Picking up the vibes

While flying is temptingly fast, it is definitely not kind to our climate. The Fraunhofer Institute for Reliability and Microintegration (IZM) has therefore set itself the exciting task of making air travel greener by enhancing the energy efficiency of airplanes. By Ruben Vorwald

Researchers are investigating how airplanes could glide more economically through the air using lightweight, durable materials and improved aerodynamics. This requires precise data on wear, drag and loads during flights.

The research team has developed an innovative sensor skin for Airbus which can be stretched over the wings of an aircraft like a second skin. The robust sensors are integrated into the outer plastic cladding and reliably measure temperature, air pressure, oscillations and vibrations. They withstand extreme winds, turbulence, differences in pressure, and chemicals. The researchers analysed the plastic used and derived process parameters for film lamination and the soldering of the components.

The team used sophisticated lithography and etching processes to create the electronic circuits for the stretchable sensor modules. Two methods were presented to protect the system from outside forces: glob tops made of polyurethane and the integration of thin chips using the flip-chip assembly method. The flexibility of the stretchable film of thermoplastic polyurethane (TPU) for the circuit boards enables optimum adaptation to the wings, and protects the electronics.

Fraunhofer IZM’s research into energy-efficiency research offers exciting potential for public transport, particularly for trams. With lighter and more durable materials, tramways could profit from lower vehicle weight, which would lower energy consumption and reduce wear of rails and wheels.

Optimising the aerodynamics of trams could reduce drag, energy consumption and noise, and mean greater energy efficiency and a more pleasant ride for passengers. The new aircraft sensors could be deployed in trams to better monitor vehicle condition and to provide precise information on wear, strain, and potential problems. This would enable targeted maintenance and minimise downtime.

The methods developed to identify weak points and to predict the service life of materials could be applied to the upkeep of trams to enable proactive maintenance and prevent downtime and disruptions.

The results of Fraunhofer IZM’s research results could lead to innovative improvements in terms of energy efficiency, safety and sustainability in the tram sector and in public transport in general. That would make PT more attractive and more environmentally-friendly, and who knows – perhaps one day we can travel to work in even greener trams!