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induStry focuS Military, aeroSPace & defence


MBe SySteMS SecureS do-178c coMPliance


MBE Systems has secured DO-178C compliance for a key project. By achieving DO-178C Design Assurance Level B (DAL-B), MBE joins only a few companies that have seen the task through the final avionics design audit known as SOI#4 for engine control systems. RTCA DO-178C / EEUROCAE ED-12C has a reputation of being the most


demanding software development standard in the world requiring systematic engineering process and four formal audits at key project stages from an FAA designated representative. MBE was the first to start the process for a US Army UAV


project, having been awarded the contract to develop a Full Authority Digital Engine Control System. The company invested


8,500 engineering hours into the process, with two separate teams now looking after the design/development and testing of the systems – these are separate areas of the company. This provides MBE Systems with a foundation to build its aerospace and


defence work as the company is now in a position to design and develop embedded airborne systems quickly. Steve Baker of MBE Systems, said: “We have always known that


our systems were efficient, effective and safe – and indeed have been improving the performance of aircraft and automotive engines for decades. However, it was important that we formally demonstrated this and DO-178C compliance is already opening doors.”


MBE Systems www.mbesystems.com


Military grade equipment often demands the highest specifications to meet specialised requirements. To fulfil these criteria, aerospace and defence OEMs regularly stipulate the need for dedicated designs, developed specifically for the task. Miniature motion systems, typically involving motors, gearboxes, and


encoders, are often used on critical military applications – from autonomous robotic vehicles through to radar systems. But with field failure, error or inaccuracy not an option, aerospace and defence OEMs regularly stipulate a dedicated, design-from-scratch, approach. The problem, however, is time. The alternative process is to use a commercial, off the shelf, motor


solution as the basis for prototype development. Motors must be selected that achieve the necessary levels of performance (speed, power, precision etc.) and durability at the outset. It is also critical that a motor manufacturer who can demonstrate a comprehensive customisation service that provides the specific attributes required for the aerospace and defence industry is selected. Design criteria for military applications usually includes the ability


to withstand shock and vibration, such as can be found in applications like missile fin actuation. Optimising resistance can be achieved by upgrading the bearing system, the focus of greatest shock loads. Feedback elements too must be ruggedised by replacing glass encoder discs with durable solutions such as resolvers or magnetic scales. Wide temperature ranges are also common. Temperature change can


cause materials to expand or contract at different rates, potentially damaging the motor. Special bearing lubrication could be used, or the winding and insulation system materials could be modified to handle the extremes. Meanwhile, vacuum conditions, particularly impacting high altitude


Kemtron Ltd. is now part of


aircraft and space vehicles, can affect the ability of the motor to dissipate heat. As a result, the standard brush materials in DC brush motors can fail. In addition, the outgassing of bearing lubrication can affect bearing life or harm the vacuum environment with unwanted particulates. Customised options such as substituting brush and commutator materials, as well as incorporating additional heat dissipation methods and mil-spec lubricants, can resolve these issues. When it comes to production of customised designs, motor


RFI/EMI shielding


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manufacturers must also respond to critical manufacturing process needs tied to ISO and quality control. Customising off the shelf designs removes the time delay in initial


development. Instead of creating a completely new design from scratch, a lightly modified version of the standard motor can be used as a proof of concept. Further modifications can then be made to the prototype according to requirements. This stage can include several iterations, as well as the extensive testing and validation required for military use.


Portescap www.portescap.com


50%-Scale PrototyPe Vtol aircraft conStructed


Horizon Aircraft has completed the construction of its 50%-scale ‘Cavorite X5’ prototype. The company’s approach and technology allows the aircraft to fly 98% of its mission in a very low-drag configuration like a traditional aircraft. Flying most of the time as a normal aircraft is said to be safer and should make the aircraft easier to certify than radical new eVTOL designs. The full-scale aircraft will also be powered by a hybrid electric


system that can recharge the battery array in-flight while providing additional system redundancy. Comprehensive testing of this 50%-scale aircraft will reduce technical risk moving forward, the company states.


+44 (0)1376 348115 | info@kemtron.co.uk www.kemtron.co.uk | www.te.com


5 DESIGN SOLUTIONS SePteMBer 2022 0 Horizon Aircraft www.horizonaircraft.com defence applications cots motors for


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