The critical role of advanced connectors
The future of urban mobility is unfolding before our eyes, with Electric Vertical Takeoff and Landing (eVTOL) aircraft set to redefine transportation. These aircraft, designed for rapid and efficient aerial mobility, depend on highly sophisticated electrical architectures to achieve optimal performance. Central to this architecture is the selection of connectors that facilitate the reliable transmission of power and data under extreme operational conditions. Here, Sean Fitall, European product manager at connector specialist PEI-Genesis, explores how to choose suitable connectors to meet the demands of modern aviation.
Connectors for eVTOL applications must meet a unique set of stringent requirements beyond those found in conventional aircraft. They have to balance high power density, compact design and lightweight construction, while supporting modular architectures for seamless integration with evolving powertrain technologies. For engineers, selecting the right connectors is essential to ensuring these aircraft perform safely, efficiently and reliably in the demanding environments they operate in.
Powering eVTOL
At the heart of eVTOL systems lies the need to manage high-voltage electrical power systems. These aircraft are typically powered by advanced lithium-ion or solid-state batteries, which require connectors capable of handling large currents while minimising power loss and heat generation. Given the high energy densities of modern battery technologies, connectors must facilitate the safe and efficient transfer of energy to the electric motors responsible for vertical and horizontal flight. In such high-voltage ecosystems, the risk of overheating and contact resistance is significant.
Connectors must be designed to minimise these risks by offering low contact resistance, efficient heat dissipation and excellent thermal conductivity. The design and material choice of connectors play a key role in preventing power loss, which can impact both performance and battery life. Engineers must select components that maintain low resistance over long service periods, ensuring maximum power efficiency and minimal thermal buildup.
Additionally, connectors must be capable of handling the mechanical stresses induced by rapid take-offs and landings. Vibration resistance is essential, as these forces can cause connectors to loosen or fail. Furthermore, connectors must operate effectively in systems that require rapid charging and discharging cycles without compromising performance, longevity or safety.
Durability and environmental resistance
eVTOL aircraft are subject to harsh environmental conditions during their operational lifespan. As such, connectors must be engineered to endure extreme temperatures, moisture, dust, UV radiation and electromagnetic interference (EMI). Precision-engineered sealing technologies, such as IP-rated enclosures and gaskets, prevent the ingress of environmental contaminants, ensuring that connectors remain fully functional even under adverse conditions.
Vibration and shock resistance are also crucial for connectors in eVTOL systems. Aircraft must maintain structural integrity and uninterrupted connectivity despite constant exposure to mechanical stress, both during flight and while on the ground. Ruggedised locking mechanisms, vibration-damping features, and advanced contact materials ensure that connectors remain secure throughout the aircraft’s lifecycle.
Moreover, EMI shielding is essential to prevent electrical noise from disrupting the delicate avionics and flight control systems of eVTOLs. EMI can lead to malfunctions in navigation, communication and control systems, potentially endangering flight safety. Connectors designed with advanced shielding and grounding techniques are therefore critical in maintaining operational integrity in challenging electromagnetic environments.
The importance of weight optimisation
Unlike traditional aircraft that rely on liquid fuel, eVTOLs must maximise every ounce of their energy storage. The heavier the aircraft, the shorter its range. Bulky or inefficient connectors contribute unnecessary weight, leading to performance penalties. The ideal solution integrates high-strength, lightweight materials like aerospace-grade aluminium and advanced composites, reducing mass without sacrificing structural integrity. Additionally, multi-functional connectors that consolidate power and signal paths into a single interface can significantly streamline design while reducing excess weight.
Safety and regulatory compliance
Safety and regulatory compliance loom large in eVTOL development. As these futuristic aircraft integrate into commercial airspace, their electrical systems must meet rigorous aerospace standards like RTCA DO-160 and MIL-STD requirements. This means connectors must exhibit arc resistance, fire retardancy and fail-safe mechanisms to prevent electrical faults. Redundancy is key; in the event of a failure, critical flight systems must remain operational to safeguard passengers and ensure successful mission completion.
Among the plethora of connector solutions, Amphenol’s Raptor range, offered by PEI-Genesis stands as a game-changer in eVTOL technology. Specifically engineered for high-power applications, these connectors boast industry-leading current-carrying capabilities, minimal contact resistance and top-tier thermal performance at altitude. Their lightweight yet robust construction makes them a perfect fit for eVTOL applications, ensuring that aircraft remain agile and efficient.
As eVTOL technology continues to evolve, the role of advanced connectors is increasingly crucial. From ensuring efficient power transmission in high-voltage systems to withstanding the harshest environmental conditions, connectors are vital to the successful operation of these groundbreaking aircraft. With an emphasis on durability, performance and safety, selecting the right components is crucial to achieving the level of reliability required for urban air mobility.
To find out more about the extensive range of connectors for eVTOL technology offered by PEI-Genesis or to read about Amphenol Raptor’s range of connectors, visit www.peigenesis.com.
