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BU Industry - F.Lesigne – R&D Director CONFIDENTIAL – NTN-SNR Property EMM – Toulouse – 25/09/2013

Mechatronic technology

development for aerospace and

industry bearing solutions

EMM, Toulouse, September, 25th. 2013


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.

Fly-by wire development


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

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.

Condition Based Maintenance


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.

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

Sce EUROCOPTER


Challenges for Industry

In other domains, such as Railway, Energy production, Heavy Industry, …, tendencies and expectations are similar :

Increase functions

Improve efficiency

Improve reliability / availability

Reduce costs (purchasing and TCO)

Industry tendencies

Market relevant Mechatronic offer

Weight & Cost optimization

Solutions for Condition Based Maintenance



Industry tendencies

Market relevant Mechatronics offer



Robotics Low weight products Men collaboration solutions Lifters Low cost and reliable sensors Off Road Very low speed solutions Increased environment Global Wireless Energy harvesting



Industry tendencies

Market relevant Mechatronic offer



Heavy machines with high cost for any non production time. Heavy maintenance operations with middle term forecast. Market looks for solutions allow : -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

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.

Condition Based Maintenance (CBM)


Mechatronic technology development for CBM

• 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.

• ….

NTN is permanently conducting research activities to develop the new technologies that will bring the requested information to the CBM control system :


Load measurement technologies

Wheel Bearing Load Sensor

Low strain

High strain

Contact forces

Contact forces are measured at several 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 calibrating.


Wheel Bearing Load Sensor

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

Reference dynamometric wheel

Load measurement technologies


Torque Measurement

HIGH RESOLUTION 1

REFERENCE PULSE 1

Two high resolution angles are measured at each shaft end.

A calculation algorithm has been

developed to evaluate the applied torque.

Angle 1

TORQUE

VALUE

Angle 2

HIGH RESOLUTION 2

REFERENCE PULSE 2

Torque measurement technologies


High Resolution Speed Sensing

angle

C

B

A

NTN-SNR MPS40S ASIC

Outer track : Reference Pulse (C)

Internal track : High Resolution (A & B) (up to x40 the pole pairs number)

HIGH RESOLUTION

REFERENCE PULSE

The only “all-in-one” solution on the market with: - High Resolution Speed output (low speed detection) - Direction of Rotation - Reference Pulses

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:

Speed and angle measurement technologies


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

information gathered thanks to measures done in the bearing.

Our added value : bearing knowledge

Basic bearing technologies


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

Condition Monitoring Wireless & Energy harvesting

Others


Franck LESIGNE

BU INDUSTRY R&D Director

Email: [email protected]

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