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Tag Archive: Space

  1. Four Ways to Use Space Brakes for Actuation

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    Spacecraft use many motion control systems during normal operations, such as opening door latches, moving cameras and antennas, or positioning solar panels. Actuators are used in motion control systems to move objects or components by converting electrical, pneumatic, or hydraulic energy into mechanical force that is applied to a load to control its movement. Here, we’ll look at some common ways space-rated brakes are used in outer space and spacecraft actuation applications.

    Electromagnetic Brakes in Space-Rated Actuator Systems

    Electromagnetic brakes are an integral part of the many motion control systems that automate the movement of equipment and components found in spacecraft and outer space.

    Some examples include actuator brakes for:

    • Locking and latch systems
    • Docking mechanisms
    • Cargo door activation
    • Robotics
    • Thruster control
    • Antenna control
    • Camera movement
    • Solar panel adjustments

    Different electromagnetic brakes are used in actuator systems to decelerate, stop, or hold loads. Common types include:

    • Magnetically Engaged (Power-On Brakes). A metal armature sits on the face of the brake unit, and the magnetic field generated by the supplied current attracts and holds it to the brake face. This generates the braking force.
    • Spring Engaged(Power-Off Brakes). These brakes engage when power is turned off, which disables the electromagnetic field. The spring pushes the armature against a friction plate, which generates the braking force.
    • Friction Brakes. Friction brakes can engage dynamically and offer infinite resolution, meaning they can engage at any point around their 360° surface.
    • Tooth Brakes. Tooth brakes offer higher torque in a smaller package than friction brakes; however, they cannot engage dynamically or with infinite resolution.

    Electromagnetic Space Brake Applications

    Four main applications of electromagnetic space-rated brakes include:

    Thrust Vector Control (Position Control)

    Thrusters typically utilize rotary actuators to control the motion of a spacecraft. These actuators generally rely on spring-applied, or power-off, brakes. When power is removed, the brake engages, allowing the actuator to hold the position of the thruster.. When power is on, the brake disengages and the actuator can move the nozzle in a different direction.

    Satellites

    Satellites use rotary and linear actuators to hold equipment in position, especially components with arm-type architectures. These actuators rely on spring-applied, or power-off brakes to maintain their position. Examples include solar panels, antennas, cameras, and the fins that guide a satellite’s orbital path. Space brakes can also prevent components from moving due to shock or vibration during launch. When power is applied to these brakes, the actuator can change position.

    Docking & Latching

    Space brakes are used in space docking and latching systems, which incorporate linear and rotary actuators. This technology is the international standard for interfacing with the International Space Station (ISS). Power-off, or spring applied, brakes are placed at the back of the motor and hold latches open during docking. Once docking is complete, these brakes engage and hold the actuator in place. These brakes are also used within separation and umbilical actuators.

    Lunar and Martian Rovers

    Servo motors are used in the actuators on the wheels of lunar and martian rovers. Once the motor slows and stops the wheels, power-off, or spring-applied, brakes hold the wheels in their stopped position, similar to a car’s parking brake.

    Electromagnetic brakes are also used to control the arm movement of rovers’ drilling apparatuses, as well as hold the position of solar panels, antennas, cameras, and more.

    For more information about how our electromagnetic brake products can be used in outer space, visit our aerospace industry page.

    Learn More About EM Space Brakes with SEPAC

    SEPAC has a long history of developing highly specialized actuator brake technology for challenging and unique situations, including spacecraft and outer space applications.

    Our team manufactures industry leading standard electromagnetic brakes and spring-engaged brakes, while bringing our experience and expertise to custom design, and advanced product engineering. All our motion control products are produced and quality ensured in our AS9100 and ISO 9001-certified facility.

    Contact us to learn more about our space-ready brake technology, or get a quote for your next aerospace 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. Reliable Motion Control for Aerospace & Defense

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    Motion control systems are vital to the proper function of aerospace and defense machinery and devices. These systems can control the velocity or position of a machine utilizing a range of movement technology, including servo motors, electric motors, and linear actuators. The aerospace and defense sectors rely on electromagnetic brakes and clutches for a variety of actuation applications, and these technologies require quality brakes and clutches to ensure optimal safety, precision, and performance.

    At SEPAC, we deliver electro magnetic clutches and brakes to some of the top aerospace and defense leaders. Our extensive capabilities and expertise have allowed us to work on critical projects for high-profile companies, such as NASA and SpaceX, that are revolutionizing the aerospace and defense industries with innovative technological advancements.

     

    SEPAC’s Motion Control Systems Partnerships: Top Tier Trust

    SEPAC is trusted by the best-of-the-best in the defense and aerospace industry for motion control systems. Some of our clients include:

    • BAE Systems
    • Boeing
    • Curtiss-Wright
    • Eaton
    • Honeywell
    • Lockheed Martin
    • Marotta
    • Moog
    • Northrop Grumman
    • Raytheon
    • UTC

    At SEPAC, our highly experienced team of engineers, designers, and manufacturers create solutions tailored to our clients’ specifications. With this expertise, we develop advanced motion control solutions for critical industries and applications. Our proven track record ensures we deliver quality products within our client’s budget and timeline. 

    We work with a wide range of materials, including composites and specialized alloys, to deliver products that meet specific performance requirements. We can also work with our customers to help in selecting the best friction material, whether dry or submerged in oil. In addition, SEPAC has extensive experience in testing and validating motion control solutions to ensure their safety and reliability. We maintain strong relationships with leading partners and suppliers, enabling us to source quality components and materials, and our commitment to innovation and continuous improvement allows us to stay ahead of the latest technologies and trends.

     

    Motion Control Products Supplied by SEPAC

    SEPAC has gained a reputation for delivering motion control solutions that meet the aerospace and defense industry’s strict quality requirements. This experience allows our team to produce industry trusted clutches and brakes for a range of applications. Some of these applications of motion control systems include: 

    Motion Control Components for Space Applications

    SEPAC designs and manufactures electromagnetic clutches and brakes for space applications that are depended on for critical and challenging applications, including the following:

    • Flight Actuation Systems such as thrust vector control actuators.
    • Robotic Arms for automation tasks like solar panel positioning.
    • Space Electromechanical Actuation Systems such as docking and latching systems.

    Aircraft & Defense Motion Control Components

    SEPAC can provide various motion control components including spring-set brakes, power-off brakes, and more for aircraft and defense systems. Common applications include:

    • Aircraft Landing Gear rely on our electromagnetic brakes and clutches.
    • Throttle Control Actuators in aircraft engines and other systems.
    • Autopilot Actuators for automatic flight control.
    • Heli-SAS® Autopilot and Stability Augmentation System for rotorcraft flight control.
    • Winch Systems for cargo handling and similar needs.

     

    Why SEPAC’s Motion Control Solutions Are Trusted

    SEPAC is a trusted partner in clutch and brake manufacturing for aerospace and defense industry leaders. Our clients choose us primarily because of our quality customer service and capability to deliver custom solutions. We are committed to continuous improvement and innovation and offer high levels of technical expertise and proven reliability. As an ISO 9001:2015 and AS9100 D certified electromagnetic brake and clutch manufacturer, we can consistently exceed our clients’ expectations.

    For more information about our motion control solutions, or to discuss your particular needs with one of our experts, contact us or request a quote today.

     

  5. SEPAC Partners With Motiv Space Systems on NASA Contract For DEEDS

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    SEPAC, Inc is honored to partner with Motiv Space Systems, Inc. on new technology for future flight missions, including space flight. Through the Small Business Innovation Research (SBIR) Sequential Phase II Program, Motiv Space Systems has been awarded a $5 million contract with the National Aeronautics and Space Administration (NASA) to develop the Distributed Extreme Environments Drive System (DEEDS). 

    The SBIR program incentivizes small businesses to conduct federal research and development with the possibility of commercialization. The DEEDS project focuses on R&D for long-term, sustainable operation on the moon or Mars. According to Motiv Space Systems, Inc. forecasts, this tech advancement will become a critical asset for developers looking to assist future astronaut planetary surface explorers. 

    SEPAC is offering our expertise in this new environment and innovating using our technical knowledge and design engineering capabilities. Our partnership and involvement in the two-year project is an exciting move considering our aerospace capabilities. In fact, this is not the first time NASA has utilized our technology — their docking system architecture uses many power-off brakes manufactured by SEPAC. 

    What is DEEDS Technology?

    DEEDS is an actuation system that functions in extreme environments of the moon and mars. It enables sustained operations in these environments, thus addressing the challenges of NASA’s goals (Surviving and operating through the lunar night). 

    There are many use cases of DEEDS, including: 

    • Payload off-loading systems 
    • ISRU systems
    • Robotics
    • Advanced lunar mobility applications
    • And more! 

    However, the notional Lunar Terrain Vehicle (LTV) system is the specific design reference case chosen for DEEDS development. It is expected to demonstrate the applicability of the technology to other applications, thus allowing users to establish an infusion path for their system. 

    The work builds upon the Dual Axis Controller for Extreme Environments (DACEE), demonstrating the extreme environment manipulation activity for the Lunar surface. The minimum operational temperature targeted by the original DACEE was -180°C. Unlike the current actuation systems that require drive electronics and lubricants that must remain warm to operate in extreme environments, the DEEDS system won’t need external heaters at -180°C. Therefore, DEEDS lowers the burden on the power systems since there won’t be any need for heaters.

    SEPAC’s Role in DEEDS

    SEPAC, Inc. is a leading manufacturer of various motion control products, including brakes. We have a substantial role in developing DEEDS owing to our high quality and reliable, innovative solutions. SEPAC, Inc. already manufactures products for use in various industries, including robotics, aerospace, defense, etc. 

    In this collaboration with Motiv Space Systems Inc., SEPAC’s role is to develop cryogenic braking systems. We will integrate our expertise and vast knowledge into the project to create braking systems custom-built to withstand extreme heat and cold conditions without external support. 

    SEPAC believes in developing, implementing, and continually improving our quality systems to meet or exceed customers’ precise needs and high standards. Therefore, we have the capacity to develop products for this critical project. 

    Supporting Aerospace and Planetary Exploration Capabilities

    Aerospace technology is undergoing constant evolution to enhance efficiency and performance, and SEPAC leads the industry in offering custom motion control products. There is a demand for specialized motion control solutions in aerospace. Fortunately, SEPAC has the necessary skills, knowledge, and tools to match the developments in aerospace actuation systems. 

    All designs consider factors such as usage scenarios, DO-160, shock and vibration, and environmental conditions, guaranteeing long-term use. With such aerospace capabilities, SEPAC expertise and technology play a major role in DEEDS technology that is pioneering planetary exploration. 

    Innovation at Full Throttle With SEPAC

    SEPAC offers complete in-house capabilities, including design, engineering, onsite manufacturing, full prototypes, custom fabrication, and quality control. Our team commits to pushing the limits of designing and creating effective motion control solutions that meet unique requirements. Contact us or fill out this RFI data application form to learn more about our aerospace capabilities. 

  6. 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.