The Benefits of Electric Drives in Downhole Equipment
Every oil and gas extraction operation now includes gathering big data and managing the down-hole processes, from surveying and preparing extraction areas to maximising and optimising the production of mature oil and gas wells.
Over the years, the oil and gas extraction sector has maintained the same objectives: maximise output to satisfy the energy needs of the market while doing it effectively, affordably, and sustainably. Efficiency and sustainability are becoming a more prominent role as the sector sets its sights on achieving zero nett carbon emissions. Even though it has significant technological and environmental obstacles, downhole drilling has the greatest potential for technological advancement. To achieve these goals, industry mindsets must change to embrace a more data-driven strategy, which is driving downhole drilling towards electrification.
Electric drive benefits
The concept of electrifying downhole operations is not new, but advancement has lagged over time as a result of a combination of overcoming the extremely challenging climatic conditions, a lack of cutting-edge technology, and resistance to change. Technical advancements in motor, electronics, and battery technologies are providing the tools needed to move towards the electrification of the oil and gas industry, however, since old solutions like hydraulics are no longer cost viable in fulfilling the new targets set by the industry. There are key advantages of an all-electric system as well.
Efficiency gains are made possible by digitisation. Operators can make better and more consistent strategic production control decisions when they have access to a real-time data reservoir and precise control positioning. For the administration of manufacturing activities in the future, both onshore and offshore, digitalisation is becoming more and more crucial. Large volumes of data, including information on reservoir behaviour, production procedures, well integrity and safety, and the health and operation of the equipment, may be gathered in real time using electric production systems. With this digital strategy, a project’s overall efficiency and safety are increased, and its carbon impact is decreased.
Electric infrastructure construction is far more affordable and simpler to maintain. In comparison to hydraulics, an electric wire may be extended further, and a single line can be used to control various systems and provide sensor input. This enables creating and maintaining infrastructure with numerous branches and expansions easier. Additionally, the leakage danger associated with hydraulic lines is fully eliminated by an electric connection. Battery technology advancements have also made it possible to use batteries in harsh environments.
Electric motors allow for precise and quick control when used for valve actuation and control. Electric drive inputs and commands are received in real-time and are immediately carried out, allowing operators to quickly adjust and immediately optimise their operation. Electric motors can be controlled using a variety of factors, including torque (by measuring the motor’s current), speed and position (using motor halls or resolvers), and possibly other parameters depending on the sensors used. Full motor control is made possible as well as the opportunity to gather data that may be utilised to forecast the state of the motor health condition.
Technical challenges and solutions
Extreme environmental conditions have been a significant barrier to using electric drives more frequently in downhole operations. Components of conventional electric motors cannot survive downhole temperatures, which frequently exceed +200°C, high pressures, and potentially significant shocks and vibrations. Motors must run consistently, increase the lifetime of a downhole tool, and require less maintenance in order to meet specified cost efficiency targets and prevent expensive downtime. In order to achieve the industry’s goals of increased productivity and efficiency, it is essential to maximise the output of already-existing wells while simultaneously drilling into harder, unconventional wells and pushing electric motor technology even further.
As conventional motors are not suitable for these industry demands, custom solutions tailored to downhole specifications needed to be developed. To do this, successful motor manufacturers must have the expertise and resources to perform all the development steps, plus ensure reliable production and testing processes. Designing such drive system requires specialized knowledge in material behavior at extreme temperatures as well as extensive testing to make sure all components can survive the HPHT (high pressure, high temperature) environment found in downhole operations.
Conventional permanent magnet DC motors typically use neodymium magnets which start to demagnetize once temperatures of +150°C are exceeded. Similarly, conventional winding insulations are not able to withstand the extreme conditions. It is important to keep in mind that temperature ratings include ambient, and the added temperature caused by the load. That means a certain safety margin needs to be considered as the motor must be able to operate under load without overheating. Other motor parts must be made of high-grade stainless steel and the use of adhesives or plastics should be avoided.
The process of development includes more steps than just selecting the appropriate components. In order to validate that the correct design has been implemented and that the motor can deliver the requisite life-time in these harsh conditions, it is also necessary to specify and carry out acceptable environmental tests. To achieve reliable manufacturing, production processes must be developed and include appropriate testing both during production and during final inspection.
The maxon solution
maxon’s heavy-duty platform portfolio provides the robust design that is critical for extreme operating conditions. For example, their EC 22 HD brushless DC motor with GP 22 HD planetary gearhead provides:
- An Ultra compact (Ø22 mm), highly efficient
(>75 %) and powerful (240 W) drive solution - A fully welded stainless-steel assembly along with encapsulated samarium-cobalt magnet
- A high temperature ironless core winding, proven to withstand temperatures up to 240° C
- A gearhead designed for high torque (12 Nm overload torque capability)
Along with these technical capabilities, these motors incorporate new materials and process technologies. An ironless core winding and high-performance rotor is the “heart” of maxon heavy duty motors. Together with the powerful gearhead, maxon provides high torque drive solutions. Most parts of heavy-duty drives are made of stainless steel. The assembly minimizes the use of adhesives, concentrating instead on the connection of individual components through mechanical fits and secured with laser welding. This results in a reliable and mechanically robust drive system.
Some key advantages of maxon HD motors include:
- Wide temperature range
(-50 to 200°C) components tested up to 240°C - Robust design laser welded connections
- High performance to volume ratio, compact, high-power density
- Low energy consumption, high efficiency
- Excellent control properties, linear motor characteristics
- Operation in air or in hydraulic oil
- Low magnetic interference
- High quality/reliability production process controls
Qualification and production testing
To ensure that motors can withstand harsh downhole conditions, it is important to define and conduct proper tests during the design qualification phase as well as during serial production. Manufacturers must have enough resources and expertise to develop and conduct these tests and implement all the necessary steps on the production line to ensure that each unit produced meets the requirements. There are three specific tests that are required to assure the long life and proper operation of these motors.
To ensure that motors can withstand harsh downhole conditions, it is important to define and conduct proper tests during the design qualification phase as well as during serial production. Manufacturers must have enough resources and expertise to develop and conduct these tests and implement all the necessary steps on the production line to ensure that each unit produced meets the requirements. There are three specific tests that are required to assure the long life and proper operation of these motors.
Internal full load test
Motors are tested in air or in hydraulic oil at extreme temperatures and under full load during continuous operation. During this load test the winding heats up to its maximum rated temperature. Continuous monitoring provides information on the drive’s performance characteristics.
Vibration and thermal stress test
Drives are placed in a climate-controlled enclosure and subjected to high vibration. Testing is carried out with the motors in operation at high temperature. The motors are required to continue functioning within their performance specification while vibrations are applied in all directions.
Shock test
The laboratory system performs a variety of shock loads of more than 1,000 G. After the shock test, the drives must be fully functional.
Standard test procedures are also performed prior to delivery to the customer. All of maxon’s HD drives the motor plus accessories must pass these procedures, which include:
- Environmental Stress Screening (ESS)
o high temperature test
o load test
- General Electrical Test
o insulation test
o maxon standard test
- Visual and Dimensional Check
o visual inspection
o dimension checks
Application examples
A typical use for electric motors in downhole operations is in Measurement While Drilling (MWD) systems, which use electric actuators in their mud pulser units. This equipment is responsible for using the complex technology that provides a second-by-second feed on the progress of the bore. Because the data transferred to the drilling technicians is critical to the operation—allowing them to respond quickly to make drilling corrections—the motor used in the actuator must provide power efficiency, reliability, and robustness.
Battery technology developments have increased the use of electric motors in downhole operations where they can also be used as generators to power the batteries. For this to happen, the motors must be very efficient. Brushless HD motors from maxon are not only suitable for the extreme environments attributed to downhole operations they can be used as DC or AC voltage generators using the drilling fluids pumped downhole. A voltage rectifier is required for DC voltage production, while AC voltage can be acquired using two of the three motor phases. The basic calculations are very simple due to the linear behavior of motors with slotless windings.
Another emerging use for electric actuators is in intelligent flow control valves. Instead of switching between fully open or closed positions, electric motors allow for highly precise control of flow valves to achieve optimal flow rate at any time. Software development has provided easy monitoring and control via user friendly interfaces at the surface. For example, it has been shown that smart gas lift systems have the potential to reduce lifting costs significantly, plus increase the well production capabilities with less intervention.
Well inspection is another segment with large potential for using electric actuators to achieve more efficient operation. Whether actuating a wheel assembly to drive a conveyor or controlling fingers of a multi-finger imaging tool to inspect the casing, electric drives are a great choice for increasing operational speed and precision. High precision positioning linear movements can be made by incorporating linear actuators with ball screws integrated into the gearhead and a heavy-duty resolver at the back of the motor. Overall, electric motors can solve challenges in various downhole tools, from drilling operations to completion and well inspection.
Conclusion
The oil and gas sector will undergo a great deal of change and innovation in the coming years and decades in order to satisfy strategic targets like providing affordable, carbon-free energy. These advances and modifications may be fueled by the development of all-electric systems. It is anticipated that an oil and gas extraction project will electrify all of its components, including the downhole portion. Many applications are actually migrating from more conventional technologies like hydraulics to electric actuation right now. With the industry facing difficult targets it is thrilling to see where the road leads and what kinds of innovations emerge in the future.
For information:
maxon motor Australia tel. +61 2 9457 7477.
60 Years of Excellence
Since 1961, maxon has focused on customer-specific drives, quality, and innovation. The products are manufactured in state-of-the-art production facilities, for example, under clean room conditions. Today, the company has more than 3,000 employees worldwide.
The name maxon pays homage to the enterprising founder Max Braun and his sons Erwin and Artur.
Now, maxon is celebrating 60 years of success – 60 years of excellence.
Roll the anniversary film!
It all started with shearing foils for electric razors. Our anniversary film tells the tale of the fascinating journey of the maxon drives from the center of Switzerland to Mars.
> Watch now
Anniversary Magazine
In our anniversary magazine, we shine the spotlight on 60 wonderful years and celebrate the number 60. Read about the 60 spontaneous decisions made by the Braun family, and what happens at maxon in 60 minutes, and discover some bold predictions about maxon and the world 60 years from now.
> Read now
maxon motor Australia tel. +61 2 9457 7477.
maxon’s driven magazine is out now!
The latest edition of driven brings you interesting reports, interviews, and news from the world of DC motor and drive technology.
driven magazine from maxon is now available online and can also be ordered in print, free of charge. The magazine is published in three languages.
Which brushless DC motor to choose?
The technical article in the current issue of driven gives engineers an excellent overview of the various brushless DC motors made by maxon and their properties. All beautifully summarised using graphics. Least but not least, readers are transported to Great Britain and the gear motor specialist Parvalux. The long-established company joined the maxon Group in 2018. What has changed since then? And what synergies can be used in future?
Robot on four legs
Wherever it goes, it is sure to attract attention. The red walking robot ANYmal provokes a reaction, which is why it also made it to the cover of the maxon magazine driven – representing the ever-increasing number of inspection robots worldwide.
Climbing, crawling, walking, or flying: inspection robots can be found everywhere, whether in sewer systems, on wind turbines, or at the bottom of the ocean. And their numbers are expected to increase dramatically in coming years. This is because they do work that is either too monotonous or too dangerous for humans. One of the most well-known of their ranks is the red walking robot ANYmal developed by Zürich-based start-up ANYbotics. The editorial staff of driven magazine took a look behind the scenes and found out from the engineers how they taught their “baby” to walk.
BIKEDRIVE – the electric bike system
For readers who prefer two wheels to four legs, we have an interesting report about the new electric bike system BIKEDRIVE AIR. It makes it possible to design and produce lightweight electric sports bikes – for the mountain or the road. They provide a natural cycling experience and represent an alternative to electric bikes, which are increasing in weight and power.
For more information contact maxon motor Australia tel. +61 2 9457 7477.
maxon reports a steady result for 2020.
Sachseln, Switzerland – The maxon Group based in Sachseln, Switzerland, succeeded in largely keeping its revenue stable in the demanding 2020 financial year, in spite of the difficult market conditions caused by the COVID-19 situation.
The revenue amounted to CHF 553.5 million, compared to CHF 567.8 million in the previous year. There were some revenue losses in the automotive and aviation sectors, however, maxon was able to largely compensate this with the huge demand for drives for precise laboratory automation and ventilators in the fight against the coronavirus. This quick pivot required a high degree of flexibility and pragmatism from the management and employees. Undeterred by all the crises of 2020, maxon invested CHF 50.3 million in new factories, machines and systems. The cash flow amounted to CHF 37.1 million, compared to CHF 44.9 million in the previous year. Worldwide, the maxon Group has 3,059 employees at nine production sites.
“2020 was a rollercoaster ride like none we experienced before,” said Karl-Walter Braun, majority shareholder of the maxon Group. “In fact, it is our global presence and our international customers that are active in a wide range of markets and applications that enabled us to weather the pandemic.” Even during the shutdown, maxon managed to uphold the global supply chains. “This once again demonstrates the resilience of well-networked global value chains and a broad range of diversified contacts all over the world,” said Karl-Walter Braun.
The research & development (R&D) and sales departments in particular faced great challenges in the last year. “On the one hand, direct contact at the customer was impossible. On the other hand, direct contact with the suppliers, for detailed clarification of technical feasibility or delivery options, was difficult.” Around the world, maxon has some 330 employees in R&D and the company invests around CHF 35 million in this field.
Continued innovative strength
Even under the difficult conditions maxon faced, the company launched several new products in the field of precision drive technology. This includes micromotors for medical robots, but also multi-axis controllers for highly dynamic positioning tasks. A special highlight was the Mars expedition with the first excursions of the Perseverance rover, equipped with maxon BLDC motors, and the successful flights of the Ingenuity Mars helicopter, equipped with six maxon motors,” said Eugen Elmiger, CEO of the maxon Group. “All expectations regarding the length, altitude and duration of its flights have already been met.”
And down here on Earth, maxon exhibits continued innovative strength. For example, in the medical field, the company and one of its customers cooperated to develop a minimally invasive aorta pump, which helps cardiac patients to heal quickly. And in intralogistics, intelligent motion control solutions for AGVs (automated guided vehicles) are increasingly being used. In the past few months, the drive specialist also developed an innovation in the field of e-mobility: this summer, maxon presents the BIKEDRIVE Air, an light and invisible e-bike system that consists of mid-mounted motor, integrated battery and control element. It weighs only 3.5 kg and can be incorporated into elegant frames by bicycle manufacturers. The e-bike system will be available exclusively to bicycle manufacturers worldwide.
Looking ahead with confidence
maxon is satisfied with the current financial year. “Due to high-volume orders, the suppliers reached their capacity limits,” explained Eugen Elmiger. “The result is that we are experiencing supply shortages.” In the future, the company will continue its development as system supplier. “The customers should be able to get everything drive-related that they need for their products from a single source. This includes motors, gearheads, electronics, motor controllers and plugin solutions,” said Eugen Elmiger. “Additionally, we are pulling out all the stops to become the digital leader in drive technology.”
maxon motor Australia tel. +61 2 9457 7477.
When lives are at stake – switching to crisis mode.
The COVID-19 pandemic meant a lot of laboratories had to quickly increase their testing capability in 2020, and acquire additional devices for liquid handling. For maxon, this meant creating special medical express lines for orders. They were managed with a lot of hard work and close co-operation.
NTEGRA Biosciences develops and produces electronic pipettes and pipetting robots which have been used in a large number of laboratory processes relating to COVID-19. During the pandemic, the testing capacities of the laboratories have been pushed to their limits. INTEGRA had to act fast to cover the high demand for automated liquid handling instruments. DC motors and drive systems from maxon are used in the electronic pipettes. For maxon too, fast action was required in order to supply additional electric DC motors to the customer more quickly.
Stephan Hegetschweiler, sales engineer at maxon Switzerland, and Amir Mujkic, head of the Cylindrical EC motor production line in Switzerland, explained how they and their teams mastered the challenge.
What caused the impending bottleneck at INTEGRA?
Stephan Hegetschweiler: The orders from INTEGRA increased substantially already at the beginning of the year. But the bottleneck was not yet foreseeable at that stage. Then, in the middle of the first coronavirus wave in April, their purchasing manager contacted us. The demand for liquid handling devices had increased so sharply that there was an imminent risk of a production stop in INTEGRA’s device assembly due to a lack of materials. To head off that bottleneck, we took action immediately and switched to crisis management mode. After all, this was about saving lives.
And what kind of action did you take?
Amir Mujkic: We rescheduled all our ongoing orders at short notice, and freed up extra human resources for the EC-max DC motor production line. To keep the lead time for the express order as short as possible, it was very important to keep a close eye on our overall coordination and the information flow in the production process. Downstream departments, such as the final QA inspection and shipping, were informed in advance about the important orders.
What are the most important prerequisites for successful delivery and processing of orders like this?
Stephan Hegetschweiler: The best thing the members of the team can do is to communicate continuously. That means talking to people, analysing bottlenecks in detail, communicating your success, and just involving everyone who can successfully move the order forward. The rapid flow of information between maxon and INTEGRA was effective for the express order.
Amir Mujkic: An express order can come at any time, and our production staff know that too. So I know I can rely 100% on the flexibility of the staff. In these situations, there is always a high level of willingness to work beyond the usual working hours. Cooperation plays a very important role here. If the communication and processes in the team are right and everyone knows what their tasks are, then on-time delivery to the customer goes smoothly.
How can future bottlenecks be prevented for customers?
Stephan Hegetschweiler: With rush orders, it’s important that senior management gets involved too, so the customer knows that we take the problem very seriously. It’s also helpful if the customer submits more orders right from the start. In the case of this express order, we suggested to INTEGRA that we should produce and store a safety buffer of drives that they can then access in an emergency. Close collaboration with the customer and the transparent communication that goes with that helped us to process the order quickly, to the customer’s satisfaction.
maxon motor Australia tel. +61 2 9457 7477.
maxon complete new state-of-the-art production centre.
For the past 60 years, maxon has focused on customer-specific solutions, quality and innovation. Continuous growth saw a need to build additional facilities and a new production site, to meet customer demand for their DC motors, gearboxes, sensors and controllers.
Construction work has been in progress at maxon headquarters in Sachseln (Switzerland) since 2020. maxon’s original building from 1961 was demolished and replaced by a new state-of the-art facility with twice the production space than was previously offered. The relocation to the new building will take place in the later part of 2021 and be completed by the end of the year. The products involved are maxon’s pancake DC motors, EC cylindrical motors, X-Drives DC motors (DCX and ECX motors), as well as their assemblies.
Businesses from a wide range of industries, including medical technology, robotics, industrial automation, mobility, and aerospace, place their trust in reliable DC motors and systems by maxon since it opened its doors 60 years ago. maxon DC motors excel where extreme precision and the highest quality standards are vital, and where compromises cannot be tolerated – not only here on Earth but on Mars. Over the past three decades, maxon has provided more than 100 DC motors for robots sent to Mars, working with the Jet Propulsion Laboratory (JPL) on various missions. In 1997, the first rover (Sojourner) landed on Mars – powered by 11 maxon DC motors. maxon brushed and brushless DC motors are also used in demanding robotics applications in surgical equipment, humanoid robots, and industrial automation. maxon were an Official Supplier to Emirates Team New Zealand, winners of the 36th America’s Cup in March 2021 and selected for their uncompromising quality that can be relied upon in even the harshest conditions.
maxon motor Australia tel. +61 2 9457 7477.
maxon involved in another historical milestone: a one-way flight on Mars.
Ingenuity helicopter currently on Mars made its first one way flight. Six DC micromotors from maxon are inside Ingenuity helping steer the direction of flight.
In its fifth flight on the Red Planet, Ingenuity helicopter has reached another historical milestone succeeding in the first one-way flight from Wright Brothers Field to another airfield 129 metres to the south. Upon arrival, the rotorcraft rose to an altitude of 10 metres and captured high-resolution colour images of the surrounding terrain before touching down. The one-way flight began at 3:26pm EDT, 12:33pm local Mars time and lasted 108 seconds.
There are six maxon DC micromotors with a diameter of 10 millimeters that control the tilt of Ingenuity’s rotor blades, which determines the direction of flight. Aiko Stenzel, Aerospace Design Engineer at maxon, was part of the team that developed the DC motors. “The biggest challenge was the extreme weight requirement. We had to take off every tenth of a gram we could, so that the helicopter can fly in the thin atmosphere on Mars. It’s great that we were able to find a solution with enough power to adjust the rotor blades, despite the weight reduction — and which could handle all the vibration and temperature fluctuations as well.”
According to NASA JPL, the flight marked Ingenuity’s transition to a new operations demonstration phase, which will focus on investigating the range of capabilities rotorcraft operating from Mars can provide . This is expected to include scouting, aerial observations of areas not accessible by a rover, and detailed stereo imaging from atmospheric altitudes.
Ingenuity is now expected to await future instructions, relayed via Perseverance, from mission controllers.
The Perseverance rover is also scheduled to travel south, where it is expected to commence scientific operations and sample collection. Perseverance has 10 maxon DC motors inside, including for the first time brushless DC motors: nine EC 32 flat DC motors and one EC 20 flat DC motor in combination with a GP 22 UP (Ultra Power) planetary gearbox. Years of collaboration between maxon and the space experts at JPL led to the development of the BLDC motors which handle the valuable soil samples on Mars during Perseverance’s mission.
Like all of our electric DC motors used on Mars, they are based on standard catalogue products especially modified to suit the harsh conditions of Space travel. Florbela Costa, SpaceLab Project Manager at maxon said “(the DC motors) are different from other applications, above all because of their generally higher quality requirements for things like resistance to vibration and temperature. Consequently, everything needs to be analysed and tested. Parts used in our standard motors are re-evaluated to make absolutely certain that they will function in space or on other planets”.
The Aerospace team at maxon can’t afford to make mistakes as not only is there no way to fix materials once they’re on Mars but it could also cause the entire mission to fail. “When making motors for Mars, nearly everything has to be done by hand. Every move and every assembly step have to be documented and has to be right — we can’t afford to make mistakes. We’re working with materials that you can’t just get from the warehouse” said Dominik Omlin, Production Engineer Aerospace at maxon.
maxon have expertise in space applications and have established quality assurance processes that meet the expectations of the industry. Customers from other industries where requirements can be just as demanding, like the medical sector, also benefit from this know-how.
For more information about DC motors for harsh environments please contact maxon motor Australia tel. +61 2 9457 7477. Visit maxonworld to follow the Mars adventure.
Congratulations to Emirates Team New Zealand – winner of the 36th America’s Cup!
They have gone and done it again. Emirates Team New Zealand have retained the America’s Cup over the Italian Challenger Luna Rossa Prada Pirelli.
maxon Group extend their heartfelt congratulations to Emirates Team New Zealand. In the historical 36th America’s Cup that endured extra challenges including Covid-19, race cancellations and delays meaning interruptions and last minute tactical changes, the Kiwis have retained the oldest trophy in international sporting history.
Creating a boat from simulation and the use of AI technology were big risks for Emirates Team New Zealand, who were frank about the lack of boat-on-boat racing experience in this new AC75 class at the beginning of the Cup. This meant the team had to lift their game and learn fast, taking key lessons out of regatta as they moved forwards one race at a time. The risks paid off for the Kiwis who forged a spectacular win 7 races to 3. Winning skipper, Peter Burling, said “…..we have been learning all week, and today we really showed what this boat can do – and so to win on home waters is something our entire team is incredibly proud of.”
Back in 2018 maxon joined Emirates Team New Zealand as an Official Supplier, supplying 480W DC motors with 42mm gearbox combinations, and EPOS motor controllers. This particular DC motor combination was selected because of its outstanding power density and ability within even the harshest of environments. The America’s Cup AC75 Class Rule allows the use of electric motors to operate hydraulic valves, drive clutches, rudders and foils. Teams may also use motors for driving simulator platforms and numerous test jigs.
maxon motor Australia Managing Director, Brett Motum, said “We’ve been watching the races globally across our offices cheering on Emirates Team New Zealand. We’re proud to have supported Emirates Team New Zealand as an Official Supplier and see them cement their place in history winning this 36th America’s Cup match”.
This is the fourth time that New Zealand has triumphed in the America’s Cup and is another victory to add to their three previous successes. Well done team and congratulations to Luna Rossa Prada Pirelli who put up a great challenge.
maxon Group tel. +61 2 9457 7477.
maxon Group is an Official Supplier to Emirates Team New Zealand. We follow the progress of their journey as Defender in the 36th America’s Cup campaign, March 2021.
Mars landing explained.
All landings on Mars are difficult. For NASA’s Perseverance Rover, set to land on Mars on February 19, 2021 at 7.30am AEST, this one is particularly tense.
With the biggest supersonic parachute ever sent to another planet, the first helicopter drone Ingenuity onboard, the touchdown site the most challenging terrain on Mars ever attempted and with maxon DC motors onboard, this is one landing not to be missed!
Dr Carlos Bacigalupo, Astrophysicist and Head of R&D at maxon Group, Australia, talks us through the complex landing sequence. Watch the video here.
The intense Entry, Descent, and Landing phase, known as EDL, begins when the spacecraft reaches the top of Mars’ atmosphere. It takes approximately seven minutes to enter the atmosphere and land safely on the ground – and these have been referred to as the seven minutes of terror. During these nail biting minutes, the spacecraft autonomously lands itself and until the data is received that Perseverance has landed safely, this window of lagged communication is wait-and-see if the spacecraft has crashed or landed safely.
Dr Bacigalupo also takes us through the maxon brushed and brushless motors that will be used for numerous mission-critical tasks. They will power the small robotic arm in the rover moving the soil samples from station to station and for sealing and depositing the sample containers. There are also six 10mm DC micromotors used to control the tilt of the rotor blades, which determines the direction of Ingenuity’s flight.
Images courtesy NASA/JPL-Caltech/ University of Arizona. With thanks to NASA Jet Propulsion Laboratory (California Institute of Technology), ES/DLR/FU Berlin, maxon Group, Mark Sheppard. Music from Bensound.com and zapsplat.com.
maxon motor Australia tel. +61 2 9457 7477.
Searching for signs of life on Mars
Mars once had liquid water and an atmosphere — was there life too? To answer this vital question, NASA sends the Perseverance rover, a robot of unparalleled complexity, to explore the Red Planet. For the first time, we will see live images of a Mars landing, supplied by high-resolution video cameras.
The planned touchdown of NASA’s Perseverance Rover is February 18, 2021. Only a few craft make it to the planet’s surface intact. The European Space Agency (ESA) had a painful demonstration of that in 2016 when their lander Schiaparelli smashed into pieces on the Red Planet. Nevertheless, US space agency NASA has so far taken four robotic vehicles to Mars successfully. It is now looking to make history again with the Perseverance rover. For the first time, we on Earth will see live images of a Mars landing, supplied by high-resolution video cameras.
It will still take a while, however, before people land on Mars. This is why robots need to do the work for now, and Perseverance has quite a lot of it in store. It will land in the Jezero Crater, which was once filled with water, with the task of investigating whether the area was once habitable. At the same time, the rover will search for signs of earlier life, known as biosignatures. It is equipped with a variety of measuring instruments for this purpose.
Its third task is to pave the way for human missions with a technology demonstration: An instrument named MOXIE will extract oxygen from the small amount present in the Martian atmosphere. This technology would be crucial for human missions, as oxygen is not only required for breathing, but can also be used for making fuel.
Investigating life forms
We now come to the fourth mission, the most spectacular and most technically demanding: Perseverance will take up to 30 soil samples, place them in individual vessels, seal the vessels, and then finally deposit them at a suitable location so a later mission can collect the samples and bring them back to Earth. For scientists, it doesn’t get much better than this: getting clean samples from Mars and being able to investigate them here, with all the latest techniques available. As NASA puts it, these samples have the potential to tell us more about the basis and origin of life in our solar system.
Three systems have to work together seamlessly for the sampling to succeed. First, the big robotic arm at the front of the rover drills into the Martian rock and takes a core sample, which is then inserted into a carousel. The carousel takes the sample inside the rover. There, the third system takes over. It is another robotic arm, a much smaller one called SHA. This arm takes the sample from the carousel, moves it to the volume assessment and scanning stations, then to the sealing station, and finally into temporary storage—all autonomously.
This is where maxon comes in. Several brushless DC motors are being used to handle the samples. Some of them are installed in the SHA robotic arm, which transports the samples from station to station; others are used when sealing the sample tubes and positioning them.
A base-line of successful products
Just like the more than 100 maxon drives that have previously done work on Mars, the Perseverance motors are based on standard catalogue products: specifically, nine brushless DC motors of the EC 32 flat type and one of the EC 20 flat type, in combination with a GP 22 UP planetary gearhead. Naturally, modifications were required so that the drives could meet the high demands of the mission. Nevertheless, the basis of the drives is no different from the models that are used in all kinds of applications on Earth.
maxon’s engineers have modified and repeatedly tested the motors and gearheads for three years, working closely with the specialists at the Jet Propulsion Laboratory (JPL), which handles all unmanned missions for NASA. The space experts from Pasadena were frequent visitors at the Swiss headquarters of the electric motor experts. “We’ve learned a lot from this collaboration,” said Robin Phillips, head of the maxon SpaceLab. This can be seen specifically in higher quality standards and new test procedures and processes. “Customers from other industries, like the medical sector, where requirements are often similar, also benefit from this know-how.”
Phillips and his team will pay close attention to the landing of the Perseverance rover and its activities, as much will depend on the functioning of the maxon drives. In his words, “We are involved in absolutely critical applications. If the robotic arm on which our brushless DC motors are mounted doesn’t move, or if the gripper doesn’t work, then the entire mission will be a failure.”
The mission
Perseverance will search for signs of earlier life (biosignatures) on Mars, take rock and soil samples, and prepare them for return to Earth. It will also conduct experiments to pave the way for human missions.
The journey
Launch vehicle Atlas V-401
Launch site Cape Canaveral Air Force Station, Florida (USA)
Landing date February 18, 2021
Landing site Jezero Crater
The facts
Planned At least one Martian year (687 Earth days)
duration
of mission
Weight 1025 kilograms
Length 3 meters
Height 2.2 meters.
For more information contact maxon motor Australia tel. +61 2 9457 7477.
maxonmotoraust 