A Review of Electrical Insulation Challenges for Electrical Powertrain Components in the Future More- and All-Electric Aircraft Under Low-Pressure Conditions

Abstract

Over the past few decades, a significant amount of research has been conducted on the electrification of commercial aircraft, aiming to substitute mechanical, hydraulic, and pneumatic systems with electrical alternatives. The objective is to attain a state of net-zero emissions by the year 2050. Most greenhouse gas emissions in the aviation industry, specifically over 75%, are attributed to the operation of large aircraft, encompassing both narrow- and wide-body models. Because of the average 4%–5% annual growth in air travel, this situation is expected to become much more difficult. The next-generation more-electric aircraft (MEA)/all-electric aircraft (AEA) will be a promising solution for solving these difficulties. The forthcoming MEA/AEA is anticipated to operate at a higher voltage level, facilitating the transmission of significant electrical energy. Higher voltage poses a serious risk to the insulation systems of the electrical components. Extreme damage to insulating systems will occur in high-altitude regions under low-pressure conditions, resulting in accelerated aging and degradation and, eventually, system failure. Insulation failure is responsible for over 85% of equipment failures, as indicated by statistical data. This article provides a critical overview of the insulation challenges faced by MEA/AEA, particularly under low-pressure circumstances. The insulation challenges associated with electric machines (EMs), cables, and printed circuit boards (PCBs) and the future solutions to mitigate these challenges are discussed and analyzed in this article.