Edward Dryden, Vice President Actuation Systems for Collins Aerospace:

10 Eylül 2019
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You can read the news article published in the DSEI’19 Special Issue of MSI Turkish Defence Review here:

 

“We want to contribute to the success of the Turkish industry”

 

Talking to MSI in preview of Defence & Security Equipment International (DSEI) show, Edward Dryden, Vice President Actuation Systems for Collins Aerospace, explained Actuation Systems commitment to be at the forefront of the industry to offer to customers latest innovations and particularly for the future of Turkish aircraft programs.

 

“We, at Actuation Systems, express Collins Aerospace’s vision using these words: We are redefining Aerospace. That’s a bold statement but we, at Collins Aerospace, want to be at the forefront of the way our industry works to deliver sophisticated solutions to our customers and establish strong and trusted relationships with them” explains Ed Dryden.

Created in 2018 by bringing together UTC Aerospace Systems and Rockwell Collins, Collins Aerospace is committed to providing the best in innovation and intelligent solutions for the global aerospace and defence industry. Collins Aerospace has the capabilities, comprehensive portfolio and expertise to solve customers’ toughest challenges and to meet the demands of a rapidly evolving global market.

This is particularly true for the Actuation Systems business that Mr. Dryden is leading.

Collins Aerospace provides simulation solutions for fighter jets.

Collins Aerospace provides simulation solutions for fighter jets.

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Breadth of Capability

Collins Aerospace has the latest developments in technology supplying a large portfolio of Actuation Systems for Fixed Wing, Rotorcraft and Military platforms. The Company has more than 50 years of actuation experience, and is able to provide solutions to its customers for a range of actuation products including: Primary Flight Controls (Fixed Wing & Rotorcraft), Trimmable Horizontal Stabilizer Actuator, High Lift Systems, Nacelle Actuation, Anti-Ice Valves, Composites, Utility Actuation and Missile Actuation.

Looking to the future, Collins Aerospace is focused on providing system value through more electric technologies, integrated components and health parameter monitoring. Customers designing aircraft for Unmanned Air Systems (UAS), Fifth and Sixth Generation Fighters, Trainers or Future Vertical Lift (FVL) can turn to Collins ,knowing they will be delivered solutions that enable them to meet the demanding mission profiles of next generation aircraft.

Collins Aerospace Actuation Systems has accomplished more than 10 billion flight hours of experience using Fly-By-Wire actuators. From hydraulic or mechanical to electro-mechanical solutions, Actuation Systems are able to create tailor-made solutions dependent on customer requirements for full or partial Actuation Systems; they can also provide full system integration and testing to ensure product performance.

“One of our key assets to support our customers is our aftermarket solutions”, stresses Ed Dryden. Collins Aerospace has a truly global capability for the products and services it provides. Collins Aerospace Actuation Systems provide a full range of capabilities for aftermarket/MRO services administering a truly global support network that is available 24/7, 365 days a year.

At DSEI, Collins will present its full portfolio of actuation systems “We see a lot of potential  for  military  programs such as TX, Future Vertical Lift, Tempest, FCAS, TFX and in areas such as fixed wing fighters and trainers” said Ed Dryden.

F35_Weapons Bay Door Actuation System - C - Collins Aerosapce

Collins Aersoapce Actuation Systems provides tailor-made Utility Actuation for a host of purposes including: Weapon Bay Door Drive System (WBDDS).

 

Actuation Systems is ideally placed to support these opportunities with a global capabilities  and a extensive  experience including programs such as V-22, NH90, A400M, KC-390, HAWK, M-346, Eurofighter, to name a few.

“Turkey is a very important location for Actuation Systems” Mr. Dryden said. “Actuation Systems will look to continue to build upon existing partnerships, and explore new partnership opportunities with companies like Turkish Aerospace, ASELSAN, HAVELSAN, Roketsan and TUBITAK”.

On current Turkish programs, Collins provides the Environmental Control System (ECS) on the HÜRKUŞ, and the main and tail rotor actuators on the T625. But if we look at the broader Collins Aerospace, also provides radio and navigation systems on the Black Hawk variant and on the T625 and we have simulation on the F-16 and flight controls on the unmanned vehicles.

“TF-X and HÜRJET, for example, are two strategic programs that Actuation Systems is currently pursuing. Through increasing our existing presence and focus on indigenous content and solutions, we are interested in collaborating with local industry leaders in Turkey”, said Ed Dryden. “We are encouraged by the growth in the Turkish Aerospace industry and we see potential opportunities for Actuation Systems to develop a supply base that we can use for our global projects”.

 

Strong Capabilities

Collins Aerospace Actuation Systems has extensive experience in Control Actuation Sections for precision guided missiles including programmers such as GLMRS and Standard Missile.  Actuation Systems are able to provide the Control Actuation System (CAS) and Thrust Vectoring Actuation (TVA) for a range of missile applications. For example, it has developed CAS for a wide variety of missile applications with packaging concepts ranging from discrete actuators to fully integrated missile CAS sections. Collins manufacturing processes cover both low and high production rates – from a few development units to several thousand systems per year.

Collins Aerospace has the latest developments in technology supplying a large portfolio of Actuation Systems for Fixed Wing, Rotorcraft and Military platforms.

Collins Aerospace has the latest developments in technology supplying a large portfolio of Actuation Systems for Fixed Wing, Rotorcraft and Military platforms.

 

Collins Aerospace delivers high quality aviation systems that have logged billion hours of flight time.

Collins Aerospace delivers high quality aviation systems that have logged billion hours of flight time.

Another capability of Actuation Systems, is also the design, development, manufacture and qualification of Utility Actuation Systems. Utility Actuation Systems consist of a collection of specialist actuators with a single-use that provide movement of doors, valves and other mechanisms that are found on military platforms. Actuation Systems provides tailor-made Utility Actuation for a host of purposes including: Weapon Bay Door Drive System (WBDDS), Refuel Probe, Air Brake, Wing Rotation System, Wing Fold, Other Door Actuators, Common Strategic Rotary Launcher (CSRL), Wing Sweep Actuation System and Bearing Uplock.

Actuation Systems has a significant pedigree with Main Rotor, Tail Rotor, and Tilt Rotor Flight Control Actuators, specifically Fly-By-Wire solutions on a range of rotorcraft platforms including Direct Drive Value (DDV) and Electrohydraulic Servovalves (EHSV) solutions. “We have a long heritage in supplying mechanical flight control actuators and electro-mechanical solutions, and Collins has indeed an extensive experience of failsafe design including redundancy and fail safety parts”, said Ed Dryden. “We continue to invest heavily in Research & Development to extend time between overhaul of our actuator technologies and to simplify actuator control system architecture. We have bespoke, custom made test equipment and an ability to offer vertical integration” he said.

Collins Aerospace has also more than 50 years of flight control experience, and has developed the first in-service commercial actuator technologies for Fly-By-Wire (FBW), Electro-Hydrostatic (EHA), and Electrical Back-Up Hydraulic Actuator (EBHA). The Company has over ten years’ in-service experience of supplying Electric Actuators (EHA/EBHA) and have introduced SMART actuator technology on recent platforms. Its product portfolio serves both commercial and military aircraft. Actuation Systems is setting its sights to the future developing a new range of Electro-Mechanical Actuators (EMA) for the next generation of Aircraft.

 

Collins Aerospace works on a series of next generation technologies.

Collins Aerospace works on a series of next generation technologies.

At the Forefront of Technology

High Lift Systems is another area for which the company is focusing to drive innovation. Recently, Collins Aerospace, Actuation Systems business began work on a $8.5 million next-gen high-lift system project to deliver systems, components and installation technology concepts for a high-rate/high-production-volume high-lift system by 2022. “Our engineers are exploring a distributed architecture for the new system that drives units at each station, rather than a central power unit that drives out all surfaces mechanically synchronized. In this way, pilots could exercise greater precision in operating the system through individual control of the panels, and the transmission shafts required by traditional systems could be eliminated. Making our systems potentially easier and more cost effective for aircraft manufacturers to install”, explains Ed Dryden. The next-generation high-lift system should use fewer parts compared to existing systems, thus reducing aircraft build time, and it should also reduce the loads transferred to the aircraft structure, thus enabling possible reduced structural component weight, size and corresponding fuel burn. The system itself should also be lightweight thanks to its innovative gearing architecture, and could also be additively manufactured using advanced materials to achieve further weight reductions.

Collins manufacturing processes cover both low and high production rates – from a few development units to several thousand systems per year.

Collins manufacturing processes cover both low and high production rates – from a few development units to several thousand systems per year.

In addition, Actuation Systems is looking to equip the next-generation high-lift system with a smart system of wireless sensors that should allow designers to provide electronic torque limitation and provide operators with a predictive health maintenance capability by monitoring the system’s operating condition.

One of the key trends in the aerospace industry is a shift from hydraulic technologies to more electric systems. Collins Aerospace is developing and fielding products to realize the benefits of the more electric aircraft solution, including a reduction in weight and cost, as well as increases in reliability and flexibility. Electric, motor-driven actuators and systems eliminate electrically controlled hydraulic servovalves and hydraulic lines. Collins has extensive experience in the optimization of electric actuation motors to achieve high efficiency at the necessary speed and torque of the application. Collins’ development of low cost, scalable motor drives can be used across a wide range of system power requirements, resulting in a high reliability solution that delivers repeatable performance due to the re-use of common components and architecture. Finally, electric systems allow flexibility in terms of operation and diversion of hydraulic power to more critical use systems.

As a natural progression of integration, Collins seeks out opportunities to combine functional elements together. One example of this includes exploring the benefits of integrating utility actuation controllers into Vehicle Management Computers (VMCs). Collins’ VMC features triple multi-core processors, high-speed communications and open architecture for use in high-redundancy flight critical applications. The system’s advanced functionality will enable fly-by-wire control, support autonomy and unmanned operation, and allow the system to host multiple applications, such as mission management and utility management. This integration will mean less discrete control units, resulting in sizable aircraft weight savings.

Collins is also developing actuation packages equipped with smart systems of sensors. Using sensors that monitor parameters such as vibration, temperature, and load with advanced predictive algorithms, Collins can help OEMs find early failures or allow maintenance to be conducted on a more cost-effective, condition-based basis, rather than a more costly, time-based maintenance schedule. These sensing systems can be implemented with negligible impact to system or actuator weight.

Collins Aerospace provides the Environmental Control System (ECS) on the HÜRKUŞ.

Collins Aerospace provides the Environmental Control System (ECS) on the HÜRKUŞ.

On the composite side, Collins Aerospace is challenging the perception of high cost Composites. In the aerospace industry, traditional thinking holds that the weight savings of composites must come at a cost. Thanks to breakthroughs in joining and material technologies, as well as in design and production methods, Collins Aerospace is now delivering the benefits of composites to customers worldwide, often without the added cost. To accomplish this, the Collins Aerospace, Actuation Systems Composite Centre of Excellence in Banbury, UK has developed innovative composite-to-metal joining technologies for the transmission of axial loads, as well as a patented process using high viscosity resin systems and a highly automated production system. Struts and tie rods, structural components in aircraft wings and fuselages, are key beneficiaries of these new developments, enabling Collins to use their materials expertise to get the most out of composites.

With an understanding of how to optimally use materials in locations best suited to their properties, Collins Aerospace provides products that are both cost and weight-effective. For example, when load paths and geometries are complex, metal is often advantageous due to its isotropic properties, meaning the material has the same characteristics in all directions. Composites are often superior where load paths can be aligned with the main fibre direction. In the case of struts and tie rods, Collins uses a lightweight carbon fibre composite tube with an optimised laminate for compressive and tensile loads, and end connections such as clevises utilise metal due to the complex stresses and geometries required.

Collin Aerospace is the supplier of the main and tail rotor actuators, as well as radio and navigation systems on the T625.

Collin Aerospace is the supplier of the main and tail rotor actuators, as well as radio and navigation systems on the T625.

 

When it comes to joining metal and composite together, Collins Aerospace Actuation Systems’ proven design philosophy does not rely on adhesive bonding. This removes the difficulties inherent in manufacturing, testing and qualifying bonded joints and leads to a cost effective, robust and reliable transfer of load under all operating conditions. These adhesive-free joining technologies are also cost effective for the less critical aircraft structures, yet still certifiable for flight critical applications. Actuation Systems’ joint technologies provide a mechanical interface whilst negating the need for rivets which weaken the laminate as a result of high stress concentrations. The joints are preloaded to prohibit fretting between the composite and metal surfaces; no relative movement means high fatigue loads can be sustained without detriment to the joints. For customers, this means no in service maintenance is required. Components are designed and tested to last well over the life of the aircraft.

Collins Aerospace, Actuation Systems, has also developed a proprietary manufacturing technology to integrate the benefits of both pre-impregnated fibre and dry fibre processing. Typically within the aerospace industry, there exists a large trade-off between performance and manufacturing cost. High viscosity resin systems, which offer superior performance, have to be procured and processed as expensive prepregs. Collins has enabled the use of high viscosity resin systems at a fraction of the cost of prepreg through a proprietary patented process that integrates resin filming and impregnation. This “prepreg” material is then fed into a filament winding machine that operates with a high level of automation. Using fibre and resin as the inputs, rather than traditional prepreg materials, enables greater product optimisation and flexibility while dramatically reducing raw material costs.

These innovative joining and processing technologies means that Collins Aerospace, Actuation Systems, can offer weight savings of up to 50% over aluminium swaged rods, at the same price, delivering a huge leap forward in the business case for composites in aerospace applications.

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