looms can equally suffer degradation. Installation practices too, affect the condition of wiring in operational aircraft; sharp bend radii, improperly supported wire, mixed insulation types and poor routing of high and low power circuits in the same bundle, all exacerbate the known environmental effects.

Wire in Composite (WiC) from Norfolk-based BERU F1 systems is an innovative technology that could provide the solution. Highly regarded for its work in designing durable electrical systems, notably for highest echelons of motor racing, the company believes this latest technology offers the aerospace industry weight, package and reliability benefits. Originally conceived by the company for Formula One racing cars, WiC completely encloses the wires in a composite sleeve, protecting wiring assemblies against damage caused by vibration and harsh environmental conditions. In addition, the technology reduces packaging size by laying wires securely side-by-side as opposed to a traditional bundle.

The firm has successfully demonstrated through the production of prototype parts that WiC looms can be constructed to virtually any shape or form, creating a durable harness that, in many instances, could replace the structure that it would have originally been secured to. The result is a simpler and lighter component with improved durability, even in harsh conditions. Keen to present the many opportunities for this technology, BERU F1 systems' engineers have demonstrated that complex routing and tight bend radii can be incorporated, reducing strain and chafing. Fully encased in composite, WiC also prevents damage from external forces or accidental human interference during installation or maintenance procedures. Research undertaken by the firm highlighted this was a real area of concern for aircraft operators. “WiC is highly versatile,” says BERU F1 systems' managing director John Bailey. “We have produced components with different wire gauges in a single composite component to demonstrate how capable it is,” Continuing the theme of simplified maintenance, the company aims to offer the option to change connectors fitted to each end of the harness. With a long partnership already established for their motorsport parts it is perhaps

unsurprising BERU F1 systems is working closely with harsh environment connector specialist Souriau to develop specific connectors for WiC.

Environmental testing undertaken demonstrates that WiC will easily match the temperature and humidity performance of existing loom technologies. “We have tested to EUROCAE ED-14D Section 4, temperature and altitude high temperature test, section 8, vibration and section 11, fluid susceptibility,” says project engineer Ingmar Geiss. Using ceramic coatings has also allowed the firm to go further; testing heat resistance up to 400ºC. “The trials completed have also demonstrated a small improvement in EMC performance thanks to the shielding effects of the fibres,” adds Geiss.

The company has focused its initial development around carbon fibre but the patent and process cover other composite materials. “The properties of carbon make it ideal for replacing structural parts,” says Geiss. “For a more cost effective solution, where we are looking to simply protect the harness, then glass fibre could be feasible. Kevlar could be specified for its anti-ballistic capabilities.”

Looking to specific applications the company believes that with engine and flight control systems subject to severe space and environmental restrictions, these are key areas but by no means the only possibilities. “Very Light Jets where a weight reduction is larger in relation to overall weight is another good example,” adds Bailey. “Constructors looking to lower maintenance costs would equally benefit. I think, from the reaction we have had from the aerospace industry, there are applications in the fuselage, control systems and perhaps even engines.”

Keen to try out the technologies in other applications, BERU F1 systems is very interested to find out about specific issues that engineers are struggling to resolve. “BERU F1 systems is well known in motorsport for developing solutions that work especially in small package spaces and harsh environments,” says Bailey. “I would like to think that we could share that knowledge and experience with the aerospace industry.”