With over 60 years experience operating across the aerospace and defence industries, NEMA Ltd is at the forefront of the design and manufacture of high speed motors/generators. With its aerospace standard AS 9100 accreditation, NEMA designs, develops, manufactures, repairs and overhauls Electric Motors, Electro-Mechanical Assemblies and components including springs and pressings. In this webinar, recorded in June 2021, the NEMA team share more about how they: - develop technology for blue chip aerospace companies, holding customer specific quality approvals including: Airbus UK, Heroux Devtek, BAE Systems, GE Aviation Systems, AIM Aviation, UTC Aerospace, Martin Baker, Hawker Beechcraft, & Leonardo - have established partnerships with leading academic institutions, including the University of Nottingham & Newcastle University, on UK and European funded initiatives aimed at reducing aircraft emissions - see potential opportunities for collaboration within the PEMD community in the future

1. Innovating the Future of EM Technologies
www.nema.ltd.uk
Dean Evans
Unit 16 Chichester Business Centre
Chichester Street
Rochdale
OL16 2AU

2. BUSINESS & CAPABILITIES OVERVIEW
www.nema.ltd.uk

3. 1950 1960 1970/80/90 2000 2002 2004 2006 2008 2010 2012 2014 2016 2018 2020 2022
2009 AS9100 awarded for Repair and Overhaul
2006 in-house machine shop
2017 CleanSKy2 Project: ACHIEVE
2015 Innovate UK
Project 102374: HARAS
1954 Nordale Spring Co. begins to supply
the aerospace and defence industries
1960’s company moves into
pressed components
1999 start of wound component
business. Change of name to NEMA
2011 130Nm
subsea actuator
2014 Designed and
built 183,000 rpm
motor/generator
2011 AS9100 awarded for
Design and Development
2005 Awarded AS9100
2019 Innovate UK Project
113227: EMFIS
2019 120krpm MGU
2022 Active
magnetic bearings
www.nema.ltd.uk

4. Boeing F18
Tech TP
AIRBUS A330
BAE Hawk
ASTUTE
End-User Platforms
Type 26
www.nema.ltd.uk

5. • Airbus UK
• Collins Aerospace
• MOD
• Leonardo Helicopters
• Heroux Devtek
• BAE Systems
• Bombardier
• Martin Baker
• MacTaggart Scott
• MOOG – UK sites
• Triumph Actuation UK
• Incora
• SAFRAN (LABINAL) – GPS
• Magellan Aerospace
• Stirling Dynamics
• Nasmyth Group
• Sentient Blue
• Innovate UK / ATI
• CleanSky2
Existing Customers
www.nema.ltd.uk

6. ELECTRO-MECHANICAL ACTUATION
(EMA) DIVISION
BDC motor with failsafe brake
BLDC Stator Squirrel Cage rotor
www.nema.ltd.uk

7. • Electrical Motors:-
• AC Motors
• DC Motors Brushed & Brushless
• Housed or un-housed (frameless)
• Limited Angle Torque Motors
• Stepper Motors
• Gear motors with and without speed/position feedback, brakes, clutches
• Small Actuators – Rotary & Linear
• Transformers / Rectifiers
• Position Sensors
• RFI/EMC Filters
• Permanent Magnet Alternators
• Starter/Generators
• Solenoids
Product Development
www.nema.ltd.uk

8. • Speed Range: 0 to 183,000 rpm
• Power Output: 2 W to 50 kW (working up to 200 kW)
• DC Supplies: 5 V to 610 V
• AC Supplies: 1 phase, 3 phase, 50 Hz to 400 Hz & VF
• Frame sizes: Diameter 10 mm to 500 mm
• High power density / short duty cycle
• Harsh environment
• Critical applications – Redundant configurations.
Motor Design Capability
www.nema.ltd.uk

9. Typical applications include:-
• Direct/Remote Drive Winch
• Compressor Drives
• EHA Pump Drives – Including Wet Rotor
• Turret Drives
• Radar System Drives
• Electro Optical & Infra-red Focusing
• Missile Seeker & Fin Control Actuation Systems
• EMA – Electro-mechanical Actuators
• Position Sensors
• Fly-By-Wire Flight Controls
Application Portfolio
www.nema.ltd.uk

10. NEMA PRECISION MACHINING DIVISION
www.nema.ltd.uk

11. NEMA Ltd is a vertically integrated organisation and
performs the following manufacturing processes in house:-
• Precision CNC Machining – 3 & 4 axis
• Precision CNC Grinding (Studer)
• Pressings/fabrications & sheet metal components
• Winding/Impregnation/Encapsulation
• 3d Printing
• Wire eroding
• Brazing/Soldering
• Magnetising
• Electronic Balancing
• Heat treatment
• Paint facility
• Sub-assembly
• Final Assembly & Test (FAT)
Manufacturing Capability
www.nema.ltd.uk

12. Assemblies Coiled springs
Laminations
Flat springs
Springs, pressings and mechanical assemblies
www.nema.ltd.uk

13. NEMA has the capability and approvals to R&O the following:-
• Electric motors
• Electro-mechanical actuators
• Electro-mechanical components
Repair and Overhaul Capability
www.nema.ltd.uk

14. Scavenge Fan used on the Challenger II tank
Ejection seat actuator – Martin Baker
Repair and Overhaul Capability
www.nema.ltd.uk

15. • 3m stroke linear
• Sub-sea environment
• Stroke rate of 0.5m per second
• Full load of 65kN
• Mechanical output at full load 32.5kW
• Position accuracy ± 2mm
Limit switch
RAM
Ballscrew and cover
Motor
Brake
Subsea Actuator – Application communications mast on Submarine
Recent Projects
www.nema.ltd.uk

16. 600 VDC Brushless DC Motor – Application Sub-Sea Actuator
• Envelope – 210mm Dia x 160mm long
• Incorporates
• BLDC Motor
• Resolver
• Fail Safe Brake
• Power output – 40kW (12 sec duty)
• Torque - 130 Nm @ 3k RPM
• Duty Cycle – 12 secs on, 168 secs off
Recent Projects
www.nema.ltd.uk

17. Recent Projects
• Envelope – 185mm x 46mm x 645mm long
• Stroke – 188mm in 20 secs
• Ultimate load – 1581 Nm (14k lbf in)
• Gearbox ratio – 36:1
• Max Motor power – 240 Watts.
• Motor Load Torque – 0.088 Nm
• Full Load Motor Speed – 10k RPM
• Mass – 1.76kg
• EMC to Mil-Std-461
• Potentiometer position feedback
www.nema.ltd.uk

18. Recent Projects
28 VDC Frameless Motor – Application Airborne Counter Measure
• Envelope – 125mm Dia x 25mm long
• Torque Constant kt – 0.45 Nm/A Nom
• EMF Constant – 0.525 Vs/rad Nom
• Cogging Torque – 0.06 Nm Max
• Terminal Inductance – 3.5 mH Nom
• Mass – 0.525 kg Max
www.nema.ltd.uk

19. Recent Projects
28 VDC Motor & Controller – Application AFV Dual Blower
• Continuous duty brushless Motor and
Electronic Controller with integrated EMC filter
• Motor Envelope – 100mm Dia x 50mm long
• Electronic Controller/EMC Filter – 122mm Square X 58mm deep
• Power – 650 Watts @11,500 RPM
• Variable speed control – 0-10V input or PWM signal
• Dual output mechanical shaft
• EMC filter to Mil-Std-461 included
www.nema.ltd.uk

20. 28 VDC Brushed Motor – Application Aircraft Seat Actuator
• Nom. operating Voltage – 28VDC
• Incorporates fail safe brake
• Envelope – 50mm Dia. x 140mm long
• Full load Speed – 10,980 RPM
• Full Load Torque – 80 mNm
• Peak output – 90 Watts
Recent Projects
www.nema.ltd.uk

21. Actuator Rate Sensor for Aircraft Wing Tip
Senses rotation of the wing flap actuator from end of wing,
completing the full system communication loop.
• Nom. operating Voltage – 10VDC
• Hall Effect position sensing using
quadrature output signal for direction feedback
• Envelope – 50mm dia x 35 mm height
• Weight – 74g
• Ambient Operating Temperature – -55 to 80⁰C
• Lightning Strike Protection
Recent Projects
www.nema.ltd.uk

22. Recent Projects
High Speed Motor/Generator
• Nom. output Voltage – 200 V rms
• Envelope – Ø80mm x 90mm
• Max. Withstand Speed – 183 krpm
• Full load Speed range – 125 krpm to 148 krpm
• Full Load Torque – 1 Nm
• Peak output – 12.5 kW continuous
• Ambient Operating Temperature - 100⁰C
www.nema.ltd.uk

23. Recent Projects
Winch Drum Motor
• Nom. operating Voltage – 600 Vdc
• Envelope – Ø420mm x 130mm (active magnetics)
• Weight - < 70 kg (active magnetics)
• Full load Speed – 1250 RPM
• Full Load Torque – 110 Nm
• Peak output – 30 kW (60 secs)
• Ambient Operating Temperature – -40 to +70 ⁰C
www.nema.ltd.uk

24. Recent Projects
High Availability Redundancy Actuations System (HARAS)
• Nom. operating Voltage – 270 Vdc
• Envelope – Ø50mm x 65mm
• Weight – 0.6 kg (active magnetics)
• Full load Speed – 1500 rpm
• Full Load Torque – 2.5 Nm
• Peak output – 300 W cont. (1 kW peak 60 secs)
• Ambient Operating Temperature – -55 to +70 ⁰C
Multiple linear
actuation
Multiple rotary
actuation
www.nema.ltd.uk

25. Recent Projects
(ACHIEVE) – CleanSky Horizon 2020
• Nom. operating Voltage – 270 Vdc
• Envelope – TBD
• Weight - TBD
• Full load Speed – 18000 rpm
• Full Load Torque – 24 Nm
• Peak output – 25 kW
• Ambient Operating Temperature – -55 to +70 ⁰C
www.nema.ltd.uk

26. Current Projects
Electro Magnetic Flux Imaging Scanner (EMFIS)
www.nema.ltd.uk

27. Recent Projects
120krpm Motor Generator Unit (MGU)
www.nema.ltd.uk

28. NEMA applications NEMA requirements
• Electric propulsion systems
• Electric actuation systems
• Magnetic bearings
• High speed Motor/Generators
• NDT machine characterisation
• Reverse engineering of legacy
systems
• Build-to-print aircraft components
and assemblies
• Design consultation up to full
airworthiness certification
• Power and control electronics
• EMC/EMI consultation
• Material suppliers (Hard/soft
magnetics, alloys, composites etc)
• Bearings, ballscrews and
mechanical parts
• Partners for EM technologies
• Advanced manufacturing and
productionisation consultation
www.nema.ltd.uk

29. Thank You
NDT motor scanner
Winding patterns / N / B
The electric transport revolution is driving the need for high power density,
high speed electric motors & generators (MGU)
NEMA are at the forefront of developing and manufacturing this technology
www.nema.ltd.uk