For decades, hydraulic systems have been used to distribute power throughout aircraft. As the aerospace industry moves toward more-electric and all-electric flight, manufacturers are increasingly adopting electromechanical actuators and Power-by-Wire systems for safety-critical applications including flight controls, landing gear, engines, and other aircraft systems. wp-actuators-in-air
This in-depth white paper from Averna explores the transition from traditional hydraulic actuation to Power-by-Wire and electromechanical actuators. It examines the technology readiness process, the benefits of replacing hydraulic infrastructure with electrical systems, and the validation and production testing required to safely implement these technologies in aircraft. wp-actuators-in-air
Rather than focusing only on the benefits of electrification, the white paper explains why aerospace manufacturers must carefully validate new actuator technologies through rigorous testing before they can be certified and deployed.
You will learn:
• How aerospace manufacturers are progressing toward more-electric and all-electric flight
• Why Technology Readiness Levels are important when introducing new aerospace technologies
• How Power-by-Wire replaces hydraulic piping, shafts, tubing, and fluids
• Where electromechanical actuators are being used across modern aircraft
• How PBW can reduce system complexity, weight, and maintenance requirements
• Why eliminating hydraulic fluids can improve safety and environmental performance
• How actuator validation testing is performed using static and dynamic load systems
• How iron bird testing simulates aircraft systems and actuator behavior
• Why aerodynamic loads and mechanical linkages must be accurately reproduced during testing
• What production and end-of-line testing must measure before an actuator can enter service
• Why Acceptance Test Procedure documentation is critical for regulatory release wp-actuators-in-air wp-actuators-in-air
The white paper begins by examining how change happens within the highly regulated aerospace industry. New technologies progress through Technology Readiness Levels, ranging from TRL 1 for early concept development to TRL 9 for successful field deployment. The paper uses the development of electrostatic actuators as an example, describing how testing progressed from TRL 4 in the early 1990s to successful TRL 9 deployment with the Airbus A380 in 2007. wp-actuators-in-air
A major focus is Power-by-Wire technology. PBW transfers energy between devices through electrical wiring instead of hydraulic piping, shafts, tubing, and fluids. This approach enables greater use of electromechanical actuators across flight control surfaces, landing gear, vectored thrust, and engines. wp-actuators-in-air
The transition provides several potential benefits. Removing hydraulic fluids can reduce the risks associated with flammable and hazardous materials. PBW can also simplify system integration and diagnostics while reducing the complexity associated with hydraulic materials and leaks. wp-actuators-in-air
Weight reduction is another important advantage. Replacing hydraulic infrastructure with electrical wiring can reduce the volume and mass of the actuation system. The paper explains that reducing aircraft weight can support flight objectives and reduce fuel consumption. wp-actuators-in-air
The white paper then examines the extensive testing required for electromechanical actuators. Safety-of-flight testing must be performed before actuators can be certified for field use. Validation can include static and dynamic load frames, environmental chambers, shock and vibration testing, and integrated aircraft-system testing. wp-actuators-in-air
A key testing method is the iron bird. This ground-based simulator reproduces portions of an aircraft and places rotary gear actuators or linear actuators in positions corresponding to their real aircraft locations. The system can simulate thousands of takeoffs and landings under extreme temperatures while recording real-time control inputs and outputs, torque, and force. wp-actuators-in-air
The guide also highlights the challenge of reproducing aerodynamic forces accurately. As control surfaces move, the forces acting on the actuator change dynamically. Test systems therefore need high-speed control capabilities to recreate these force curves while accounting for actuator angles, opposing loads, mechanical linkages, and other aircraft dynamics. wp-actuators-in-air
Production testing introduces another level of precision. Every actuator must undergo testing on a smaller-scale setup before release, including simulated flight conditions and measurements such as load curves, efficiency, power input and output, maximum force, and backlash. Even very small amounts of gear movement can affect performance, making the balance between backlash and actuator efficiency critical. wp-actuators-in-air
The final testing results must be documented through an Acceptance Test Procedure report. The report establishes acceptable procedures and limits for the product, and changes to those requirements may require regulatory approval. The white paper emphasizes that this documentation is necessary for field release and that end-of-line testers should be capable of automatically generating the required reports. wp-actuators-in-air
The white paper concludes that all-electric flight is progressing, but significant challenges remain. Battery life, range, production capabilities, and continued testing all need to advance alongside electric aircraft technologies. The development of Power-by-Wire and electromechanical actuation represents an important part of this broader transition. wp-actuators-in-air
This white paper is designed for aerospace engineers, aircraft manufacturers, avionics teams, actuator developers, test engineers, systems engineers, aerospace manufacturers, and organizations developing more-electric and all-electric aircraft technologies.
Download Actuators in Air: Achieving All-Electric Flight from Averna to understand how Power-by-Wire and electromechanical actuators are changing aircraft architectures and what testing strategies are required to validate these systems for safe, reliable deployment.
