Collins Develops Prototype High-Voltage Power Distribution Components for Clean Aviation SWITCH Engine

November 4, 2024

Collins Aerospace has developed prototype high-voltage power distribution components that will eventually be tested for system integration into the hybrid-electric engine demonstrator the company is developing as part of the SWITCH clean aviation project. The engine, pictured here, previously completed a preliminary design review in June. (Image: Collins Aerospace)

Collins Aerospace has completed prototype development of a solid-state power controller and power distribution panel as part of the SWITCH project, supported by the European Union's Clean Aviation Joint Undertaking (Clean Aviation). Following design and production in Nördlingen, Germany, the megawatt-class power distribution components will now be shipped to Collins' state-of-the-art electric power systems lab, The Grid, in Rockford, Illinois for system integration testing.

To support hybrid-electric propulsion systems, new high-voltage distribution technologies are required as electric power levels increase from hundreds of kilowatts in today's aircraft, to megawatt levels in the aircraft of the future. For SWITCH, RTX is developing a new hybrid-electric propulsion system that combines two Collins megawatt-class electric motor generators within a Pratt & Whitney GTF™ engine. With the ability to handle increased electric loads, Collins' solid-state power controller and power distribution panel will enable the safe management of high-voltage electricity at altitude throughout the SWITCH hybrid-electric architecture.

"Hybrid-electric aircraft are an integral part of the aviation industry's drive to achieve net-zero carbon emissions by 2050, yet without new, safe high-voltage power distribution systems, they will not fly," said Tino Schuldt, General Manager for Collins' Nördlingen facility. "Here in Nördlingen, we're leveraging our decades of experience in power distribution solutions and world-class facility to break new ground in the development of these critical enabling technologies for the next generation of hybrid-electric and all-electric platforms."

A Collins engineer works in the lab at the company's facility in Nordlingen, Germany, where they have developed prototype high-voltage power distribution components for integration into the SWITCH hybrid-electric engine. (Image: Collins Aerospace)

"The hybrid-electric propulsion solution is one of the key features offered by the SWITCH consortium to reach the CO₂reduction target of our programme for short-medium range aircraft," said Pierre Durel, Project Officer for SWITCH. "We are excited to see tangible technology bricks becoming available, representing the significant efforts made by the team to deliver critical items needed to run the ground test demonstrator by the end of Phase 1."

Hybrid-electric propulsion is a central pillar of RTX's sustainable aviation technology roadmap. In addition to SWITCH, RTX is advancing hybrid-electric technologies through multiple demonstrator programs applicable to a variety of future aircraft, including the RTX Hybrid-Electric Flight Demonstrator, STEP-Tech and Airbus PioneerLab.

Collins' solid-state power controller was initially developed as part of a collaboration between the RTX Technology Research Center, Collins and Pratt & Whitney under NASA's Advanced Air Vehicles Program.

The SWITCH project is a collaborative consortium including MTU Aero Engines AG, Pratt & Whitney, Collins Aerospace, GKN Aerospace, Airbus and others.

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