From Cockpit to Control Surface: The Motors Behind Modern Autopilot Systems

As the aerospace industry advances, autopilot systems are becoming essential for enhancing flight safety, reducing pilot workload, and enabling more complex missions. Historically, light helicopters have lacked autopilot capabilities due to strict weight and size limitations, leading to increased pilot fatigue and a higher risk of incidents. To address this challenge, OEMs are now introducing compact automatic flight control systems (AFCS) tailored specifically for light helicopters. These systems deliver enhanced stability and control with minimal impact on weight and space.

Advancing Flight Control with Brushless DC Motors

At the heart of this innovative autopilot system are high-performance brushless DC (BLDC) motors, which play a critical role in the flight control actuator system. These motors serve as the critical interface between pilot commands and the hydraulic actuators, enabling precise control of flight surfaces and smooth aircraft maneuverability. Designed to meet the rigorous demands of rotary-wing aircraft, Portescap’s BLDC motors are built to perform reliably in high-vibration, high-stress aerospace environments, ensuring consistent operation throughout the helicopter’s operational life.

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Portescap’s motors meet the stringent RTCA DO-160 aerospace standard, ensuring they can withstand harsh environmental conditions such as extreme temperatures, humidity, and mechanical shock. To maximize performance, these motors are optimized for Size, Weight, and Power (SWaP), delivering high torque in the smallest possible package while maintaining safety as the primary design driver.

To further enhance the performance of flight control systems, rotor inertia is a key factor in motor design. Our engineers precisely optimize inertia to boost command responsiveness, enabling real-time feedback to the pilot, hydraulic system, and flight control management system. This leads to faster reaction times and improved flight accuracy—capabilities that are vital in high-stakes operations such as search and rescue missions and medical evacuations

Innovative Motor Technologies for Superior Performance

Portescap offers a range of motor configurations, including inner and outer rotor designs, as well as advanced axial flux motors. The axial flux architecture, featuring a disc-shaped rotor and stator, delivers high torque density and reduced inertia in a compact form factor, making it ideal for aerospace applications where space and weight are critical.

Figure 1: Rendering of an axial flux motor

That’s why Portescap works hand-in-hand with customers to design motion solutions tailored to their specific needs. This collaboration extends beyond design; it includes thermal modeling, product life simulations, and exhaustive reliability testing. Through this comprehensive approach, each motor is engineered to meet the highest standards of performance and regulatory compliance. And for applications where redundancy is essential, Portescap can develop dual-winding motor designs that satisfy even the most stringent safety requirements.

Figure 2: Example of a dual-winding motor

A Trusted Partner for Aerospace Innovation

With decades of expertise in aerospace motor development, Portescap is more than just a component supplier; we’re a strategic partner. By working closely with flight control system manufacturers, we ensure seamless integration of high-reliability miniature motor solutions. Through continuous innovation and engineering excellence, Portescap is helping shape the future of flight control – making aircraft safer, more efficient, and more capable. For more information on Portescap’s solutions for the aerospace industry, visit us here.