Aviation

Saft's aircraft battery systems

Saft’s proven nickel-cadmium (Ni-Cd) and lithium-ion (Li-ion) aircraft battery solutions are critical to safety, providing high-peak-power for engine or APU starting and emergency power backup. They outperform lead-acid batteries in both power and reliability and offer a long and predictable service life with no risk of ‘sudden death’ failure. Optimized maintenance ensures safety, maximum service life, and superior performance. Consequently, even with the cost of maintenance included, Saft provides a lower total cost of ownership (TCO) compared to other aviation battery providers.

At Saft, we produce over 400 different battery designs to suit virtually every requirement, each optimized for energy and power, guaranteeing integration with the electrical architecture of all fixed-wing and helicopter aircraft – even drones.  We can do this thanks to close cooperation between our teams and all the major aircraft OEMs over the whole product lifecycle. 

ULM® aircraft battery system 

Saft ULM® (Ultra Low Maintenance) aviation batteries have a well-established track record with major aircraft manufacturers. The most advanced Ni-Cd technology, first developed by Saft, is used in its ULM aircraft batteries. These batteries have the industry’s lowest TCO due to their reduced maintenance and extended life duration. Since ULM batteries serve a flight-critical function, they meet more than 100 different qualification criteria to uphold safety.  

How our aircraft battery technology works 

ULM performance hinges on our plastic bonded electrode (PBE) technology. This engineering solution measurably reduces water consumption due to a reduction in overcharge current compared to sintered technology. Thanks to PBE technology, our ULM aircraft batteries provide added safety and longer life, even at high operating temperatures. 

The following features offer the ideal combination to enable significant reduction in the TCO for commercial and military aircraft:

• Intelligent: Along with smart design of separators between cells, temperature sensors prevent any risk of thermal runaway
• Long service life: High-quality proprietary membrane and separator between the electrode plates inside cells extends the service life
• Safe: Nylon vent valves on each cell ensure safety
• Robust: Batteries recover from the most extreme conditions, including deep discharge
• Durable: Nickel-plated copper cell links and terminals for maximum durability
• Protective: Cells are housed inside leak-proof thermo-welded containers 
• Efficient: Seam-welding of tabs onto electrode plates ensures efficient energy transfer
• Easy exchange: System is designed for an easy exchange of individual cells instead of replacing the entire battery
• Tough: Maintenance-free, stainless steel case provides extreme toughness.

Key benefits of Saft’s Ni-Cd aircraft battery systems 

• Reduced maintenance: Our PBE technology reduces maintenance requirements by over 50 percent
• Long service life: Smart design, high-quality materials and solid construction extend life by up to 10 years
• Less weight: The use of lightweight PBEs reduces fuel consumption
• Exceptional storage life: Allows long-term storage of up to 10 years without any intervention
• Easily replaceable spare parts: Designed for individual cell replacement at a low cost
• For new or retrofit installations: Form, fit, and function is interchangeable, streamlining spare parts inventories and with no need to modify aircraft
• Supporting environmental sustainability: Over 75 percent of materials from returned, spent batteries are extracted for reuse. Saft’s worldwide network of collection partners recycle our batteries, in full compliance with local, national and international laws 

Li-ion aircraft batteries 

The aviation industry is moving towards more hybrid and electric aircraft as an alternative to the conventional thermal engine. This means cleaner aircraft with less, or even zero, fuel consumption. Li-ion technology is the battery technology of choice for these hybrid and electric engines. We have spent more than 15 years researching Li-ion solutions to provide cutting-edge battery systems in anticipation of this demand.

Our Li-ion aircraft battery systems comply with the highest standards, including DO-254, DO-178B and DO-311A, and are adapted to More Electric Aircraft (MEA) platforms to ensure support for increased electrical demands.

Battery-powered hybrid and full electric propulsion systems hold promise for the aviation industry as they can significantly reduce aircraft CO2 and NOx emissions, as well as noise. However, propulsion batteries for aviation come with a range of obstacles, including cell selection, total energy storage requirements, space availability and the need to comply with standards and certification. 

The challenge for the sector lies in increasing energy and power density of lithium aircraft battery systems and optimizing aircraft integration solutions while making sure they remain safe. The rise of new chemistries, and especially solid-state technology, will be a game changer for the industry. With a strong focus on solid-state battery technology, Saft is already a leading player in this emerging market.

Why choose Saft’s aircraft battery solutions? 

Saft is a dedicated supplier and partner, delivering quality products, technical expertise, professional service, and round-the-clock support at the lowest total cost of ownership. 

• We pride ourselves on having 90 years of experience in aircraft batteries
• Over 100,000 of our tried and trusted ULM batteries have entered service globally since 2010
• We have more than 130 OEM-approved batteries
• We have first-hand experience working with Airbus, Bell, Boeing, Bombardier, Dassault, Embraer and more 
• Only Saft ULM batteries maintain 100% rated capacity throughout their entire life
• We have world-class, high-quality manufacturing production facilities in France and the United States
• Our lightweight aircraft batteries provide the same consistent level of quality and high performance, no matter when or where they were manufactured
• Beyond the aircraft battery pack, we offer dedicated technical and product support teams, FAA-approved training courses in service life optimization and operational cost control, a worldwide distribution network including AOG services and a worldwide network dedicated to recycling batteries.

We design and create high-performance batteries across the aerospace and defense sectors. Learn more about our satellite battery systems within our defense and space range. 

Alternatively, discover the other sectors we work with. We supply:

• Transport batteries including traction batteries, lightweight racing batteries, marine batteries and railway batteries 
• Hospital battery systems and medical equipment batteries
• Buildings and industries batteries including data center batteries and construction equipment batteries
• Telecom batteries
• Utilities battery technology including off-grid battery solutions, renewable energy batteries and substation battery maintenance 
• Oil & gas sector batteries

Aircraft battery maintenance

When it comes to support, our global distribution network is ready to respond to customer needs. We provide certified repair and maintenance battery shops as well as in-house dedicated support and service teams and battery maintenance training. We work with nearly all aircraft manufacturers (OEMs) worldwide to create aircraft batteries that are fully compliant with all recognized international aviation, safety, environmental, and quality standards. We are there for customers throughout the life of their battery system.

Why is aircraft battery maintenance important? 

Unlike valve-regulated lead-acid electrochemistry, our ULM aviation batteries are designed to allow operators to perform preventive maintenance. Not only does this guarantee performance, but they can also collect valuable data to avoid any onboard problems or unscheduled removals. With proper maintenance, the life of your Saft ULM battery can reach up to 10 years.

Aviation battery training 

With 90 years of experience, Saft has been making batteries for the aviation sector for almost as long as the sector has existed. Our highly skilled trainers work with operators to make sure our batteries are used and maintained correctly to ensure optimum performance and longevity.

Saft offers:

• Saft Ni-Cd Battery Maintenance Training (BMT)
• Saft Ni-Cd Refresher Battery Training (RBT) eLearning
• Saft Ni-Cd Battery Maintenance Basics Online eLearning (online BMB)

Connect to our Saft4U portal to register online

Tools 

Our toolkit for any Ni-Cd aircraft battery pack (download the datasheet 22095-2-0907 below) has everything needed for the standard maintenance of a Saft Ni-Cd aircraft battery, including a universal vent wrench, equalizing resistors, syringe, cell extraction wrench, and nozzles.

Battery Shop Support and Services, offered by Proponent Battery Services

With 30 years’ experience in the aviation battery market, Proponent Battery Services manufactures and supports a wide range of battery shop equipment, including chargers and testers.  Please visit their website, Proponent: Battery Shop equipment, Setup, maintenance, repair, pool (proponent-battery.com) for more details, product videos and specifications.

ATEQ, recommended by Saft

With a new configuration of charge/discharge benches, Saft recommends ATEQ’s new Battery Charger Analyser the ATEQ BCA . The solution has been specifically designed for maintenance, certification, and approval of all types of aviation batteries worldwide. Thanks to its improved user interface, increased versatility, and a new integrated voltmeter, the new models allow maintenance experts to deal with several batteries at a time, to be more effective and productive on a daily basis, and with a solution that is extremely competitive from a cost point of view. 

Click here to view Aviation documentation (Saft4U):

Saft has three Aircraft on Ground (AOG) service partners, all of which hold Saft aviation batteries and parts in warehouses around the world. To find out more, please ring one of the following three hotlines:

Boeing (formerly Aviall) 24/7 AOG Hotline +1 972 586 1985
 

Proponent (formerly D+C Airparts) 24/7 AOG Hotline +1 205 650 4938 ext.3
 

Satair 24/7 AOG hotline +45 4040 1224