offer products with very high shielding performance and exceptional durability.

Moreover, SOURIAU actively supported BOEING in the definition of the required performance for the composite connections of the Dreamliner 787. It should be emphasized that the use of composite materials for the external structures of airplanes exposes all the internal components (flight systems, connectors,…) to new and severe conditions, such as lightning strikes inducing extremely high current. Through tests defined with the airframe manufacturers, SOURIAU proved that its metal-plated composite MIL DTL 38999 connectors can be used in this new challenging environment and guarantee excellent performance over the life of the products (shielding, resistance to lightning currents up to 10000 Amps, chemical resistance,…). After several months of testing, BOEING awarded SOURIAU a supply contract for the MIL DTL 38999 series III composite connectors for the 787 Dreamliner.