Mechatronic Technology Development For Aerospace and Industry Bearing Solutions

Mechatronic technology
development for aerospace and

industry bearing solutions
EMM, Toulouse, September, 25th. 2013
BU Industry - F.Lesigne – R&D Director

CONFIDENTIAL – NTN-SNR Property EMM – Toulouse – 25/09/2013
Aerospace market
Fly-by wire development
• During the second half of the 20th century, hydraulically

driven systems replaced the original mechanical flight
controls.
• The main technological breakthrough came in 1984, when
Airbus introduced fly-by-wire controls on its A320 single-
aisle jetliner, with a computer controlling the actuators for
flight control. Boeing developed a similar approach starting
with its 777 widebody twinjet.
Design engineers began to think about enhancing this baseline

design around the year 2000, taking a much closer look at
electrical systems. The Airbus A380 super-jumbo jet, for
instance, eliminated one of the three traditional hydraulic
circuits, replacing it with an all-electric backup system for
flight controls.

Aerospace market
• During the second half of the 20th century, hydraulically

driven systems replaced the original mechanical flight
controls.
• The main technological breakthrough came in 1984, when
Airbus introduced fly-by-wire controls on its A320 single-
aisle jetliner, with a computer controlling the actuators for
flight control. Boeing developed a similar approach starting
with its 777 widebody twinjet.
Design engineers began to think about enhancing this baseline

design around the year 2000, taking a much closer look at
electrical systems. The Airbus A380 super-jumbo jet, for
instance, eliminated one of the three traditional hydraulic
circuits, replacing it with an all-electric backup system for
flight controls.
Sce SAFRAN

Aerospace market
The development of electrical systems increases the needs of new

actuators and sensors to bring performance and save:
 Cost
 Weight
with a high level of reliability
Fly-by-wire systems should integrate a lot of functions in a limited

package.
For new actuators generation, the need is to measure:

 Absolute position
 Temperature
 Loads
 Information for diagnosis or condition based
maintenance

Aerospace market
Condition Based Maintenance
In parallel to the development of fly-by-wire systems, the aerospace operators

want to purchase Pay By Hour solutions. It requires a customized
maintenance per aircraft to reduce maintenance costs and increase the
aircraft availability => Condition Based Maintenance (CBM)
The introduction of CBM should also enable to increase flight security by a

better follow-up of the mechanical parts.
For instance helicopter “Oil and gas” market is demanding this PBH offer.

Aerospace market
Condition Based Maintenance
For example, the target is not to manage OTL

(Operating Time limit) anymore for helicopters
transmission bearings but to continuously
know the actual condition of the bearings.
The challenge for NTN Corp is also to use the

measurements through the bearings to monitor
the surrounding mechanical parts.
Sce EUROCOPTER
The target would be to have a inflight system

that would enable to know the real conditions
of usage of the different systems to predict the
optimized maintenance period.
Sce EUROCOPTER
Sce EUROCOPTER

Challenges for Industry
Industry tendencies
In other domains, such as Railway, Energy production, Heavy Industry, …,

tendencies and expectations are similar :
Increase functions Market relevant

Mechatronic offer
Improve efficiency Weight & Cost

optimization
Improve reliability / availability Solutions for Condition

Based Maintenance
Reduce costs (purchasing and TCO)

Industry tendencies
Robotics
Low weight products
Men collaboration solutions
Market relevant
Lifters Mechatronics offer
Low cost and reliable sensors
Weight & Cost
optimization
Off Road
Very low speed solutions Solutions for Condition
Increased environment Based Maintenance
Global
Wireless
Energy harvesting

Industry tendencies
Heavy machines with high cost Market relevant

for any non production time. Mechatronic offer
Heavy maintenance operations Weight & Cost

with middle term forecast. optimization
Market looks for solutions allow Solutions for Condition

: Based Maintenance
-A better maintenance
operations efficiency
-A better forecast of
maintenance operations
-A lower cost by implementing
predictive maintenance .
Maintenance : main challenge
for Industry and Aerospace
Condition Based Maintenance (CBM)
CBM is based on physical measurements and parameters evolutions.
At the interface between moving and static parts of any machine, the bearing is naturally the
most direct place to collect data in order to survey systems.
NTN-SNR in continuously developing a range of technology bricks that will allow, in the
future, to know in real time the status and estimate remaining life of the most critical parts.

Mechatronic technology
development for CBM
NTN is permanently conducting research activities to develop the new

technologies that will bring the requested information to the CBM control
system :
• Loads applied on the system
• Torque applied on a transmission or a driveline
• Precise speed and angular position information
• The deep and extensive knowledge of the bearing system to

simulate the impact of these loads.
• ….

Load measurement
technologies
Wheel Bearing Load Sensor
Contact forces
Contact forces are measured at several High strain

positions on the bearing.
Fx, Fy, Fz, Mx, Mz can then be calculated

thanks to a real-time algorithm, temperature
independent and without power-on Low strain
calibrating.
Load measurement
technologies
Reference
Wheel Bearing Load Sensor dynamometric wheel
Tests on vehicle:
Whatever the driving condition (straight, curve, braking..) :

- Accuracy :
Forces < 3%
Torque < 0.5 %
- Very good estimation of gear shift
- No delay of sensor response

Torque measurement
technologies
Torque Measurement
HIGH RESOLUTION 1 HIGH RESOLUTION 2

REFERENCE PULSE 1 REFERENCE PULSE 2
Two high resolution angles are

Angle 1 Angle 2 measured at each shaft end.
A calculation algorithm has been

developed to evaluate the
applied torque.
TORQUE
VALUE

Speed and angle measurement
technologies
High Resolution Speed Sensing

The only “all-in-one” solution on the market with:
- High Resolution Speed output (low speed detection)
- Direction of Rotation Outer track :
- Reference Pulses Reference Pulse (C)
Internal track :
High Resolution (A & B)
(up to x40 the pole
pairs number)
HIGH RESOLUTION
A
B
REFERENCE PULSE
C
angle
NTN-SNR MPS40S ASIC
Speed and angle measurement
technologies
TMR Generation
Coming from Spintronics (Nobel Prize in Physics 2007)
A new Frontier for Speed and Position Sensing

• Ultra Low Power (100 times less than AMR / GMR / Hall)
for wireless applications
• Large Air Gap (x2.5 compared to a standard sensor)
for reading through a housing
• High Temperature (above 150°C)
• 2x Larger Positioning Tolerances at all temperatures
easy assembly
low function cost
Possible Applications:

Basic bearing technologies
Our added value : bearing knowledge
As bearing developer, our knowledge allows us to optimize the amount of

information gathered thanks to measures done in the bearing.

CMS Experiences
Vehicles
9 years ago, this collaboration with an OEM

was the first experience for NTN to check new
technologies for bearings failures detection.
Tests have been conducted on test bench as

well as on vehicle.
Very encouraging results pushed NTN to

continue its efforts whereas passenger cars
and light trucks markets were not confirmed.

CMS Experiences
Railway
Motivated by high owning costs, Railway

market also proved to be a very good
candidate.
A multi partners project led to :

- extensive lab characterization
- 4 years field experience in
commercial use.
Multi parameters analysis has been improved

to lead to the actual proprietary technology.

CMS Experiences
Wind turbines
Inscribed in the tremendous growth of CMS

demand in Wind Market, NTN corp decided to
develop competitive as well as innovative
products.
Recognized by the market, our product is GL

certified and available.
Since 2 years, for new technology, measures
are done in real wind turbine conditions.

CMS Experiences
Global Industry
After several programs targeted on specific

applications, NTN-SNR is now extending its
new multi-parameters technology in order to :
- fulfill any Industrial case
- be able to see outside the bearing
- enhance its core advantages
All this is driven making the very early

degradation detectable in any environment.

Mechatronic products
Speed Position Others
Condition Monitoring Wireless & Energy harvesting

Franck LESIGNE
BU INDUSTRY
R&D Director
Email: franck.lesigne@ntn-snr.fr


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Mechatronic technology

development for aerospace and

BU Industry - F.Lesigne – R&D Director

Fly-by wire development

• During the second half of the 20th century, hydraulically

Design engineers began to think about enhancing this baseline

BU Industry - F.Lesigne – R&D Director

Fly-by wire development

• During the second half of the 20th century, hydraulically

Design engineers began to think about enhancing this baseline

BU Industry - F.Lesigne – R&D Director

Fly-by wire development

The development of electrical systems increases the needs of new

Fly-by-wire systems should integrate a lot of functions in a limited

For new actuators generation, the need is to measure:

BU Industry - F.Lesigne – R&D Director

Condition Based Maintenance

In parallel to the development of fly-by-wire systems, the aerospace operators

The introduction of CBM should also enable to increase flight security by a

BU Industry - F.Lesigne – R&D Director

Condition Based Maintenance

For example, the target is not to manage OTL

The challenge for NTN Corp is also to use the

The target would be to have a inflight system

BU Industry - F.Lesigne – R&D Director

In other domains, such as Railway, Energy production, Heavy Industry, …,

Increase functions Market relevant

Improve efficiency Weight & Cost

Improve reliability / availability Solutions for Condition

Reduce costs (purchasing and TCO)

BU Industry - F.Lesigne – R&D Director

BU Industry - F.Lesigne – R&D Director

Heavy machines with high cost Market relevant

Heavy maintenance operations Weight & Cost

Market looks for solutions allow Solutions for Condition

Condition Based Maintenance (CBM)

CBM is based on physical measurements and parameters evolutions.

most direct place to collect data in order to survey systems.

BU Industry - F.Lesigne – R&D Director

NTN is permanently conducting research activities to develop the new

• Loads applied on the system

• Torque applied on a transmission or a driveline

• Precise speed and angular position information

• The deep and extensive knowledge of the bearing system to

BU Industry - F.Lesigne – R&D Director

Wheel Bearing Load Sensor

Contact forces are measured at several High strain

Fx, Fy, Fz, Mx, Mz can then be calculated

Whatever the driving condition (straight, curve, braking..) :

BU Industry - F.Lesigne – R&D Director

HIGH RESOLUTION 1 HIGH RESOLUTION 2

Two high resolution angles are

A calculation algorithm has been

BU Industry - F.Lesigne – R&D Director

High Resolution Speed Sensing

Coming from Spintronics (Nobel Prize in Physics 2007)

A new Frontier for Speed and Position Sensing

BU Industry - F.Lesigne – R&D Director

Our added value : bearing knowledge

As bearing developer, our knowledge allows us to optimize the amount of

BU Industry - F.Lesigne – R&D Director

9 years ago, this collaboration with an OEM

Tests have been conducted on test bench as