According to Vicor, power modules are key to driving new clean aviation initiatives for commercial airlines

Based on the commercial aviation data currently available, it is indisputable the demand for additional capacity in Europe and the world is a forgone conclusion. Airbus forecasts that by 2038 the average annual growth of commercial aviation will be 4.3% globally.

A clear consequence of the unstoppable growth of commercial aviation is the increase in the number of aircraft in service that is expected over the next two decades. As an example, in 2019 Airbus reported having 21,000 commercial aircraft in service and estimates that number will almost double by 2042 to a staggering 40,850 aircraft with an emphasis being placed on smaller passenger aircraft serving shorter regional routes (Figure 1).

Also, in Europe with the introduction and continued popularity of discount airlines, like Ryanair and easyJet, the increase in passenger traffic is the highest in every region. These short-haul, low-cost airlines are creating new regional routes and are expanding into smaller airports.

The willingness of low-cost airlines to move beyond the traditional model for additional growth is enabling them to give a real boost to the growth of European and global commercial aviation.

With all this growth comes increased noise pollution and greenhouse gas emissions that will contribute to global warming. Fossil fuels – coal, oil and gas – are by far the largest contributor to global climate change, accounting for over 75% of global greenhouse gas emissions and nearly 90% of all carbon dioxide emissions. Aviation emissions in 2022 reached almost 800 Mt CO₂. Harder to qualify is the noise pollution caused by aviation and its impact on local residence. Aircraft engines in aggregate produce gases, noise, and particulates from fossil fuel combustion, raising environmental concerns over their global effects and their effects on local air quality.

Cutting environmental impact

Based on the surging growth estimates it is vital for governments and private industry to come together to formulate a plan to manage this unprecedented growth responsibly.

The European Union's Clean Aviation Joint Undertaking (CAJU) is a testimony to this commitment, aiming to bring together public and private entities to foster breakthroughs in greener, cleaner aviation. Part of the charter is to “explore cutting-edge technologies that will make aviation climate-neutral by 2050.” One pivotal technology in achieving these objectives is the use of DC-DC power modules. Power modules enable superior design flexibility and are power dense and highly efficient in part because of their propriety planar packaging (Figure 2). An alternative to discrete power designs, power modules offer many advantages that reinforce CAJU's broader objective for being climate-neutral and an innovator in the space.

Optimizing energy efficiency

DC-DC power modules optimize the efficiency of power conversion in aircraft systems. By allowing for precise voltage regulation and reduction of power losses, power modules maximize the utilization of stored energy, which is significant for electric or hybrid propulsion systems. Power modules integrating Sine Amplitude Converter topology as part of a Factorized Power Architecture can deliver world-class efficiency in a small, compact package without sacrificing performance. Greater efficiency translates to longer flight durations and less environmental impact.

Scalable solutions for easier re-design and re-use

DC-DC power modules are a smaller, more compact alternative to discrete power supplies (Figure 3). They can be used in series, offering simple scalability when more power is needed. They can be easily integrated into various aircraft systems regardless of the aircraft size or complexity.

This flexibility is vital for the dynamic needs of the aviation industry, where aircraft designs can vary considerably. As the CAJU seeks to encourage innovation in diverse aircraft forms, from drones to commercial airliners, the scalability of DC-DC power modules becomes indispensable.

Lightweight, compact and power-dense - essential for mobility

Aviation, perhaps more than any other transport medium, is highly sensitive to weight and size. The compactness of modern DC-DC power modules minimizes aircraft's weight, allowing for more space for passengers, cargo, or additional green tech innovations. A lighter aircraft also translates to lower energy consumption, emissions, and longer duration. Power dense modules, on the other hand, provide the ability to efficiently convert high voltage down to load with little power loss.

Uncompromising reliability under rugged conditions

Safety is paramount in aviation. DC-DC power modules are renowned for their reliability, offering consistent performance even under arduous conditions. The semiconductor like approach to manufacturing power modules is a differentiator that builds higher quality into the Vicor modules. The packaging is unique and leverages 3DI (Three Dimensional Interconnect) technology to enhance overall performance. Power modules have been used for decades in aerospace applications for their long-standing reliability under the most rugged conditions. By ensuring stable voltage outputs and protection against potential electrical faults, these modules bolster the safety of the overall aircraft electrical systems.

Compatibility with advanced technology and systems

The era of green aviation is characterized by rapidly evolving technologies, from advanced sensing systems to autonomous flight controls. Many of these systems have specific power requirements that a modular approach to power can adeptly support. By delivering the proper voltage levels efficiently, these modules enable the smooth operation of a wide variety of cutting-edge, mission-critical sensors and technologies.

Cost-effective integration

Compared to complicated discrete power designs, a modular approach offers greater long-term benefits in terms of reduced operational costs, lower maintenance and extended lifespan. When evaluating total cost of ownership, modular power has a positive return on investment. This aligns well with CAJU's aim of promoting sustainable aviation solutions that are not just environmentally, but also economically viable.

The European Union's Clean Aviation Joint Undertaking is a monumental initiative, focused on creating a more sustainable future for aviation—one that operates in concert with the global environmental concerns. The success of this initiative relies heavily on available technology and the ability to safely harmonize innovations with the demands of commercial aviation. Green technologies are on the rise and more will form around solving this problem.

Today inroads can be made by designing better power systems that move beyond traditional discrete design methods, which cannot deliver the SWaP needed. More importantly, they cannot deliver the high efficiency, which directly effects the carbon footprint.

Vicor DC-DC power modules, on the other hand, with their myriad advantages from their compact size to their efficiency and reliability, are poised to play a central role in this green revolution to reduce greenhouse gasses. Embracing and investing in such technologies unleashes innovative potential that is needed to succeed in this daunting endeavor. High density power modules are an important component that helps pave the way for a cleaner, more efficient aviation future for Europe and the world.