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Aviation (Commercial Aerospace)

Tag Archive: Aviation (Commercial Aerospace)

  1. Electromagnetic Clutches and Brakes in UAVs and OPVs

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    Unmanned aerial vehicles (UAVs) and optionally piloted vehicles (OPVs) are designed with autonomous and remote control features. To function properly and safely, they must be made with the most reliable, precise components. 

    Electromagnetic clutches and brakes can simplify design, reduce wear and maintenance, and improve reliability compared to traditional mechanical clutches and brakes. With better precision, torque transfer, and safety mechanisms, electromagnetic clutches and brakes can meet the stringent performance demands required to manufacture defense UAVs and OPVs.

    Read on to learn more about these innovative motion control components and how they serve the military UAV and OPV markets. 

     

    Electromagnetic Clutches in UAVs and OPVs

    In February 2022, an autonomous, uninhabited Black Hawk helicopter flew for the first time. The project, led by the Defense Advanced Research Projects Agency (DARPA) and Lockheed Martin, represents a significant milestone in the military UAV and OPV space and the components that power these systems. 

    Clutch systems control the transfer of torque or power from the engine. Traditional clutches are activated by mechanical means, such as levers. With electromagnetic clutches, an electrical current creates a magnetic field to engage or disengage the clutch mechanism. A clutch is considered engaged when the armature makes contact with the rotor whether by a magnetic force or a spring force. Torque is transmitted once teeth or friction discs engage. When the rotor and armature separate, the clutch is disengaged. 

    Many types of vehicles, including automated UAVs and OPVs, rely on electromagnetic clutches to control and halt movement. In onboard flight control systems of OPVs, pilots can disengage the clutch or brake to take over operations in case of system failure. Electromagnetic clutches offer a high degree of automation in manned and unmanned aircraft systems, with the potential to take on additional autonomous duties. These components are beneficial in:

    • Launching and landing mechanisms
    • Propulsion systems
    • Payload deployment systems

     

    Electromagnetic Brakes in UAVs and OPVs

    Electromagnetic brakes function similarly to electromagnetic clutches and rely on either a magnetic force or a spring force to engage and disengage the brake in order to slow, stop, or hold a load stationary. Power-off brakes act as a failsafe, automatically engaging the brake when power is intentionally or accidentally interrupted. Power-on brakes engage the brake when electric power is applied.

    In UAVs and OPVs, these fast-acting, reliable brakes can improve safety, minimize the risk of human error, and enhance performance in hazardous or challenging conditions. Because of these characteristics and the ease with which a human pilot can take over control, they are frequently used for UAV and OPV applications such as:

    • Emergency braking systems
    • Landing gear systems
    • Stabilization systems

     

    Advantages of Electromagnetic Clutches and Brakes in Autonomous Control Systems

    Benefits of using electromagnetic clutches and brakes include:

    • Precision control
    • Smooth, consistent operation
    • Reduced wear on parts 
    • Minimized maintenance requirements
    • Quiet operation
    • High torque transmission
    • Rapid engagement and disengagement

     

    Considerations for Brake & Clutch Engineering

    Our customers often approach us with demanding application requirements, so we work closely with them to develop a customized solution. From prototyping to calibration to full production, SEPAC delivers innovative engineering solutions for even the most complex projects.

     Several of the key factors we consider for every brake or clutch application include the following:

    • Torque, shaft speed, horsepower, type of load
    • Environmental factors like dust, moisture, vibration, shock, corrosion, and altitude
    • Heat dissipation, ambient temperatures, heat sink
    • Other conditions, such as required service life, space available, and over-run speed

     

    SEPAC Electromagnetic Clutches & Brakes in Action

    At SEPAC, we provide a comprehensive selection of electromagnetic clutches and brakes, with the design and engineering capabilities to manufacture a custom product to meet your requirements. Our products are key to the success of many mission-critical operations, saving lives and protecting aerospace and defense equipment.

    Here is an overview of our electromagnetic clutches and brakes in various real-life situations:

    • Missile fin operation: Accurate missile guidance has no room for error. Our electromagnetic brakes hold missile fins in position according to instructions from operators.
    • Gimbal deployment: Our electromagnetic power-off brakes hold the gimbal actuator in place or release as needed.
    • Weapons bay door actuation: Our power-off brakes can also hold various utility-type actuators in place, including weapons bay door drives.
    • Flight control actuation: SEPAC’s power-off brakes can hold flight control actuators in position. These actuators include primary and secondary flight control, and high-lift, leading-edge control systems.
    • Autopilot control and stability augmentation systems: Our electromagnetic clutches are used in these systems to produce high torque and low backlash. They take over in case of pilot incapacitation and other emergency scenarios.

    Other applications for our electromagnetic clutches and brakes include:

    • Latch, separation, and umbilical systems
    • Cargo bay actuators
    • Flap actuators
    • Horizontal stabilizer trim actuation
    • Thrust reverser actuation
    • Thrust vector control actuation
    • Throttle control actuation
    • Cocking system electromechanical actuation

     

    Choose SEPAC for Your Electromagnetic Clutches and Brakes

    At SEPAC, our innovative electromagnetic clutches and brakes are designed to meet or exceed the rigorous demands of military UAVs and OPVs. As this field continues to grow and develop, it will require advanced components with rapid engagement and disengagement, precise control, high torque transmission, and enhanced safety mechanisms that electromagnetic clutches and brakes provide. 

    When you work with us, we bring superior customer service, our AS9100 and ISO 9001 certifications, and an extensive history of designing our products to meet  MIL-SPEC and other demanding standard requirements.

    Contact us today to learn more about our full capabilities. Submit an application data form or request a quote for your project.

  2. Brakes and Clutches with Life Saving Capabilites

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    Brakes and clutches with lifesaving capabilities and motion control systems are critical aircraft elements. They not only help pilots navigate smoothly during challenging weather conditions, but they also play a lifesaving role during mid-air emergencies. SEPAC products are developed with reliability at the forefront of design and, through a partnership with Genesys Aerosystems, have helped to make helicopter flight safer.

    Mid-Air Mayday: Air Evac Lifeteam Helicopter Crew Survives Pilot Medical Emergency

    Pilot incapacitation is one of the worst-case scenarios for any flight. When it happens in light helicopters flown by a single pilot, however, it usually means catastrophe. In 2018, there was no form of autopilot or stability augmentation system (SAS) in Air Evac Lifeteam LongRanger helicopters. If the pilot stopped actively controlling the helicopter, control would be lost within seconds. 

    Luckily, this was not the case for one crew in Kinder, Louisiana. While transporting an elderly woman to a nearby hospital, the pilot experienced a medical emergency. With the aircraft about 800 feet above the ground, the pilot became incapacitated. Luckily, this helicopter had recently been updated with Genesys Heli-SAS stability augmentation systems and autopilot.  

    Flight nurse, Tara Coupel, made a mayday call to Air Evac’s headquarters where communications specialist, Tim Cinotta, quickly realized that Heli-SAS was the crew’s best chance at survival. Cinotta assumed that the Heli-SAS was working since, “had the autopilot or SAS not been engaged, they probably never would have called,” he explained in an interview with Vertical Magazine. 

    Then, suddenly, the pilot looked at a nearby open field and said, “There.” His flight crew encouraged him to land the helicopter in that location. Coupel knew the autopilot would disengage as they approached the ground and expected a rough landing. However, the smooth control continued until the aircraft reached the ground. Coupel called it “the most controlled, gentlest landing” she’s ever experienced. 

    Heli-SAS® Autopilot and Stability Augmentation System with SEPAC Motion Control

    Heli-SAS technology equipped with SEPAC motion control products is essential for reliably responding to urgent situations. SEPAC clutches are used in throttle control actuators and autopilot control actuation to deliver high levels of torque and low backlash. In these applications, actuator performance is directly related to a pilot’s ability to control the helicopter.

    The Heli-SAS Autopilot and Stability Augmentation System (SAS) is a simple autopilot that will take aircraft close to the ground in controlled runaway environments. This system is a crucial component of flight safety measures and disaster preparedness. Reliability for these components is crucial since total failure means an inability to control the aircraft. SEPAC’s commitment to quality helps ensure these control systems perform without failure.

    Preparing for the Unexpected with Motion Control Technology

    SEPAC’s Motion Control technology features custom-designed products that have been optimized to deliver the highest possible level of reliability. Electromagnetic systems offer enhanced dependability compared to hydraulic actuator systems, which can be challenging to control and require higher maintenance demands, leading to more frequent downtime. Electromagnetic systems offer a much higher degree of control and greater security.

    There have been many helicopter crashes relating to failed hydraulic actuator systems. The 2009 A-Star AS350B air ambulance crash in Doyle, California, is one of numerous unfortunate tragedies that are suspected to have been caused by failed hydraulic actuator systems. The Aviation Law Monitor states that in this particular crash, the pilot was unable to attempt an emergency landing after losing control of the aircraft due to a suspected hydraulic actuator system failure. “A problem with the hydraulic system can make the helicopter difficult to control,” they report. 

    Reliable Clutch and Brake Systems from SEPAC

    SEPAC is committed to quality and reliability in clutch and brake systems. Our products help flight crews prepare for the unexpected and better navigate emergencies. In addition to our standard product offerings, we also specialize in prototype development and design engineering. Our design engineering department is equipped with the most advanced technology and top engineering experts, allowing SEPAC, Inc. to develop clutch and brake solutions that meet even the highest performance requirements. 

    Our custom products are made with the highest quality materials and designed to endure the harshest environments. You can learn more about our custom design capabilities on our website or by contacting our team with any questions. If you’re interested in a quote for a specific project and would like to fast-track the process, you can fill out our RFQ application data form. 

  3. Aircraft Actuation Systems and Electromagnetic Actuators

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    In the past, pneumatic and hydraulic systems have been the most common actuator types for aircraft due to their high power density and cost-effectiveness. However, in recent years, attention has been focused on the limitations of these systems, including their level of performance, weight, high maintenance requirements, and more. 

    Recent advances in electromagnetic actuator technology have included more robust and efficient designs that offer increased power density and superior performance. This has resulted in a gradual shift towards the use of electromagnetic actuators in the aerospace and defense industries. 

    At SEPAC, we’re a leading design expert in aircraft actuation components used to control everything from engine components to landing gear, cargo bay doors, and more. Our experience in the aerospace industry allows us to deliver quality electromagnetic brakes and clutches to meet your critical motion control requirements.

     

    Overview of Aircraft Actuation Systems

    Aircraft actuators work to convert electrical signals from the flight control system into mechanical movement. By facilitating precise and rapid adjustments, aircraft actuation systems help to ensure a safe and controlled flight. 

    Actuators can be found in the primary and secondary flight control systems, as well as other areas in the aircraft.

    • Primary flight control systems. Primary flight control systems include elevators, rudders, and ailerons, which are necessary for controlling altitude and direction. Actuators are used to move primary flight control parts, and they have a large bearing on flight performance and reliability.
    • Secondary flight control systems. Actuators are used to control the movement of secondary flight control systems such as flaps, slats, and spoilers. These components further stabilize the aircraft, leading to greater maneuverability and performance.
    • Other actuation systems in aircraft. Actuators also provide safe and reliable operation of landing gear, thrust reversers, and other devices essential to safe takeoff, landing, and ground operations.

     

    Traditional Aircraft Actuation Systems

    Actuators are mechanical devices used to convert energy into motion. Before the introduction of electromagnetic actuators, aircraft relied on hydraulic or pneumatic actuation systems to control the movement of parts.

    • Hydraulic actuators. These systems rely on hydraulic fluid to transmit motion and force, providing robust actuation capabilities. However, they suffer from drawbacks such as potential leaks, complex and bulky infrastructure, and high maintenance costs.
    • Pneumatic actuators. Pneumatic actuator systems depend on compressed air or gas rather than fluid to transmit motion. While they eliminate the risk of fluid leaks, they come with other disadvantages, including their heavy weight and reduced efficiency.

    While some aerospace applications continue to use hydraulic and pneumatic actuators, their drawbacks as well as recent technological advances have led to a shift toward electromagnetic aircraft actuation.

     

    The Industry Shift to Electromagnetic Aircraft Actuation Systems

    The limitations of hydraulic and pneumatic actuators, such as their larger footprint, high maintenance and operational costs, reliance on hydraulic/pneumatic power sources, and more, have resulted in a growing demand for electromagnetic actuation systems in aircraft. Electromagnetic actuators address the pain points of hydraulic and pneumatic systems by providing:

    • Increased reliability and safety. Electromagnetic actuators eliminate the risk of pneumatic and hydraulic fluid-related issues such as leaks and contamination. In addition, they offer enhanced fault detection and redundancy capabilities, as well as the reduced risk of system failure and improved safety margins.
    • Enhanced precision and control. Electromagnetic actuation systems provide high accuracy and repeatability of actuation, improved responsiveness and agility, and fine-tuned control for optimized aircraft performance.
    • Reduced weight and size. Compared to bulky hydraulic and pneumatic actuators, electromagnetic actuators are more compact for a more streamlined aircraft design. Additionally, they are more lightweight, resulting in improved fuel efficiency.

    Important elements of any aircraft actuation system are brakes and clutches. At SEPAC, we are experts in delivering quality electromagnetic brakes and clutches for the aerospace industry. Our products are custom-designed for actuator system integration for applications such as thrust reversers, flap actuation, engine inlet control, and more.

     

    Challenges and Considerations in Implementing Electromagnetic Actuators

    When implementing electromagnetic actuators into aircraft, there are many key factors to consider, including:

    • Environmental factors (e.g., temperature, humidity, electromagnetic interference)
    • Power supply and energy management
    • Redundancy requirements for critical applications
    • Certification and regulatory requirements

     

    Learn More about Electromagnetic Actuators

    At SEPAC, we’ve been a leading provider of custom electromagnetic brakes and clutches since 1984. Our years of aerospace industry experience give us the necessary skills and knowledge to design quality electromechanical solutions that hold up under even the most demanding environments. 

    For more information about the shift from traditional actuators to electromagnetic actuators, download our free Switching Hydraulic to Electromechanical Actuation eBook today. You can also contact us or request a quote to learn more about SEPAC’s latest electromagnetic actuator technologies for the aerospace industry.

  4. Types of Aerospace Actuation Systems and Applications

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    Aerospace technology is in a constant state of evolution. From engines and fueling systems to electronics, navigational instruments, and exterior designs, aerospace manufacturers and operators are always working to make aerospace equipment more streamlined, efficient, and cost-effective. Advances in aerospace actuation systems have been a key player in making aircraft faster, more maneuverable, and more economical.

    Aerospace actuators are used to transmit and redirect motion energy from mechanical sources to create usable linear or rotary motion. Initially, aerospace actuators operated mechanically through the use of cables, gears, and rods. These systems later gave way to hydraulic and pneumatic systems with levers, control columns, hydraulic cylinders, and compressed air. As electrical technology continued to advance, control levers and columns were slowly replaced with computerized electronics. Although hydraulics and pneumatics continue to be used in a variety of aerospace applications, electromechanical actuators are becoming increasingly common for their size and streamlined design.

    Interest in energy-efficient, sustainable technology in recent decades has encouraged this shift from traditional hydraulic systems to electromechanical actuators. Aerospace actuator manufacturers are motivated by a desire to reduce fuel consumption and emissions while enhancing aircraft performance and efficiency. Due to their simpler design and computerized control systems, aerospace electromechanical actuators help to improve fuel efficiency and sustainability and offer the added benefit of enhanced control and reliability.

    Advantages of Aerospace Electromechanical Actuators

    SEPAC’s design expertise has led to component integration for aerospace actuation systems which are used to operate everything from landing gear to cargo bay doors, flight control surfaces, and engine components. It is important that actuators be dependable, lightweight, and compact, and these characteristics make electromechanical actuators particularly useful for aerospace technology. A key component in each actuator design is the brake which SEPAC is an expert in providing with many years of experience across hundreds of platforms. In general electromechanical actuation systems are more:

    • Compact: Electromechanical actuators are more compact than their hydraulic and pneumatic counterparts, so they require less space while producing the same amount of thrust.
    • Lightweight: With fewer components and lighter parts, electromechanical actuators are lighter than other actuator designs, which reduces the load on the aircraft and improves fuel efficiency.
    • Precise: Electromechanical aerospace actuation systems operate with a higher degree of precision and can be more easily controlled by operators for more reliable performance.
    • Energy-efficient: Electromechanical actuators use less energy than hydraulic and pneumatic actuators.
    • Low-maintenance: Since electromechanical actuation does not require compressed air or fluid, there are fewer components to operate and maintain. The design simplicity makes them easier and less expensive to maintain over the course of the system’s service life.

    Common Aerospace Applications

    Aerospace actuation systems are integral to many critical aircraft functions. This is why leaders in the aerospace industry depend on SEPAC’s aerospace experience for their critical motion control needs. We are pleased to offer custom-designed brakes for actuator system integration for everything from thrust reversers and engine inlets to control surfaces and bay doors. Common applications that benefit from SEPAC’s superior brake systems include:

    • Thrust reversers
    • Horizontal stabilizer trim
    • Flaps
    • Throttle control
    • Autopilot control
    • Cargo bay doors and lifts
    • Winch and gimbal systems
    • Doors and elevators

    Clutch & Brake Integration for Aerospace Actuation Systems by SEPAC

    Since 1984, SEPAC has been a leading provider of precision-manufactured electromagnetic clutches and brakes for customers around the world. An American company, SEPAC is AS9100- and ISO 9001:2015-certified, and our products are designed, engineered, manufactured, and assembled in accordance with the highest industry standards.

    For more information on our quality aerospace actuation systems, contact our experts today.