Magnetic Sensors for Next-Gen Flight Control Systems
As commercial aircraft systems become increasingly electrified and automated, the demands on flight control systems continue to grow. Precision, reliability, and safety are more critical than ever, especially for the actuators that manage vital control surfaces like flaps, rudders, and slats. Behind these sophisticated systems are high-performance magnetic sensors, working quietly to deliver accurate, real-time position feedback.
The Role of Sensors in Flight Control
In modern aircraft, both primary (rudder, elevator, aileron) and secondary (flaps, slats, spoilers) control surfaces are often actuated by electro-mechanical actuators (EMAs). These systems rely on embedded sensors to monitor and confirm surface positions, ensuring each movement matches the pilot’s input or flight computer commands. Without precise feedback, aircraft control becomes less predictable, putting safety and performance at risk.
Why Magnetic Sensors?
Magnetic sensors are ideally suited for flight control applications for several key reasons:
- Non-contact operation eliminates mechanical wear, improving long-term reliability.
- Resistance to contaminants like oil, dust, and moisture makes them ideal for harsh aerospace environments.
- Compact design allows integration into space-constrained assemblies.
- High accuracy and stability are maintained even under extreme vibration and temperature shifts.
Common types include Hall Effect sensors, magnetoresistive (MR) sensors, and reed switches—each paired with high-strength permanent magnets or multipole encoder rings for reliable signal generation.
Applications in Action
In flap systems, magnetic sensors monitor actuator movement to ensure synchronized deployment across the wings—critical during takeoff and landing. Rudder actuators use sensors to provide precise yaw feedback, helping maintain smooth directional control. Similarly, slat actuators depend on magnetic sensing to confirm full extension or retraction, especially during low-speed flight.
These sensors not only support real-time control but also feed vital data back to onboard diagnostics and maintenance systems.
Built for Aerospace Demands
Dexter designs magnetic sensor assemblies to meet the toughest aerospace standards. We consider:
- Thermal stability, often requiring magnets that operate reliably up to 200°C.
- Vibration and shock resistance, essential for flight safety.
- EMI/EMC compliance, to prevent interference with sensitive avionics.
We use materials like Samarium Cobalt (SmCo) for high-temperature resilience, and apply specialized coatings to protect against corrosion and humidity. For mission-critical systems, we also support redundant sensor designs to ensure fail-safe operation.
Our Engineering Expertise
From sensor magnets to full sub-assemblies, Dexter offers tailored solutions that integrate seamlessly into your actuator or control system. Our team works closely with aerospace OEMs to:
- Design custom magnetic profiles for optimal field strength and sensor response.
- Support rapid prototyping, design validation, and magnetic field mapping.
- Deliver production-ready components that align with aerospace quality and documentation standards.
Magnetic sensors are at the core of next-generation flight control systems—delivering the precision, durability, and intelligence today’s aircraft demand. At Dexter, we understand the unique challenges of aerospace environments and offer engineered solutions to meet them head-on.
Looking to integrate magnetic sensing into your next actuator or avionics system?
Connect with our aerospace experts to start the conversation.