Alva Industries recently engaged with UnmannedSystemsTechnology.com to explore the innovative manufacturing techniques behind the ALTUS X60 Duo and X60-Kv120 electric UAV motors.
Alva’s next-generation ironless and slotless motors utilize groundbreaking patented FiberPrinting™ technology, which ensures remarkable reliability, durability, and performance.
Can you elaborate on Alva Industries’ exclusive FiberPrinting™ Technology?
FiberPrinting™ represents a notable advancement for slotless motors,enabling the mass production of high power-density slotless motors for the first time. This innovative approach was conceived by our founder and CEO during his final year at university.
The technology merges industrial weaving with stator winding methods.With FiberPrinting™, we can create slotless stators that feature a high copper fill-factor and straight slots, as opposed to the skewed windings typically found in conventional slotless motors.
This innovation results in a motor that combines the power density of iron-cored motors with the benefits of slotless designs, such as outstanding step-response, minimal speed-dependent losses, absence of cogging, and compatibility with inrunners.
The ALTUS X60 Duo is a cutting-edge, fully integrated UAV propulsion system tailored for multirotors. What distinguishes the ALTUS X60 Duo in the drone motor landscape?
The ALTUS X60 Duo was meticulously designed to address the evolving demands of the growing UAV sector. As UAV operations expand globally, we recognized a significant market gap. Operators scaling their activities often faced operational challenges and unexpected costs due to unreliable propulsion systems, necessitating motor replacements as frequently as every two weeks.
The ALTUS X60 systems cater to multicopters with a maximum takeoff weight (MTOW) ranging from 15 to 30 kg. The motor,electronic speed controller (ESC),and propeller are co-optimized to enhance performance,with a strong emphasis on reliability and durability during development. The outcome is a propulsion system that performs well in various weather conditions and boasts a long lifespan, making it the most economical choice for high-volume operations.
The X60-Kv120 is celebrated as one of the most reliable multicopter motors globally. What contributes to its exceptional reliability?
The X60-Kv120 is designed with numerous features that enhance its durability. Its stator is crafted using FiberPrinting™, which not only boosts performance but also provides inherent weather resistance, as all active materials are encapsulated, eliminating the risk of corrosion from iron components.
FiberPrinting™ also facilitates the design and manufacturing of high-performance inrunner motors, where the rotor is situated inside the motor. This configuration is more robust and offers better protection against particle ingress compared to traditional outrunners. The inrunner rotor employs a Halbach magnet array for optimal performance and is reinforced with glass-fiber threads to endure high forces and rotational speeds. An advanced bearing system secures the rotor, designed to handle the significant cyclic loads exerted on the motor shaft. additionally, a high-airflow impeller cools both the stator and rotor effectively, while particle ingress is mitigated by fine metal meshes at the inlets and outlets.
Thes features collectively enhance the durability of the X60-Kv120. However, the cornerstone of its reliability lies in the rigorous testing we conduct.Our dedicated 1,000 square meter testing facility allows for rapid iterations, providing insights that enable us to refine the design to meet stringent reliability and robustness standards.
The X60-Kv120 exemplifies excellent design; however, the quality of production is equally crucial. Manufacturing occurs in our facility in Norway, where all processes are meticulously documented and monitored. This, combined with both in-line and end-of-line testing of each motor and propulsion system, ensures that every unit meets the performance and reliability benchmarks it was engineered for.
Alva Industries has recently completed a significant Series A funding round. Can you share insights into Alva’s plans for growth and scaling production capacity in 2023 and beyond?
We are lucky to have secured substantial funding in this challenging financial climate. This investment will enable us to expand our operations to meet the increasing demand for our products. We aim to boost our production capacity from 1,000 to 15,000 motors annually by implementing a new production line in our facility, utilizing manufacturing technologies and processes developed over the past few years.
Additionally, we plan to broaden our product range based on the success of the ALTUS X60.our future portfolio will encompass a wide array of industrial multicopter solutions,positioning us as a comprehensive provider for manufacturers seeking cost-effective propulsion systems for large-scale operations.
Can you highlight any current research and development projects at Alva Industries related to motor technology?
Three years ago, we entered into an R&D agreement with Lockheed Martin to develop a performance demonstrator for an underwater thruster utilizing our FiberPrinting™ technology. We are nearing the project’s conclusion with promising results. The unique characteristics of FiberPrinted™ motors suggest the potential for creating marine thrusters that are both compact and high in power density. We will provide further details once the project is finalized.
