Preparation for the flight test of Airbus' advanced high-voltage battery technology, known as EcoPulse, is underway. This cutting-edge technology will push boundaries, not just for the upcoming test, but for future aviation endeavors.
Airbus has taken a significant step forward in the electrification of aviation with the development of a high-voltage Lithium-Ion battery system for its EcoPulse demonstrator. This battery, designed and built in-house by Airbus, is a critical component of the hybrid-electric propulsion system, delivering an output of 350 kilowatts at an 800-volt DC level.
The battery is the result of several years of research and development as part of Airbus' aircraft electrification and sustainability initiatives. Previously, less powerful high-voltage batteries were installed on the CityAirbus and Airbus Helicopters FlightLab. The EcoPulse battery, however, is a significant technical leap compared to traditional aircraft electrical systems, which operate at 28 volts in light aircraft and 115-volt AC in commercial airplanes [1].
The battery features several thousand Lithium-Ion cells and incorporates safety measures to prevent thermal runaway. It also includes an active cooling system to maintain optimal temperature during operation. This cooling system is crucial for ensuring the battery's performance and longevity.
The development of the high-voltage battery system was a collaborative effort between Airbus, Safran, and Daher. Safran led the design of the hybrid-electric propulsion system, Airbus provided the advanced flight control systems and high-performance battery, and Daher converted the TBM 900 turboprop platform for flight testing [1][2].
One of the challenges faced during the development process was designing a battery capable of operating at a much higher voltage than conventional systems. This required overcoming electrical and thermal management hurdles to ensure safety and reliability. Another challenge was integrating the high-power battery system with multiple electric motors in the wings, requiring seamless coordination between propulsion, energy storage, and aircraft control systems.
Despite these challenges, the EcoPulse project has achieved several notable accomplishments. The successful demonstration of the high-voltage, high-power battery system established a model for greener aviation technologies. The completion of extensive flight testing validated the battery's performance, resilience, and contribution to cleaner, quieter, and more efficient flight operations. The project also proved the feasibility of replacing traditional propulsion architectures with hybrid-electric systems in a small aircraft platform, marking a milestone in sustainable air transport development.
The high-voltage Li-ion battery is one of the enablers for decarbonizing future Airbus aircraft, along with wings, hydrogen, structure, and flight controls. It weighs around 350kg, can achieve 800 Volts DC, and can deliver up to 350 kilowatts of power. The battery is approximately 2.3m long, 75cm wide, and 20cm deep, and is mounted under the fuselage and integrated with a reinforced aerodynamic fairing.
The battery system also includes a tailored Battery Management System to minimize maintenance and monitor charge status. It is one of the two electric sources on the demonstrator, the other being an "e-Auxiliary power Unit" (e-APU) provided by Safran. Testing will evaluate the battery's performance, environmental, and safety attributes.
The high-voltage battery concept is a key 'technology brick' in Airbus' "micro-hybridisation" research, exploring the use of the battery's power level for an airliner's non-propulsive secondary systems. The battery system is unique in the aerospace and automotive industries due to its capabilities. The battery system will soon be subjected to testing in Toulouse according to stringent aeronautical standards.
Julien Laurent, Airbus Battery Project Leader, stated, "We started working on the high voltage Li-ion battery a few years ago and designed it entirely in-house. It's a pioneering element of the EcoPulse project, showcasing major advancements in voltage scaling and integration for hybrid-electric aviation, overcoming substantial technical and operational challenges through multi-company collaboration and rigorous testing."
EcoPulse is a registered trademark of Daher and is a collaborative project with Airbus, Daher, Safran, CORAC, and DGAC.
[1] Airbus (2023). EcoPulse: The Hybrid-Electric Aircraft Demonstrator. Retrieved from https://www.airbus.com/innovation/electric-and-hybrid-flight/ecopulse.html
[2] Daher (2023). EcoPulse: Hybrid-Electric Propulsion Aircraft. Retrieved from https://www.daher.com/en/our-innovations/ecopulse-hybrid-electric-propulsion-aircraft/
The battery, a significant component of the EcoPulse demonstrator's hybrid-electric propulsion system, represents the culmination of several years of Airbus' research and development in aircraft electrification and sustainability initiatives. In parallel with these efforts, Airbus has made strides in the finance sector, forging partnerships with Daher and Safran to drive innovation and sustainability in the technology industry.
