Bombardier Aircraft Executes Technology Demonstration Flight in Alaska

June 20, 2011 — Paris
Aerospace

Bombardier Aerospace today announced the completion of another milestone in the execution of its Strategic Technology program for civil aviation: a Bombardier Global 5000 test aircraft executed a series of flight tests in known icing conditions equipped with a composite electro-thermal wing leading edge ice protection system.

“One of Bombardier Aerospace’s strategic priorities is to develop innovative, environmentally conscious products that meet customer needs globally, and we take great pride in this commitment to aircraft innovation,” said François Caza, Vice President and Chief Engineer, Bombardier Aerospace. “These successful flight tests highlight Bombardier’s commitment to the advancement of aviation technology. They are part of a comprehensive technology development program covering various areas, including avionics, aircraft systems, advanced structures and advanced manufacturing methods,” he added.

The Electro-thermal Ice Protection System (EIPS) flight testing lasted in excess of 35 hours, seven of which were completed with the Electro-thermal Ice Protection System selected “on” in both dry air and natural icing conditions. The main components of the EIPS are a Meggitt thermal solution with a Fokker advanced material leading edge slat structure, incorporating Meggitt heaters and ICE Corporation controllers. Extensive wind tunnel and icing tunnel tests were conducted beforehand to support in-flight safety.

On board the test aircraft were Sam Gamar and Frank Magnusson, Engineering Test pilots; Jeff Hyde and Laura Hilboldt, Flight Test engineers and Eduardo Freitas and Kheira Aboubi, Thermodynamics engineers.

“We tested the EIPS in both dry air and natural icing conditions south of Anchorage, Alaska, with great success. The system demonstrated structural integrity and successful ice protection performance as anticipated from a more efficient electrical system,” said Peter Rawlinson, System Lead engineer, Bombardier Aerospace.

“The demonstration of an Electro-thermal Ice Protection system is one step further towards a “More Electric Aircraft” that will have electrical power as the primary means to operate systems normally driven by less efficient engine compressor bleed air,” said Avraham Ardman, Chief Systems engineer, Bombardier Aerospace.

Less than two years ago, Bombardier successfully flight-tested an all electric braking system. This time, Bombardier’s strategic technology demonstrator aircraft was modified by removing the bleed air ducting and leak detection system from the most outboard slat, an eleven-foot-long span, on both wings. In their place, an electro-thermal composite leading edge, incorporating Meggitt heaters and an associated power harness, was installed on each wing.

The key benefits of this new technology are: an expected increase in aircraft dispatch reliability; elimination of bleed-air ducting, valves, and leak detection associated with hot bleed air duct failures. The new technology will simplify the aircraft manufacturing and assembly processes and lead to reduced maintenance costs for operators. It will also save energy and reduce aircraft emissions, leading to a more environmentally conscious product.

About Bombardier
A world-leading manufacturer of innovative transportation solutions, from commercial aircraft and business jets to rail transportation equipment, systems and services, Bombardier Inc. is a global corporation headquartered in Canada. Its revenues for the fiscal year ended January 31, 2011, were $17.7 billion, and its shares are traded on the Toronto Stock Exchange (BBD). Bombardier is listed as an index component to the Dow Jones Sustainability World and North America indexes. News and information are available at www.bombardier.com or follow us on Twitter @BombardierInc.

Notes to Editors

* Follow @Bombardier_Aero on Twitter to receive the latest news and updates from Bombardier Aerospace.
* To receive our press releases, please visit the Email Subscription and RSS Feed section.

Bombardier and Global 5000 are trademarks of Bombardier Inc. or its subsidiaries.

For Information
Haley Dunne
Bombardier Aerospace
+1 514 573 7124

www.bombardier.com

WheelTug 'Front-Wheel Drive' for Airplanes Improves Aviation Ground Operations

June 20, 2011 22:02 ET

PARIS--(Marketwire - Jun 20, 2011) - The revolutionary onboard electrical drive system for aircraft being developed by WheelTug plc has stimulated aerospace industry efforts to revamp ground operations. Recent developments are being unveiled at the Paris Air Show this week.

The WheelTug system brings front-wheel drive to aircraft, with twin electrical motors in the nosewheels giving aircraft greater maneuverability and efficiency during ground movements such as reversing from a gate and taxiing to a runway, as well as reducing fuel consumption and emissions.

New to WheelTug's display space at the Paris Air Show (Hall 4-5, Booth G10) is the latest WheelTug unit, designed for narrowbodied aircraft such as the Boeing 737NG and Airbus A320. WheelTug is also showing a hands-on demonstration WheelTug cockpit control panel by which the pilot will be able to control the system and maneuver the aircraft on the ground. The WheelTug team has been working on developing WheelTug's system design over the past year, and moving towards certification and entry into service.

While independent ground maneuverability by aircraft has long been an industry dream, WheelTug's innovative engines-off taxi technology is becoming a widespread industry expectation in the near future, far sooner than government-devised industry roadmaps projected.

A new European Union agenda for the aeronautics industry, called Flightpath 2050 and set by the European Commission on Mobility and Transport, calls for aircraft to be emissions-free during taxi by 2050. WheelTug, which first demonstrated proof of concept hardware allowing taxiing without engines in 2005, expects to conduct on-aircraft tests within 6 months and to introduce the system into service in 2013.

"WheelTug will deliver in 2013 what the E.U. has set as a target for 2050," said Isaiah W. Cox, the company's president. "We are pleased to have successfully guided the industry here, first by demonstrating that the technology is viable and then by showing that the system's overall operating cost savings well exceed $500,000 per year on a typical narrowbody aircraft."

Now that WheelTug has proven both the concept and its potential value to the industry, several competitors have emerged. Taxibot is a pilot-driven tug system primarily for use on larger aircraft. The German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) have shown an in-wheel design for use on the A320. And just this week, Safran and Honeywell announced a joint venture to offer an engines-off taxi solution in 2016.

The patented and proprietary WheelTug® electric drive system uses high-performance electric motors, installed in the nose landing gear wheels of an aircraft, to provide full mobility while on the ground without the use of the aircraft's jet engines or tugs for both pushback and taxi operations. WheelTug enables aircraft to be electrically driven from the terminal gate to the takeoff runway, and upon landing from runway exit to the gate. The resulting improvements in efficiency, flexibility, fuel savings, and reduced noise and engine foreign object damage (FOD) yield projected savings of more than $500,000 per aircraft per year, plus substantial reductions in CO2 and other greenhouse gas emissions.

The WheelTug system is being developed initially for the Boeing 737NG, one of the world's most widely-flown aircraft; systems for other commercial and military aircraft will follow. WheelTug is developing the system with a team of partner companies capable of providing airlines with fully-operational systems years ahead of any competitor.

Forward-Looking Statement: http://www.wheeltug.gi/fls.shtml
 

GIBRALTAR--(Marketwire - April 27, 2010) - ICE Corporation, a leading designer and supplier of electronic controls for aviation, will design, develop and build the controllers for the aircraft on-ground electric drive system being developed by WheelTug plc, the companies announced today.

WheelTug® is a unique concept in aircraft ground operations. This patented hybrid-electric drive system incorporates high performance electric motors installed in the nosewheels of the aircraft, providing full mobility on the ground without the use of the aircraft engines or tugs for pushback and taxi operations. WheelTug® enables aircraft to be driven without using their engines from the terminal gate to the runway, and from runway exit to the gate, upon landing. The resulting improvements in efficiency, flexibility, fuel savings, reduced engine FOD damage and CO2 emissions yield projected savings of more than $500,000 per aircraft per year.

Manhattan, Kansas, April 27, 2010 - ICE Corporation announced its decision to join the WheelTug® team from its corporate headquarters in Manhattan, KS. The WheelTug® system is an innovative new patented hybrid-electric drive system incorporates high performance electric motors installed in the nosewheels of the aircraft, providing full mobility on the ground without the use of the aircraft engines or tugs for pushback and taxi operations. WheelTug® enables aircraft to be driven without using their engines from the terminal gate to the runway, and from runway exit to the gate, upon landing. The resulting improvements in efficiency, flexibility, fuel savings, reduced engine FOD damage and CO2 emissions yield projected savings of more than $500,000 per aircraft per year.

Randy O'Boyle, ICE President and CEO, said, "The ICE Corporation has a 30+ year history of entrepreneurship in aviation. Our innovations in power electronics and high power control for aviation makes us the perfect partner for this tremendous new aviation product. We're excited to join the WheelTug® team in leveraging this new technology to reduce aviation fuel costs and improve operating efficiencies while economically making the planet a safer place. Years from now, people in the industry will be saying, "Why didn't we think of that?".

Isaiah Cox, WheelTug President and CEO, said, "ICE is the perfect partner; as an organization they are a pleasure to work with, and their engineering skills are unparalleled. We have no doubt that WheelTug® customers will benefit from such a reliable, robust, and lightweight controller."

WheelTug is moving rapidly, with its partners including ICE, in development of the system. Final specifications for the initial 737NG model are expected to be available to potential airline customers within the coming months. Systems for other aircraft types will then be developed as rapidly as possible. In addition to ICE, WheelTug is working with Luxell Technology and Co-Operative Industries as partners for the cockpit interface and wire harness, respectively.

ICE Corporation, based in Manhattan, Kansas, designs and manufactures precision electronics components for the aerospace, automotive, industrial and agricultural industries.

WheelTug plc, based in Gibraltar, is developing the WheelTug® electric drive system to move aircraft on the ground. WheelTug is a majority-owned subsidiary of Chorus Motors plc (UOTC: CHOMF). Forward Looking Statement may be found at http://www.chorusmotors.gi/fwdlook.shtml.

Randy O'Boyle
President
ICE Corporation
785-776-6423
randy@ice-ks.com

Isaiah Cox
President
WheelTug plc
410-419-0082
Isaiah@wheeltug.gi

French Defense Contractor Ratier-Figeac and its parent, U.S. company Hamilton-Sundstrand, were found to have intentionally misappropriated trade secrets in a case involving the new A400M Airbus military transport. The jury in U.S. District Court in Topeka, Kansas, found in favor of ICE's claim that the French company's termination of ICE was wrongful and in violation of the duty of good faith and fair dealing which is part of every contract. ICE had been contracted to design the deicing controller for the aircraft's propeller system.

ICE recently held its annual employee appreciation picnic. ICE employees and their families enjoyed a beautiful Manhattan afternoon at Tuttle Creek State Park while eating hotdogs, hamburgers, and side dishes. Congratulations goes to Sam Smock who won the dessert-making contest and dethroned the reigning champ Stuart Bachamp in a narrow victory. ICE will continue to host regular employee appreciation events to display our continued commitment to retaining an experienced workforce that is dedicated to quality.

ICE received a formal patent for a "System & Method for Providing Power & Control Through a Rotating Interface". This patent was formally issued today on Tuesday April 8, 2008 by the US Patent Office and was assigned US Patent Number 7,355,302. Arlie Stonestreet II, the Director of Engineering for ICE Corporation in Manhattan, KS, along with Hardware Design engineer Darin Genereux and Software Design engineer Harold Kraus, were awarded the patent on ICE's behalf for their outstanding work in solving a design solution for propeller aircraft or other rotating component equipment that requires intelligent power transfer through the rotating interfaces. This technology is key to future development of new de-icing and power control technologies.

ICE has U.S. and foreign patents pending in the area of ice protection relating to power and control. This patent originated out of ICE's engineering and development efforts in ice protection and provides significant advantages over competing solutions. More specifically, the patent concerns minimizing the number of conductors across the brush-block/slip-ring assembly, while still being able to provide electrical power and control, thus achieving an ice protection system with increased flexibility. For example, a propeller requiring control and sequencing of multiple heater zones can be realized with a slip-ring brush block assembly containing as few as 2 or 3 conductors. This method can be adapted to any power supply, either DC or AC -- including fixed or wild-frequency, 3-phase or single-phase. Additionally, this method is compliant with the new aircraft power quality requirements (i.e. harmonics and power factor) as well as all applicable EMC requirements (RF susceptibility and emissions).

Robert Keim joins the ICE engineering staff to assist in the design, development, and testing of new products. Robert is a graduate of the University of California - San Diego and worked at General Atomics for 3 years where he was involved in the detailed design of several advanced aerospace related projects prior to moving to Kansas to join the ICE Engineering Staff. Robert has an exceptional design and technical background, with familiarity in many of the common aerospace standards and requirements. He is experienced in analog, digital, and mixed-signal hardware design and is proficient in embedded system design. As ICE continues to expand its engineering capacities, finding other exceptional engineers for electrical engineering job opportunities in Kansas (where quality of life is rated "top 10") will continue to be a strategic company priority.

James Mevey, Engineering Masters Candidate, joins the ICE engineering staff as part of an exclusive research program in conjunction with Kansas State University for the development of high-performance sensorless Field Oriented Control (FOC) of electric motors. This research builds upon ICE's prior experience in the area of BLDC (Brushless DC) motor control for use in high-performance aerospace applications. FOC control, also known as Vector Control, realizes further improvements in motor control by providing increased motor efficiency and operating torque than is achievable with conventional control solutions. FOC control promises to benefit ICE customers by squeezing more power from an existing motor, or alternatively allowing the use of a smaller sized motor to provide equivalent performance at a reduced weight. Additional benefits of FOC include better dynamic load response, enhanced startup capability, and lower torque ripple.

The use of brushless motors is finding increasing use in More Electric Aircraft (MEA) such as the new Boeing 787 Dreamliner and the Airbus A380. ICE's prior motor control developments along with our research into FOC positions ICE for providing high-performance and cost competitive motion control solutions for aerospace and other high tech power intensive industries.

ICE Engineering currently has solid-state designs in development capable of controlling in excess of 75kW of power. These systems are being designed for the new More Electric Aircraft (MEA). To manage this high thermal load the solid-state power devices are mounted to a custom designed and thermally optimized heatsink power assembly. The power assembly utilizes ICE's own proprietary designs for low conduction loss while providing compliance to strict EMC and Power Quality requirements. The design is fabricated using a high performance Insulated Metal Substrate (IMS) assembly to achieve a high-density and high-power design with superior thermal conduction resulting in reduced size and weight of the heatsink assembly. The thermal interface between the IMS assembly and the heatsink is achieved with a high performance phase-change material. At the phase change temperature the thermally conductive film changes from a solid and begins to flow, maximizing wet-out of the thermal interface and optimizing thermal transfer. The phase change interface is applied in sheet form with a uniform and metered layer of phase-change material. The use of IMS combined with the phase-change thermal interface creates unrivaled thermal performance by providing the absolute minimum thermal resistance between the solid-state devices and the heatsink. The IMS process used by ICE is able to thermally outperform thick-film hybrid, metalized ceramic, and even Direct Bonded Copper (DBC) to ceramic processes. Furthermore, ICE can process the IMS circuit assembly using existing in-house automated high-speed manufacturing processes and equipment, reducing manufacturing costs and increasing production quality and yields.

ICE plans to apply this technology to its next generation of high-performance solid-state Ice Protection Controllers as well as to their motion control platforms of various sizes and capacities

ICE has recently added a number of burn-in chambers to the Environmental Test Lab thus further increasing their test capacity. Looking towards the future, ICE has once again expanded its test capacity. With more and more suppliers requesting a lean supplier network with minimum delays, ICE has responded to the call. Increasing in-house test capacity eliminates shipping and test scheduling delays routinely seen when out-sourced test labs are required for verification. ICE will continue to expand test capacity to meet every customers need.

JICE recently invested in the necessary EMC equipment (Spectrum Analyzer, Current Probes, LISN's, etc.) to perform in-house pre-compliance testing of conducted emissions. Pre-compliance can now be carried out to determine the conducted emission levels as required in standards such as DO-160, MIL-STD-461, and DEF STAN 59-41. With this added capability, ICE can now perform pre-compliance tests to DO-160 Sections 4, 5, 7, 8, 16, 17, 18, 19, and 21. This capability gives ICE additional assurance in the integrity of a design prior to performing formal qualification testing at an independent test laboratory.

ICE Corporation, Manhattan, Kansas won kudos for exceptional manufacturing processes and passed the AS9100 inspection with no noted nonconformities. The aviation industry is a quality driven, self-policing engine of excellence. Major industry suppliers, both large and small participate in a system of scrutiny, which benefits consumers of aviation products top to bottom. ICE has been an aviation supplier for 27 years. The 2007 audit noted that even with a sales increase of 62% over last year, management continues to show a strong commitment to quality. From excellent training records to excellent management review ICE passed with flying colors (no pun intended). The inspector noted, "the relationship between the various aspects of your organization, such as functions and processes appears to be enhanced by the excellent record keeping…design records are outstanding…production documentation is outstanding…all very well organized and readily available." For customers looking for a top tier supplier with a quality design and manufacturing capability, the 2007 AS9100 inspection is just one more validation of the excellence demonstrated daily at the ICE Corporation.

ICE recently invested in High-Power Variable Frequency 3-Phase AC power sources allowing for development and testing of systems that must be compatible with the newer Variable Frequency (also known as Wild-Frequency), supplies common on the new more Electric Aircraft such as the new Boeing 787. ICE is constantly exploring innovative technology to solve power control solutions. Whether for the newest business jet power control applications or for intricate requirements like the Army's new Future Combat Systems (FCS), ICE is a field leader in solving complex power control requirements. Decades of experience in aircraft deicing control, coupled with unique electronic engineering design and manufacture for the automotive, agriculture, and veterinary medicine industries has positioned ICE for future growth. A small but extremely capable company, ICE boasts not having lost one customer in its 34 year history.

ICE uses National Instrument's LabView and TestStand software to perform automated Functional Testing and Automated Data Logging. Always responsive to customer requirements, ICE routinely upgrades its engineering design capabilities with the newest industry advancement. Use of LabView for functional testing and automated data logging ensures ICE designs are always on the cutting edge and of the greatest reliability.

ICE recently installed a new Kayto 3-Phase AC generator capable of supplying in excess of 50kW of 400Hz power for testing. This new 400Hz generator allows for exact aircraft-like power sourcing, providing accurate reliability testing at the manufacturing source for products including those to elite customers like the U.S. Navy, AgustaWestland, Parker Hannifin, and Meggitt Thermal Systems. Part of a new lean design initiative on the part of ICE's design bureau (the technology incorporated into its new line of deicing controllers) are controllers like those supplied to the U.S. Navy which are tested for over 200hrs on associated custom designed test jig to ensure maximum reliability of delivered products. ICE sets the gold standard for reliable aircraft electronics.

A Thermotron F-12 AGREE Temperature chamber was recently added to the Environmental Test Lab at ICE. The temperature chamber uses two large water-cooled compressors and boost heaters to achieve rapid temperature transitions between hot and cold without requiring the use of liquid nitrogen. This is an important part of the production Environmental Stress Screening (ESS) that is being required for many new aerospace designs. The chamber is equipped with a programmable controller and is able to interface with the central lab computer for automated control and data logging of the required test profiles. This new addition has allowed ICE to screen more thoroughly resulting in better performance for aerospace designs. The core of ICE's business model is the design, manufacture, and comprehensive testing of aviation electronics. This one stop shop model is a tremendous benefit to aircraft OEM's as it eliminates the inefficiencies and conflicts between the design houses and the manufacturing companies. ICE's Lean Design Electronics for aerospace result in cost efficiency and on time arrival to customers. The in-house testing capacity provided by ICE's ever expanding test lab ensures the customer gets an aerospace electronic product that will stand the test of time.

An Unholtz-Dickie electrodynamic vibration table was recently added to the Environmental Test Lab. The vibration table is capable of customized Swept-Sine and Random vibration profiles as well as Classic Shock testing. The random vibration capability is an important part of the production Environmental Stress Screening (ESS) that is being required for many new aerospace designs. In addition to production ESS testing, the vibration table can also be used for performing many of the shock and vibration profiles required for qualification to such standards as DO-160 and MIL-STD-810. Accurate vibration profiling is important to todays OEMs. With the addition of the Sikorsky S-92 deicing controller to its list of design and manufactured parts, it became apparent the adverse operating environment this tremendously capable 21st Century helicopter was designed to operate in would require the utmost in sophisticated reliability testing. Procurement of the Unholts-Dickie table in addition to other upgrades have helped to ensure the Sikorsky S-92, an all-weather, business and commercial industrial helicopter, will handle environments like those in the North Sea Oil Fields without hesitation. The ICE controllers designed and built for the S-92 will be equally capable if this aircraft is selected for the new USAF CSAR replacement helicopter.

ICE upgraded their previous AutoCAD® software 2D drafting system with Dassault Systemes SolidWorks® 3D software. This CAD system provides ICE with solid modeling capabilities and allows for model exchanges with CATIA, Unigraphics, and other common solid-modeling platforms such as STEP and IGES. The solid-modeling capability speeds development and manufacturing times, ensures proper form and fit prior to manufacture, and facilitates weight optimization by providing accurate weight information.

Stratford, CT - Sleek and powerful, the new Sikorsky S-92 elegantly rose into the air to the delight of the throngs of employees and guests. The cheers and salutations echoed all the way back to ICE Corporation in Manhattan, Kansas, where a dedicated team of electronic engineering designers and manufacturing employees reveled in the successful completion of yet another sophisticated engineering project. For ICE the project began in 1994 when technology was sought for state of the art aircraft engine deicing equipment. Partnering with Dunlop Aviation for the engine deicing system, ICE's design and manufacturing team developed, tested and manufactured electronic controllers providing the new S-92 Sikorsky helicopter with key components of its comprehensive deicing system. Designed in part for flying in the rough and treacherous weather of the North Sea, the S-92's flying specifications demanded the highest technology and reliability available. Offering the most advanced technology in the industry, the S-92 is destined to be a market leader in offshore oil, head of state, VIP, and search and rescue operations. In that light it was no surprise the ICE Corporation was involved. ICE has a long history of aviation design. Producing its first electronic controller for Cessna nearly 25 years ago, ICE continues to be an industry leader in sophisticated electronic engineering for the aircraft industry.