Curtiss-Wright’s Defense Solutions division announced that its Avionics business unit, based in Christchurch, Dorset, has been awarded Silver accreditation by the Investors in People Standard, demonstrating the Company’s commitment to high performance through good people management.

Curtiss-Wright continually invests in research and development to ensure it maintains technology leadership to deliver high performance Commercial off-the-shelf (COTS) and custom engineered products. Curtiss-Wright’s Avionics business provides system solutions that acquire, consolidate, analyze and record sensor and avionics data on aircraft. Our core capabilities include safety critical certified design and development processes (DO-178 and DO-254) combined with mature quality processes (AS9100). A range of product and service offerings enables us to provide solutions for many applications including: airborne recording, air data computing, flight test and space data handling systems. Curtiss-Wright Avionics is one of 3 business units based in Christchurch, Dorset and employs 100 staff. 

Investors in People is the international standard for people management, defining what it takes to lead, support and manage people effectively to achieve sustainable results. Underpinning the Standard is the Investors in People framework, reflecting the latest workplace trends, essential skills and effective structures required to outperform in any industry. Investors in People enables organisations to benchmark against the best in the business on an international scale.

Paul Devoy, Head of Investors in People, said: “We’d like to congratulate Curtiss-Wright Avionics, Investors in People accreditation is the sign of a great employer, an outperforming place to work and a clear commitment to success. They should be extremely proud of their achievement.”

Commenting on the accreditation, Mark Liversidge, General Manager of the Avionics and Electronics group, said:  “I am thrilled with this significant achievement for the Avionics team.  This has been a 3 year journey of working together to make significant improvements to our business through good people management.”

Curtiss-Wright’s Industrial division has today announced the launch of the WM-H10, a shaft-operated rotary position sensor featuring a solid-state, Hall-effect sensor that offers two independent and electrically-isolated outputs. Contained in a compact housing with integrated connector, the new sensor’s robust, mechanical design offers exceptional levels of performance and is ideal for use in hostile, on- and off-highway vehicle environments.

Commenting on the launch, Kevin Rayment, Senior Vice President & General Manager of the Industrial division says: “The launch of the WM-H10 sensor showcases Curtiss-Wright’s commitment to continuous development and engineering excellence and, as we continue to look at providing engineered solutions to our industrial customers and markets, the launch also serves to grow our portfolio of rotary position sensor options.”

The full range electrical output of the WM-H10 rotary position sensor can be set to correspond to maximum rotations from 15° to 360. This provides a dual linear output voltage proportional to the absolute position of the 6mm, D-profiled shaft in either direction from a reference angle. To avoid errors associated with air-gap fluctuations, an integral magnet arrangement ensures a consistent sensor-magnet separation.

The two independent measuring circuits, each with its own +5Vdc power supply connection, enable the use of algorithms that compare the signals for error checking. By using the first output signal as the source of rotational motion detection, and the second signal for diagnostic purposes, comparing the positional data from both outputs, signal veracity can be determined, meaning high-performing, safety-critical applications can easily be addressed. Further integrity is also provided as the outputs enter pre-defined states in the event of connection errors to the sensor.

Additional features of the WM-H10 rotary position sensor include:

• Fail-safe outputs
• IP68/IP69K-rated for water and dust, shock, vibration and temperature
• Operating temperature from -40°C to +85°C (SAE J1455)
• Lifespan 10 million cycles @ 1Hz
• MTTFd >1000 years
• Packard Electric ‘Metri-Pack’ 150 series connector

In a relationship that spans nearly 15 years, AL-KO Kober Limited – the leading manufacturer of vehicle chassis systems for the automotive, commercial and leisure industries – has been working in partnership with AKFS to develop chassis for a range of vehicles, from recovery vehicles and car transporters, to commercial vehicle solutions for grounds maintenance, tool hire and traffic management vehicles.

Commenting for AKFS, managing director Ian Knight says: “The collaboration started in 2003 when we approached AL-KO Kober to buy a chassis conversion for our Ultra Car Transporter, and things have evolved since.

“That vehicle is still very much part of our portfolio, but the chassis has evolved and is now tailored to our requirements. Our vehicles are also approved exclusively in the UK by AL-KO Kober and PSA for the conversion of low-floor traffic management, car transporter and lawn mower carrying vehicles.”

Design to optimise carry capacity and offer the ultimate payload, the Ultra Car Transporter is a 3.5-ton gross weight vehicle that, thanks to its ultra-lightweight but integrally strong Type-approved chassis conversion, offers 1,660kg of payload.

Commenting for AL-KO Kober, a company spokesperson says: “Typical company/fleet cars such as the BMW 3 Series, Audi A4 or Ford Mondeo all fit on the AKFS Ultra Car Transporter, so it’s a popular choice as a dealer-transfer, bodyshop or light-recovery vehicle, where operators can be assured that they are transporting vehicles legally on a chassis conversion, rather than a chassis cab from the manufacturer.”

AL-KO Kober’s low-profile chassis solution also means AKFS has been able to reduce the overall deck height, enabling vehicles with lower front and rear spoilers to be easily loaded. Additionally, an extended wheelbase provides better weight distribution over the front and rear axles; and rear torsion bar suspension improves driving characteristics when loaded.

Depending on a customer’s specification, Fiat, Citroen, Peugeot or Volkswagen cab units are delivered to AL-KO Kober’s facility in Warwickshire where the lightweight, ultra-low chassis conversion is installed. These Type-approved vehicles are then delivered to AKFS where the specified bodywork is fitted, tailored to customer’s requirements and built without compromise.

“The partnership with AL-KO Kober has meant that we can concentrate our design resources on producing solutions that are built without compromise and fit our customers’ requirements. We simply couldn’t manufacture a chassis solution that is as well-engineered, cost-effective or lightweight a solution ourselves.”

For further information on its vehicle chassis solution visit www.alko-tech.com/en, email info@alko-tech.com or call 01926 818500.

In this article, Rockatek director James Crowley looks at the importance of mechanical testing, its benefits and how his company has become an important part of its customer’s development strategy.

Mechanical testing can often be deemed as unnecessary, costly and time consuming and, in today’s world of vast computer modelling and simulation power, it can be hard to argue against this. To cut costs, companies may decide to reduce time and budget spent on testing. However, unanticipated failures of in-service products will have far greater cost and time implications.

Test verification is a vital part of any engineering design and, in some sectors – and depending on the product and its application – it is often a mandatory requirement. But in all sectors and prior to release to production and service, it is a critical part of the design and manufacture process. 

Some of the key benefits of physical test verification include the characterisation of material properties, validation/confirmation of product function, validation of computer (FEA) simulations, provision of empirical data to refine and improve simulations, proof of iterative product improvement and clear, visible evidence of product integrity to clients.

So, is testing worth the investment? A significant amount of product testing requires specialist or bespoke equipment and skilled engineers to design the test, its equipment and to accurately analyse the results; and this upfront investment for companies can be off putting. However, using a dedicated test house can provide a cost-effective option for companies looking for a professionally-executed, reliable and accurate test program.

At the heart of Rockatek’s core offering is an ability to ‘Engineer Value’ for its clients, to optimise their products and develop new technologies. The company is working with several clients to refine their existing products and extract every bit of value; whether that be making the product more reliable, or increase the product’s operational capability. Both ultimately improve the client’s bottom line on the return from its products and services.

Rockatek’s ‘Integrated Engineering’ approach to design, analysis and testing offers clients a complete service. Based on the client’s design specification and brief, Rockatek can deal with every aspect of an engineering project. 

Rockatek’s expertise is often utilised by its clients to fix products that are unreliable, break or fail, or sometimes are just not capable of functioning how they should. Where a completely new design is not feasible, Rockatek can often work within the confines of the original product but, when required, can develop completely new designs from a blank piece of paper to full working prototypes. Both scenarios often benefit from mechanical testing to demonstrate how the improved or new product performs when subjected to the conditions it must operate in. 

While its own analysis and computer modelling usually confirms what the outcome of a test will be, testing in a controlled laboratory environment to prove functionality is not only cost effective, but often a real eye opener to the client. And you simply cannot beat the impact of seeing the product working in a real load condition rather than just as a 3D model or an assembly on screen.

One of Rockatek’s key test rigs is the Large Scale Combined Load Test Rig, which is capable of testing combined loading conditions of tension/compression, torsion and bending. At 18m long and 1.1m wide between uprights, the test rig was originally designed to test full scale downhole tools – specifically drilling tools – for the oil and gas sector, with the rig capable of subjecting the tools to the conditions seen downhole. As those in this sector know all too well, the loads are severe and can render large and robust mechanical tools useless and badly broken in very short times. 

A summary of the test rig capability is given below.

• Tension / compression load capability– 20kN to 10MN
• Bending load capability– 120 kN at multiple locations
• Torque capability– Fully reversed torque up to 120kNm
• Power capability– 50kW electrical motor or 400kW hydraulic power

There are few test rigs available with this level of capability anywhere in the world. And for Rockatek to have this capability in-house is a huge asset to the company, with them seeing enquiries to use the test rig from major companies all around the world and in various sectors, including aerospace, O&G, industrial and motorsport. In fact, a recent enquiry came from Cougar Drilling Solutions in Edmonton, Canada.

Cougar Drilling Solutions design, manufacture and deliver downhole drilling tools, services and solutions to oil companies around the world. They are dedicated to delivering creative solutions and improving existing products to meet the ever-evolving demands of the drilling industry.

Commenting for Cougar Drilling Solutions, engineering director Dan Marson explains that Rockatek is fast becoming a crucial part of Cougar’s development strategy. “A current project is critical to our business plan and strategy for 2018/19 and we are trying to develop and optimise a core product to meet an increased capability requirement for some of our key customers in the Middle East.

In doing so, we are developing new technologies to meet the client’s demands and a key part of this is to demonstrate first-hand that the equipment is designed correctly and mechanically up to the job. In layman’s terms, it’s not going to fall apart or fail whilst under load downhole. 

“In our industry, downhole failures are the worst possible outcome and the associated lost time and cost is huge. If we can demonstrate to our client first hand that the product is capable of operating under the conditions it will experience downhole, with physical testing that they can witness in person, their confidence level in the product rises massively and we increase our chance of securing the lucrative contract.” says Dan.

He goes on to say that the complete and integrated consultancy service that Rockatek can offer really ticks all the boxes. “They investigate the problem with detailed mathematical and computer analysis, design suitable solutions and develop the technology with excellent engineering principles at the core of everything they do. 

But the real bonus here is their ability to carry out tests of this nature with their own in-house equipment to verify analysis and to demonstrate first-hand the way the products will function and survive under the extreme loads products in our industry are subjected to every day.”

Replicating the loading conditions seen in the downhole environment in a controlled laboratory environment is extremely challenging. Many have tried, and the reality is many have also failed because the equipment required is complex, expensive and requires expert engineers to operate and utilise it correctly. 

“Rockatek has this capability and, as director of Global Engineering for Cougar DS, it is my responsibility to execute this project. And having spent many weeks looking at other options for the test, I could not find any other company capable of executing this test in the way Rockatek is able, from a technical, price and lead time perspective.”

To satisfy Cougar’s test requirements, Rockatek submitted formal proposals, which have been accepted with the project now underway. The company is currently commissioning the test rig, manufacturing test specific components required for the test, writing risk assessments and method statements for the test plan and preparing to begin the test in July 2018. 

Preparation for a test of this nature is key to a successful outcome. The test will be executed to a set plan, results will be logged with data acquisition equipment and final test reports will be generated and supplied to Cougar DS within one week of test completion. 

Rockatek design, analyse and test products to optimise capability and add value to its client’s technology portfolio. They are committed to becoming a leading engineering consultancy in both the UK and beyond, especially in the O&G sector and specifically with design, development and optimisation of downhole tools. 

Curtiss-Wright Industrial has today announced that it will be exhibiting at this year’s CeMAT show in Hannover, Germany and using its stand (Stand C16/Hall 26) to promote products from its four family brands – Arens Controls, PG Drives Technology, Penny & Giles and Williams Controls – all of which have extensive experience in designing and manufacturing solutions for the monitoring and control of material handling vehicles.

From the latest on- and off-highway vehicles, to the rapidly developing hybrid and fully-electric vehicle market, Curtiss-Wright engineers are focused on developing bespoke, innovative solutions and next generation technology. This intelligent engineering, from initial concept to finished product, demonstrates the Industrial division’s commitment to providing the advanced control and power management systems demanded by today's material handling vehicle manufacturers.

From its Arens Controls brand, Curtiss-Wright will be showcasing the all-new WTI-S160 Traction Inverter, which offers state-of-the-art technology and innovative design for use in hybrid and pure-electric applications. WTI-Traction Inverters have been designed with two primary safety goals in mind. The first is a high-voltage component with features that render it safe for personnel during vehicle service and maintenance. Secondly, with the industry moving toward delivering components and systems that adhere to ISO 26262, Curtiss-Wright is proactively delivering traction inverters to the market with this requirement in mind.

The PG Drives Technology brand will represented by a selection of sub-system HMI Controls and its C3-CE, a CE-marked motor controller that features EN ISO 13849 Category 3 hardware architecture, including dual microprocessors, dual inputs and a dedicated B+Safe output.

Joystick controllers and multi-function handle solutions from Penny & Giles will also feature on a selection of sub-system HMI Controls that include custom control boxes and armrest assemblies. Also on the stand will be the all-new, single-axis JC040 proportional rocker, JC050 thumbwheel roller and JC1210 single-axis paddle joystick; and the NRH27C, a no-contact rotary position sensor offering CANbus J1939 output that is suitable for use on specialty on- and off-highway vehicles utilizing CANbus communications.

For Williams Controls, the company will be promoting its WM-H10 rotary sensor, with the stand also featuring a selection of products from its electronic throttle controls range including a new, modular range of off-highway pedals.