Engineers at the Moscow Aviation Institute (MAI) have developed a prototype DC-DC converter for advanced 270-volt onboard electrical systems. The design aims to reduce cable weight and improve aircraft fuel efficiency.
The growth of onboard electrical systems in modern airliners increases the load on wiring networks. Maintaining standard 28 V DC and 115/200 V AC at 400 Hz while increasing power results in higher currents, requiring heavier cables. Switching to higher-voltage systems lowers current and enables weight-optimized wiring.
The More Electric Aircraft (MEA) and All Electric Aircraft (AEA) concepts replace some pneumatic and hydraulic systems with electrical units. Adopting 270 V DC is a global trend. The standard has been used in military aviation since the 1970s (F‑22, F‑35). In civilian aircraft, high-voltage DC segments are already integrated, such as in the Boeing 787.
MAI’s development is a 30 kW converter operating at a 60 kHz switching frequency with phase-shifted pulse-width modulation (PWM). The unit achieves over 95 % efficiency and features short-circuit and switching-fault protection that maintains load continuity.
“We use four high-speed electronic switches to apply and interrupt high voltage to the transformer 60,000 times per second. By adjusting the phase shift between pulses, we precisely control the transmitted energy,” said project lead Ilya Lukoshin.
Laboratory tests confirmed design performance. Further refinement focuses on thermal management and electromagnetic interference resilience. Serial implementation will require full certification according to aircraft electrical system standards.
International efforts in this field include NASA, European companies, and True Blue Power, which in 2025 introduced the TC6500 unit (270 V → 28 V, 10.4 lb) for business and regional aviation.
Over the next decade, 270 V DC systems are expected to expand in new passenger aircraft and urban air mobility platforms. The key challenge remains creating reliable, certifiable converters with predictable service life and stable operational parameters.
Note:
HVDC (High Voltage Direct Current) in aviation—typically 270 V or 540 V—is used in MEA/AEA concepts to optimize onboard electrical networks. It requires 270 V → 28 V DC-DC converters.
Author: Artyom Kirillov,
Aviation of Russia
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