BVR High-Efficiency Gear Products for Aerospace

BVR precision gearing solutions for aerospace offer:

• Proven airborne perfomance

• Large choice of configurations

• High torque-volume ratio

• Low backlash and backdriving torque 

BVR gear products are precisely engineered to offer high power transfer in small packages, ideal for direct-drive applications in aerospace, where performance per unit of weight and volume is critical.

Our engineering strategy follows a modular approach, based on our huge library of designs proven in demanding flight environments for decades. Our advanced manufacturing capabilities translate into tighter tolerances, better surface finishes, and more efficient transmission. We ship products with AGMA Quality 12 gears and offer optional superfinishing.

If you need something other than one of our off-the-shelf modules, we work with you to configure and fine tune a manufacturable, cost-effective solution, from a single gear to a complex transmission.

Typical engineering services include:

• Load and stress analysis

• Life expectancy analysis

• Speed and torque evaluation

• Accuracy and tolerance calculations (AGMA ratings)

• Materials, heat-treatment, and finish recommendations

 We also provide auxiliary components, including clutches, brakes, and position sensors

BVR Compact, High-Reliability Utility Actuators for Aerospace

 

BVR utility actuators from Esterline are a cost-effective, reliable solution to move doors, valves, radars, and other airframe equipment. Our engineering strategy follows a modular approach, based on our very large library of designs proven in demanding flight environments for decades.

We integrate all elements, including motors, reduction geartrains, position sensors, and control electronics. For example, we carefully match motors and gearboxes for a specific application, to deliver the required speed, acceleration, and limit load, as well as high torque-volume ratios.

Our advanced gear-cutting capabilities mean tighter tolerances, better surface finishes, and more efficient transmission, with hardened, precision gears up to AGMA Quality 12 to ensure accurate operation, long life, and long duty cycles.

BVR utility actuators offer:

• High-reliability brushless DC motors and stepper motors

• Microprocessor-based controls, reducing size and weight, helping distribute processing away from central systems, and facilitating integration

• I/O capability for discrete serial or analog commands

• BIT coverage in excess of 95 percent

• Proprietary non-contact, digital position sensors for higher-performance servos: our efficient designs yield a 30 to 40-percent reduction in footprint, envelope, and weight, and a higher power-to-weight ratio

• High-power / high-torque capabilities

With BVR actuators from Esterline, you have access to our world-class engineering and manufacturing capabilities and a mature range of reliable solutions and products. We can support your requirements with component-level solutions and subsystem integration.

BVR High-Reliability Flight-Control Servo Actuators

BVR servo actuators for the flight-control surface deliver the reliability, long life, precise operation, and ease of integration required by primary flight-control and autopilot system integrators.

Esterline offers a range of state-of-the-art aircraft-control and pilot-interface solutions, from components to subsystems, so we understand the context in which our BVR actuators operate. We can help with flight-control design and integration, offering a world-class team-based workforce with decades of skill and experience in aerospace.

We deliver servos for either linear or rotary motion and position control, and we engineer all elements to optimize their integrated performance, including motors, reduction geartrains, lead screw and ram assemblies, position sensors, and control electronics.

BVR linear actuators include thrust and radially supported lead screws for exact axis control and efficient transmission. Precise machining and finishing ensure close tolerances for smooth, reliable screw operation through the entire travel, minimized ram backlash, and improved protection against contaminants.

An additional BVR advantage is a non-jamming ram mechanism, with proprietary energy-absorbing components at the travel limits.

BVR rotary actuators feature motors and gearboxes carefully matched for the specific application. Our speed-reduction gear assemblies are fine tuned for high torque-volume ratios, as well as long life and duty cycles, with hardened, precision gears up to AGMA Quality 12.

All BVR servos offer:

• High-reliability brushless DC motors

• Microprocessor-based controls, reducing size and weight, helping distribute processing away from central systems, and facilitating integration

• I/O capability for discrete serial or analog commands

• BIT coverage in excess of 95 percent

• Proprietary non-contact, digital position sensors for higher-performance servos: our efficient designs yield a 30 to 40-percent reduction in footprint, envelope, and weight, and a higher power-to-weight ratio

• High-power / high-torque capabilities

• Gears with tighter tolerances and better surface finish, due to our higher-performance gear-cutting processes

Whether you look at component details or system integration, the Esterline team behind BVR actuators delivers the solutions you need

BVR Aircraft Data Concentration and Processing Solutions

BVR Remote DCU (RDC/PDCM)

Only available from Esterline, the BVR remote data concentrator (RDC, right), in combination with one or more programmable data-concentrator modules (PDCM, left), offers a versatile, modular solution to streamline data-transmission architecture and anticipate future growth. The RDC/PDCM pair includes firmware to allow quick toggling between up to eight I/O circuit configurations

BVR Gen 3 DCU

This DCU offers a mature design base to meet demanding concentrator requirements. With up to 250 channels and many circuit interface options, it is ideal for customization in complex high-volume, high-connectivity applications such as maintenance data computers and airframe sensor data concentrators

BVR RPU

BVR RPUs (remote processing units) form a new generation of compact solutions engineered with higher levels of built-in processing as well as data concentration and routing. Our adaptable RPUs support complex applications such as utility, power, or health management systems (UMS/PMS/HMS).

 

 

DCU Capabilities

Esterline is an industry leader in developing aircraft data collection, conversion, and routing solutions, usually referred to as DCUs (data concentrator units). Our BVR-branded DCUs deliver the technology you need to implement rugged, scalable, fault-tolerant data networks, with:

• Proven airborne reliability

• Versatile I/O and databus management

• Compact, low-weight designs

• Self calibration, self testing

DCUs collect discrete inputs, analog signals, and digital data from sensors and equipment throughout the aircraft, then convert them to digital format for streaming over the databus of the flight-control or aircraft-management system (typically ARINC 429, ARINC 664/AFDX, CAN bus, Ethernet, MIL-STD-1553, RS-422, RS-485).

Main advantages include reduced cabling and minimal signal interference, as well as improved robustness and survivability, through distributed redundancy and the elimination of single points of failure.

We optimize DCU reliability, weight, and size by engineering all our units to systematically reduce component count and connections. We implement state-of-the-art electronics technologies, including:

• Embedded passives

• System on a chip

• Configurable I/O

• FPGA circuit integration

Our electronics are so compact that the final form factor is driven by customer requirements for the number of I/O pinouts and associated connectors.

With our depth of expertise in electronics design, software, and mechanical engineering, as well as manufacturing and testing, we are able to deliver solutions perfectly suited to your platform requirements.