E lectric Motors, Fans, and Motor Controllers Innovation at the core of your systems www.thalesgroup.com Thales Avionics Electrical Motors Products and markets 2 Thales Avionics Electrical Motors on board aircraft Passenger door • Spoilers and flaps Ailerons • Slats • Pilot seat • Thrust reverser Landing gear system • Rudder • THSA* * THSA : Trimmable Horizontal Stabilizer Actuator Thales Avionics Electrical Motors designs and markets highly reliable systems. For over half a century, we have been developing solutions for markets as demanding as Aeronautics, Defence and Space. Applications Our products are fitted to: nFlight controls of commercial aircraft and business jets Primary and secondary controls nAerospace equipment Fuel pumps and hydraulic pumps, electronics cooling, doors, landing gear systems, electric brakes, thrust reversers, vectored thrust systems, flight sticks nAerospace comfort and optional equipment Air bleeding and air conditioning, seat actuators, baggage hold systems nMissiles and torpedoes Initiators, target lock-on systems, steering actuators nAnd also… Cryogenic cooling, radar phase shifters, IR camera scanners, winches Our product range will meet your needs, where accuracy, reliability, robustness and integration with the environment are required. Our offering consists of DC motors with or without brushes, asynchronous motors, stepper motors, limited displacement motors, as well as axial fans. As experts in our field, we find solutions to your problems, using custom-built embedded motor controllers. 3 Thales Avionics Electrical Motors Strengths Quality: Individually tested products Thales Avionics Electrical Motors designs high-quality products which undergo rigorous testing to ensure they are qualified to operate properly in severe conditions. Tests on electric motors ■■ Climatic testing chamber ■■ Salt spray ■■ Faraday cage ■■ Shaker Each of our products is individually tested. Our commitment to quality extends to the way our teams interact with customers to offer them our expertise. Thales Avionics Electrical Motors is certified to EN 9100, ISO 14001, EASA Part 121, and EASA Part 145. Control of programmes Our electric motors have been proven for over 50 years in highly demanding markets. As weight optimization of the system is becoming a basic requirement, we offer high-power-density motors. Our range includes liquid-cooled motors, natural-convection-cooled and self-ventilated motors. Thales’ know-how in submersible and flameproof motors makes them a major player in the aerospace industry where our products are qualified. Fitted into helicopters, our electric motors can withstand vibration. The space industry has its own requirements, which are taken into account by our engineers, as, for instance, in mastery of a special process for dealing with corona effect, which makes our electric motors unique in this area, and enables Thales Avionics Electrical Motors to take part in the latest space programmes. The presence of our electric motors in missiles and torpedoes demonstrates our reliability and our control over critical systems. 4 Our experts are ready to help you meet your challenges Our teams are committed to working out with you innovative solutions to your business needs. Thales Avionics Electrical Motors is constantly developing new, advanced solutions, and relies on their experience to meet deadlines and budgets. Adaptability Flexibility Thales Avionics Electrical Motors designs the future Thales Avionics Electrical Motors is focused on innovation. Close to our customers, we are anticipating and developing today the core elements of more integrated, more intelligent and more ergonomic systems. Thales Avionics Electrical Motors is developing electronics for vector-flux control of brushless directcurrent (BLDC) motors. Our vision is to offer complete solutions integrating brushless motors and control electronics to reduce compatibility issues and the number of intermediaries for our customers. n BLDC* motors Responsiveness n Power electronics n Control electronics n Power conditioning n Safety functions Reconciling excellence and industrial competitiveness is our primary concern. Our engineers work on designing innovative architectures that optimize manufacturing costs. * BLDC: BrushLess Direct Current 5 Brushless direct-current motors (BLDC) T hales Avionics Electrical Motors designs Brushless DC (BLDC) Motors for the Aerospace and Defence industries. Boasting the latest technological advances, these motors offer unmatched rotation speeds and weight efficiency. Remote or built into the motor, the electronic controller developed by Thales Avionics Electrical Motors very precisely controls the torque, position and rotation speed of the system. The brushless design increases the reliability of our electric motors and reduces routine maintenance. Main advantages Main features ■■ High performance ■■ Power up to 30 kW ■■ Comprehensive electronic control ■■ Rotation speed up to 100 000 rpm ■■ High reliability ■■ Input voltage up to 600 V ■■ Low maintenance costs ■■ Remote or built-in electronics ■■ Operating temperature range: - 54°C to 300°C 6 Applications ■■ Electromechanical Actuators (EMA) for flight controls ■■ Cryogenic system for camera ■■ Autopilot actuators ■■ Thrust vectoring actuators n The rotor of a BLDC* motor consists of permanent magnets and Hall-effect or optical sensors for detecting rotor position and current commutation. Electronic commutation inverts the polarity of the magnetic field in the stator windings. * BLDC: BrushLess Direct Current Unit (1/10'') Input voltage (Vdc) Power (kW) Rotation speed (rpm) Torque (N.m) Weight (g) Specific output (kW/kg) Size 12 28 0.05 5 540 0.08 150 0.3 Size 15 20, 28 0.01 - 0.13 1 760 - 2 600 0.05 - 0.7 125 - 380 0.1 - 0.3 Size 18 210 0.53 101 500 0.05 495 1.1 Size 24 270 0.4 14 500 0.26 700 0.6 Size 28 400 5.5 8 117 12 4 400 1.3 Size 43 400 22 7 000 30 16 000 1.4 7 Direct-Current (DC) motors D irect-current (DC) motors from Thales Avionics Electrical Motors are ideally suited for applications requiring high starting torques. Their design makes them easy to control, with speed varying with system load. We are capable to meet of fulfilling your requirements by designing custom DC motors. The cooling method, gearbox, and brake can be matched to your system. Main advantages Main features Applications ■■ Easy to control ■■ Power up to 30 kW ■■ Hydraulic and fuel pumps ■■ Produces constant torque ■■ Speed up to 20 000 rpm ■■ Flight controls actuators for helicopters and business jets ■■ Input voltage up to 270 V ■■ Operating temperature range: - 54°C to 125°C ■■ Liquid or air cooling 8 ■■ Aiming systems n In a DC motor, the excitation emf is produced in the stator either by permanent magnets or by stator windings. The induced emf is produced in the rotor windings. Current commutation through a commutator and brushes ensures a constant phase shift between the two fields. Power (kW) Input voltage (Vdc) Rotation speed (rpm) Torque (N.m) Weight (g) Length (mm) Specific output (kW/kg) 0.1 - 1 28 3 500 - 18 000 0.3 - 0.5 1 000 3 700 115 - 190 0.1 - 0.3 1-6 26 - 150 7 300 - 10 000 1.3 - 5.7 3 700 7 500 170 - 235 0.3 - 1.1 9 Asynchronous motors (AC) W ith high power density and reliability, asynchronous motors from Thales Avionics Electrical Motors have proven their worth in the Aerospace industry. They are sturdy enough to support your system in challenging environments, at high altitudes, or under water. Main advantages ■■ Varying frequency range with high performanceto-cost ratio ■■ Excellent performance in harsh environments ■■ Operates at high altitudes, or submerged ■■ Flameproof 10 Main features Applications ■■ Power up to 30 kW ■■ Hydraulic and fuel pumps ■■ Speed up to 24 000 rpm ■■ Belt loaders ■■ Fixed 50/60 Hz, 400 Hz or variable frequency ■■ Air cooling systems ■■ Operating temperature range: - 54°C to 125°C ■■ Liquid or air cooling ■■ Winch motors n In an asynchronous motor, the stator windings produce a rotating magnetic field. The rotor can be wound and consists of a squirrel cage (aluminium or copper bars joined at either end by rings). Current is induced in the rotor by the stator field. Power (kW) Input voltage (Vac) Frequency (Hz) (3-phase) Rotation speed (rpm) Torque (N.m) Weight (g) Specific output (kW/kg) 1 - 2.5 115 - 200 400 7 500 - 7 700 1.3 - 3.1 3 900 - 4 500 0.3 - 0.6 6 - 11 110 - 200 340/610 7 700 - 12 000 7.4 - 8.8 7 700 - 11 500 0.8 - 1 11 Stepper motors T he comprehensive stepper motor range from Thales Avionics Electrical Motors includes variable-reluctance and permanentmagnet motors, and provides the precision of operation your equipment needs. The high torque-to-inertia ratio and fast angular control minimizes the operating cycle time, and increases the productivity of the system. Featuring simple, maintenance-free construction at optimized cost, Thales’ stepper motors are ideally suited for various Aeronautical and Space applications. Main advantages n In a variable-reluctance stepper motor, the stator windings create a magnetic field. This magnetic field polarizes the stator, which consists of a ferromagnetic body (a ferrite bar). The phases of the windings are powered sequentially in order to obtain the desired angular motion. The rotor can be made of permanent magnets. Main features Applications ■■ Low inertia ■■ Power up to 400 W ■■ Air conditioning systems ■■ Very fast angular control ■■ Up to 48 steps per revolution ■■ Automatic soldering machine ■■ Operating temperature range: - 40°C to 85°C ■■ Satellite ■■ Optimized cost ■■ Pointing systems Unit (1/10'') Diameter (mm) Length (mm) Input voltage (Vdc) Number of phases Resistance/ phase (ohm) Step angle (°) Dynamic torque (g.cm) Specific output (g.cm) Size 8 19 31 28 - 40 2, 3, 4 75 - 160 15°, 90° 8 - 30 32 - 60 Size 11 27 41 28 2, 3, 4 30 - 200 7.5°, 15°, 90° 120 - 200 170 - 420 Size 15 37 52 28 2, 3, 4 17 - 55 7.5°, 15°, 90° 220 - 600 500 - 900 Size 20 51 76 28 3, 4 10 - 40 15°, 90° 400 - 1 400 2 000 3 500 12 Limited-displacement torque motors Main advantages ■■ Direct coupling to load without intermediate gearing ■■ Linear torque / current ratio ■■ High reliability ■■ Low cogging torque ■■ Operates in harsh conditions T hales Avionics Electrical Motors offers a range of limited-displacement torque motors incorporating all the features you need to meet your requirements in precision of operation. Main features ■■ Angular range: ± 30° ■■ Operating temperature range: - 54°C to 340°C ■■ Lifetime: more than 20 000 hours These motors are very simple to control due to the linear relationship between torque and current. High reliability and ability to withstand harsh environments (for instance, nearby aircraft turbojets) make them suitable for broad use. Their direct coupling simplifies the system and eliminates intermediate components. Applications ■■ Air bleeding ■■ Thermal camera Unit (1/10'') Length (mm) Weight (g) Input voltage (Vdc) Deflection angle (°) Torque constant (Nm/A) Size 10 24 43 12 ± 9° 0.03 Size 12 31.5 130 28 ± 5° 0.15 Size 12 51 260 28 ± 10° 0.19 13 Fans T hales Avionics Electrical Motors offers a full range of axial fans for cooling your system. Our fans are of standard or custom design, and are supplied with AC or DC. Main advantages ■■ Standard or customized fans ■■ DC and BLDC fans ■■ AC fans with fixed (400Hz or 50 /60Hz) or variable frequency ■■ Flow rate up to 100 l/s ■■ Pressure up to 500 Pa ■■ Operating temperature range: - 40°C to 100°C 14 Lifetime ■■ Alternating Current: 80 000 h at 25°C 40 000 h at 40°C 20 000 h at 55°C 10 000 h at 70°C ■■ Direct Current: 80 000 h at 25°C 35 000 h at 65°C Applications ■■ Rectifier transformers ■■ Calculators ■■ Heat exchangers ■■ Braking systems Category Type Volume (mm x mm x mm) Input voltage (V) Rotation speed Flow rate Pressure (rpm) (l/s) (mmH2O) Power (W) Noise (dB A) V22 AC 400 Hz 25,4 x 25,4 x 25,4 26 Vac 20 000 2,85 24 8 58 V57 DC 60 x 60 x 25 28 Vdc 6 000 - 7 000 10 - 12 7 - 10 3-5 48 - 53 V80 AC 50/60 Hz 92 x 92 x 25 220 - 240 Vac 2 700 - 3 200 16 - 18 4,5 - 5,5 12 - 13 40 V80 AC 400 Hz 92 x 92 x 25 115 - 200 Vac 3 400 - 5 400 23 - 36 9 - 24 10 - 20 56 - 63 V80 DC 92 x 92 x 25 12 - 28 Vdc 2 700 16 4,5 4 42 V113 AC 50/60 Hz 119 x 119 x 25 220 - 240 Vac 2 700 - 3 200 40 - 45 5,5 - 5,8 18 - 19 45 - 46 V113 AC 400 Hz 119 x 119 x 25 115 - 200 Vac 5 400 78 20 31 69 V113 DC 119 x 119 x 25 12 - 28 Vdc 2 700 40 5 5 45 V113 AC 50/60 Hz 119 x 119 x 38 220 - 240 Vac 2 700 - 3 200 44 - 48 7,8 - 9 20 - 23 47 - 49 V113 AC 400 Hz 119 x 119 x 38 115 - 200 Vac 3 400 - 5 400 57 - 92 12,5 - 35 20 - 45 57 - 70 V113 DC 119 x 119 x 38 12 - 28 Vdc 3 000 - 5 500 50 - 85 8,5 - 20 10 - 32 49 - 75 15 Motor controllers T hales Avionics Electrical Motors is positioned as a systems integrator. For several years, we have been designing high-tech electronic devices to control the position and speed of your electric motors. Thales Avionics Electrical Motors operates within three lines of expertise: 16 Control electronics Power electronics We have developed vector control algorithms on DSP(1) and FPGA(2) processors. Field weakening Control allows optimal use of the motor magnetic capabilities. The use of IGBTs(3) for high voltages and MOSFETs(4) for low voltages optimizes the efficiency of the electronics. Power conversion Thales Avionics Electrical Motors works on electric energy management and is able to offer this technology from a PFC(5). Participating in research programmes alongside the major players from the Aerospace industry, Thales Avionics Electrical Motors has gained an understanding of current and future stakes: ■■ Sensorless control ■■ Non-pressurized environnement ■■ Energy management ■■ Predictive maintenance Main advantages ■■ Input voltage: Direct current: 28 V to 540 V Alternating current: 115 V to 230 V 400 Hz, fixed or variable frequency ■■ Power: 5 W to 10 kW (1) DSP: Digital Signal Processor (2) FPGA: Field Programmable Gate Array (3) IGBT: Insulated-Gate Bipolar Transistor (4) MOSFET: Metal–Oxide–Semiconductor Field-Effect Transistor (5) PFC: Power Factor Corrector Applications ■■ Electromechanical actuator (EMA) motor controller for flight control surfaces ■■ Thermal camera air compressor controller ■■ Winch motor controller ■■ Hydraulic pump motor controller ■■ Operating temperature: -55°C to 85°C 17 Design to specifications With their vast experience in leading-edge sectors, Thales Avionics Electrical Motors accommodates to your requirements: cost optimisation, lifetime improvement, space saving, and weight reduction. Our experts are able to meet your requirements from specific environmental constraints: severe conditions, shock and vibration, high altitudes, and low pressures. Our teams are available to discuss your needs at the inception of the project, and assist you in defining the specifications. The customer is closely involved in the design of their product, and is given scope to intervene at every stage of the development process. ■■ Rare-earth magnets ■■ Insulation and sealing ■■ Specific ball bearings ■■ Hall-effect sensors, resolvers, or optical encoders to ensure commutation ■■ Speed and positioning sensors, thermal probes ■■ Specific windings according to the power supply 18 Thales Avionics Electrical Motors benefits from the flexibility of the building block approach to design, which enables customers to choose from a wide range of options for our electric motors to build true systems. ■■ Static or dynamic brake ■■ Gearbox ■■ Self-ventilation ■■ Mechanical release system ■■ Built-in motor controller Customer Support Thales Avionics Electrical Motors offers after-sales support from their storage facilities and logistic hubs in France, in the USA (Edison - New Jersey), and in Singapore. Main advantages n Global presence n 48-hour turn-around time nA icraft On Ground maintenance services Aware that any equipement downtime can be extremely costly, Thales Avionics Electrical Motors quickly responds to your needs in spare parts and in line replacable units (LRUs). n Customized services n EASA Part 145 certified Our technical support is available to answer your needs regarding improvements and changes. Repair centres in the world give us a local presence Seattle Montreal Toronto Minneapolis Edison San Francisco Irvine Memphis Phoenix London France Toulouse Hamburg Châtellerault Milan Beijing Charlotte Miami Dubai Delhi Singapore HUB Repair center Support center Sydney 19 5 Rue du Clos d’en Haut – BP 115 78702 Conflans Sainte-Honorine Cedex – France Tél.: +33 (0)1 39 19 60 60 – Fax: +33 (0)1 39 19 96 31 North American hub Thales Avionics Inc. 3920 Park Avenue NJ 08820 Edison, USA Tél.: +1 (732) 494 1010 – Fax: +1 (732) 494 1421 Asian hub Thales Aerospace Asia Pte Ltd 21 Changi North Rise 498788, Singapore - Singapore Tél.: +65 6424 7100 – Fax: +65 6424 7101 Conception - réalisation: Pastelle. Photos : photohèque Thales Group - THALES / Bassignac/Gamma, Boulard, Bourdin/Photopointcom, Mario Guerra, Kervel, Loubet, Photopointcom – THALES ALENIA SPACE / Briot - Alexandre Paringaux - Robineau/ Aviaplans/DASSAULT AVIATION - UK Crown - Fotolia.com / goodluz, Sahua D – Shutterstock / Dejan Milinkovic, ssuaphotos Headquarters: Thales Avionics Electrical Motors