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.

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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).

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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.

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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.

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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.

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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.

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ICE 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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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