broughton EAP

The global airline market has suffered massive changes in the last decade as first the 9/11 attacks then spiralling fuel costs have taken their toll. Nowhere has this been felt more accutely than in the US where no longer can airlines justify large capital outlays and the emphasis is now firmly on efficiency rather than speed.

Originally announced in the late 1990’s as the Sonic Cruiser and to replace the 767, the Boeing 787 is the latest design from the American manufacturer and the first to address the latest industry requirements. It is a mid-sized, wide-body, twin-engine jet airliner which showcases the latest design techniques. By utilising more lightweight composite materials, aerodynamic imporvements, better engine design and advanced systems they hope to deliver almost 20% greater fuel efficiency than the 767.

One of these advanced systems is the new Wing Ice Protection System which has been developed as a collaborative project between Ultra Electronics and GKN Aerospace. As an independent electro-thermal system rather than the cumbersome engine air bleed system traditionally used it not only improves efficiency but offers greater and more accurate control.

When dealing with aeroplanes the importance of getting everything right before ferrying hundreds of people around the globe is obviously paramount. There are no margins for error and therefore any test process has to be very specific and above doubt. Part of the test procedure for the new Wing Ice Protection System involved the use of load banks and it was for this that Broughton was approached.

The load bank was required to replicate and very accurately mimic the ‘real’ load that the Wing Ice Protection System power source will see in actual application. However, unlike a ‘real’ load which can sometimes be unpredictable and random the new load bank has to deliver a managable, constant load. The load also needed to be fully controlled, as did its dissipation.

Together engineers from Broughton and Ultra Electronics have, using our 3 phase heater designs as a template, developed a new load bank system to suit these very specific requirements. The new system operates within tolerances as tight as plus/minus 1 Ohm and Broughton has turned them around in super-quick time. They will be operational at Ultra’s Cambridge plant next month, helping to ensure the safety of millions of pasengers over the coming years.

With a reputation as a specialist in the design and manufacture of bespoke electric heating and refrigeration equipment, Broughton has a history of working with some of the worlds most high profile organisations. From Aston Martin to Coca-Cola and even the Atomic Weapons Establishment Broughtons engineers have developed numerous solutions for all manner of unique and unusual applications. Being involved in something as special as a new airliner further enhances this reputation and demonstrates the companys commitment and ability to produce quality equipment, wherever and whenever it might be required.