As hybrid‑electric vehicles become more common on the roads, and now in the skies, the need for reliable, high‑voltage charging systems is growing fast. But today, no commercial chargers can deliver the voltage and current needed to power electric aircraft.
To solve this challenge, experts from the National Research Council of Canada’s (NRC) Aerospace Research Centre joined forces with Pratt & Whitney Canada and the Innovative Vehicle Institute (IVI). Together, they designed a mobile charging unit capable of powering high-capacity batteries at up to 1,500 volts— a major leap toward hybrid-electric flight and a cleaner, more sustainable aviation industry.
Building on high-voltage expertise
In 2022, our Aerospace team completed a hybrid-electric aircraft project focused on integrating an electric propulsion and battery system. As part of that work, the team developed a bidirectional charger that can both charge aircraft batteries and send energy back to the local electrical grid to power systems such as lighting and heating.
Building on that success, our experts partnered with Pratt & Whitney Canada to design the electrical systems for the new mobile charger. The unit converts 600 volts alternating current (AC) from the local electrical grid into direct current (DC). AC power changes direction many times per second, so converting it to DC provides the steady flow needed to safely charge batteries and run electronic systems.
In this collaborative R&D project, IVI designed the charger’s software interface, while the NRC led the mechanical assembly, testing and delivery. Drawing on its experience with lithium‑ion battery systems, hybrid‑electric test beds and charging infrastructure, the team built a safe, high‑performance system that meets the demanding needs of aircraft applications.
“We based our design partially on existing automotive charging systems, but none could reach the voltage we needed,” says Sebastien Chouinard, Facility Engineer and high-voltage specialist at the NRC. “The biggest challenge was finding equipment that could operate safely at such high voltage and current.”
Advancing sustainable aviation
Pratt & Whitney Canada’s new mobile charging unit is a milestone in sustainable aviation, and a boost to Canada’s aerospace innovation ecosystem. The NRC’s expertise in hardware design, assembly and testing helped bring this technology to life, enabling the safe testing and operation of hybrid electric propulsion systems. This new ground‑support equipment is essential for testing and operating propulsion battery systems on aircraft, an important step in bringing hybrid‑electric technologies to market in Canada.
This collaboration supports the NRC’s mission to accelerate clean technologies and reduce carbon emissions in aerospace. The charger’s unique ability to both draw power and feed it back to the grid shows how smart, energy‑efficient systems can benefit not just aviation, but other industries too.
“Working with Canadian enterprises is key to the NRC’s mandate,” says Mouhab Meshreki, Director General of the Aerospace Research Centre. “It helps our partners move closer to Canada’s net-zero carbon target.”
Looking ahead
Hybrid‑electric propulsion will play a vital role in helping the aviation industry reach net‑zero emissions by 2050. The NRC’s work on developing this mobile charging unit is an important step toward cleaner, more efficient aircraft.
Key benefits of developing and testing mobile charging units at the NRC:
- improves the high‑voltage charging capability needed for power hybrid‑electric propulsion systems
- supports clean technology and sustainability through bidirectional energy flow to and from the grid
- builds strong partnerships between Canadian aerospace innovators for real-world applications
- improves safety and reliability with carefully selected components and rigorous testing
- lays the groundwork for commercializing hybrid‑electric technologies to help Canada reach net‑zero carbon emissions by 2050