Drives for Extreme Conditions

Applications that use small drives often require customized solutions. Flexible solutions can be developed using a broad range of standard products, including motors, precision gearheads, linear actuators, encoders, controllers, and various accessories. However, for particularly demanding applications, these standard offerings generally do not suffice. Solutions for challenging operating conditions—such as in the deep sea or in space—require custom drive solutions developed through co-engineering.

Ultra Motion, a U.S.-based specialist in electromechanical servo systems, designs actuators for use in harsh environments. These solutions are particularly well-suited for conditions involving high shock and vibration loads, exposure to liquids, saltwater immersion, and electromagnetic interference (EMI/EMC). The specialists in highly integrated electromechanical actuator systems with built-in control and position feedback have developed some of their systems in collaboration with Faulhaber. A common requirement for all these solutions is the need for actuators that combine high reliability with high power density.

Ultra Motion's product portfolio includes, among others, the L and T Series. The L Series offers high-precision linear positioning with high control stiffness and optional system redundancy, and is suitable for safety-critical, precise linear motion, such as in flight control systems. The T Series, on the other hand, provides reliable rotary motion under extreme mechanical or maritime conditions. In both cases, the high-power-density brushless DC motors from Faulhaber’s BP4 family, combined with precise planetary gearheads, ensure that high torques are available in compact housings.

Use in deep-sea and vacuum environments

The T Series is also available in the T3U variant, which is suitable for deep-sea use. A specially designed output shaft provides increased torque capacity, while a vented, oil-filled configuration enables pressure-compensated operation at depths of up to 6,000 m. For the L-Series, Faulhaber has implemented vacuum-optimized modifications that ensure reliable operation in space.

Integration into the specific configurations of the actuators requires a precise balance between high torque, dynamic performance, and long-term reliability. Environmental conditions in the deep sea or in space pose enormous challenges: harsh environments, high pressures, wide temperature fluctuations, or a vacuum in which the evaporation of lubricants must be prevented. These challenges can only be overcome through customized mechanical and material engineering solutions. Through the development partnership between Ultra Motion and Faulhaber, it was possible to overcome these hurdles and provide drives that function flawlessly even in the most demanding scenarios.

Nora Crocoll, Stutensee Editorial Office