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SpaceSystems
Mechanisms Overview
August 2001
Mech_over__aug01.ppt
www.honeywell.com/space/CEM
Mech_over_aug01.ppt 2SpaceSystems
Space Systems Glendale Product Areas
CommercialProducts
Reaction Wheel Assembly
Larger VolumeStandardized Products
Standardized Mechanisms
Special Projects
Unique Low VolumeProducts
Control MomentGyros (CMG)
SpecialtyMechanisms
SpaceStation
Multiplexers/Demultiplexers
Software DevelopmentSystem
DisplaysData Storage
Data and VehicleManagement
HumanSpace
Displays andSoftware
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Mechanisms Design Heritagen Over 30 Years experience in custom mechanisms for Military, NASA
and Commercial programsn Spin Systems Key Technologies and Heritagen Several Encoder Methodsn Power and Data Transfer Assembliesn Low ripple and jitter motors
n Gimbal and Pointing Systems Heritagen Precision Pointing Gimbals and electronicsn RF Rotary Joints and Flex capsulesn Deployment Systemsn Controls/Structure Interactions and Dampingn Disturbance Compensation/Reduction
n Commercial Rotary Actuators and Gimbalsn Communication Antennasn Thruster Controln Solar Array Drives
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Rotary Actuator Typesn Ambassador Series:
n High volume production (1400+)n LEO Constellation tailored designn Application:
n Antenna dish deployment and pointing
n Galaxy Series:n Currently in productionn LEO / GEO tailored designn Applications:
n Subreflector rotationn Antenna dish deployment & pointingn Thruster pointing
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Honeywell Mechanisms DesignPhilosophy
nDesign products with inherent modularityn Insure individual rotary actuators can be used
easily in single axis or two axis gimbal modesnMinimize part count for lower production costsnDesign for manufacturing and assembly
through close relationship with productionpersonneln Insure flexibility in the design to meet
customer specific requirements with minimalnon-recurring costs.
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Galaxy Series Rotary Actuators and Gimbals
n Modular Packaging Conceptn Low part count (12)n 2.2 Kg (4.9 lbs) per axis weightn Precise step accuracy (0.0075 deg)
n Theoretical step size versus actual step size
n Small step size ( 0.009375 deg)n Non-redundant coarse potentiometern Conductive track for ground path across
output bearingsn Redundant Fine potentiometer for
position telemetry
n Target Applicationsn Antenna deployment and pointingn Thruster pointing
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Assembly of GX-090221 ActuatorSTOPRING
MOTOR & FINEPOTENTIOMETERASSEMBLY
HARMONICDRIVEASSEMBLY
OUTPUTFLANGE
BEARINGSPOTENTIOMETER
MOUNTINGFLANGE
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System Applications of Galaxy SeriesRotary Actuators
Two Axis Gimbal Leveln Reflector Deployment and
Pointingn Thruster Deployment and
Pointing (Proposed design)
Two Axis Gimbal w/ Interfacen Spot Beam Antenna
Deployment and Pointingn Thruster Deployment and
Pointing (Proposed design)
Features:n Primary and Secondary
Circuits Separated on TwoConnectors
n Modularityn Extended Thermal
Environmentsn Non-Op: -60degC to +117 degCn Op. (Flight): -45degC to 105 degC
Features:n Primary and Secondary
Circuits Separated on TwoConnectors
n Modularityn Extended Thermal
Environmentsn Non-Op: -60degC to +117 degCn Op. (Flight): -45degC to 105 degC
Rotary Actuator Leveln Subreflector Rotationn Single Axis Deployment
& Positioning
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Specialized Mechanism Programs
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Hubble Space Telescope
Honeywell supplied two key subsystems for theHubble Space Telescope: Reaction WheelAssemblies and an Antenna Pointing System.
To keep its sharp focus, the Hubble relied onHoneywell reaction wheel assemblies andisolation system for positioning and stability.To send images and data back to Earth, thegiant telescope linked with NASA’s Trackingand Data Relay Satellite System via aHoneywell antenna pointing system.
Honeywell supplied similar reaction wheel andpointing systems for the Solar Max andMagellan missions, as well as for missions likeTopex and Explorer Platform.
Two Axis GimbalAssembly (TAG)
Gimbal ElectronicsAssembly (GEA)
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AMSR Honeywell provided mechanisms and momentumcontrols for Mitsubishi Electric Corporation’sAdvanced Microwave Scanning Radiometer(AMSR), an instrument used on NASA’s EarthObserving System satellite -- EOS-PM1.
SSO built and delivered an Antenna DriveAssembly and a Momentum Wheel Assembly tocontrol AMSR. The Antenna Drive Assembly, aspinning mechanism, is crafted to be the interfacebetween the AMSR instrument package and theEOS-PM1 satellite bus, providing signal andpower transfer and precision compensation for themomentum created by this rotation. Theseproducts demonstrate Honeywell’s heritage indesigning and building spinning mechanisms for anumber of successful satellite programs.
Mech_over_aug01.ppt 12SpaceSystems
Galileo
When NASA’s Galileo spacecraftviewed Jupiter’s moon, Ganymede, theflyby was made possible in part byHoneywell Space Systems’ SpinBearing Assembly and Scan ActuatorSubsystem. Because the Galileospacecraft is stabilized by a spinningmotion of about 3 rpm, the spin bearingassembly was designed to “despin” andpoint an instrument platform carryingseveral sensitive scientific instruments.The result is precision pointing of theinstruments.
Honeywell’s scan actuator subsystemswere used to point another series ofinstruments during flyby encounterswith Jupiter and its satellites.
n Single axis gimbal for pointinginstruments on Galileo orbiter
n 200 circuit flex capsulen 0.5 N-m torque outputn 16 bit optical encodern Redundant motorsn ±105 deg angular traveln 0 to 1.0 deg/sec angular raten 19.5 Kg weight
n Single axis gimbal for pointinginstruments on Galileo orbiter
n 200 circuit flex capsulen 0.5 N-m torque outputn 16 bit optical encodern Redundant motorsn ±105 deg angular traveln 0 to 1.0 deg/sec angular raten 19.5 Kg weight
Mech_over_aug01.ppt 13SpaceSystems
TOPEXHoneywell designed, developed and producedthe High Gain Antenna System (HGAS) forthe Ocean Topography experiment (TOPEX)satellite.
The system consisted of a deployment mast,gimbals and electronics and allowed theTOPEX spacecraft to maintain a two-waycommunications link between NASA’sTracking and Data Relay Satellite System andEarth.
Honeywell also provided four Reaction WheelAssemblies that stabilized and controlled thesatellite’s attitude.
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SMM High Gain Antenna System (HGAS)
Solar Maximum Mission (SMM)High Gain Antenna System
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EOS-AM Gimbal Assembly Description
n Azimuth/Elevation Rotary Actuatorn Redundant Absolute 14-bit Optical Encodersn Redundant Coaxial and Power/signal Cablesn Mechanical Stops: Az ± 202°, El -29° & + 97°n Titanium and Aluminum Structuren 36 lbs. Total Weightn 1.2 Deg/sec Slew Speedn Life Test– 10 Yr Duty Cyclen Delivered September 1995
n Azimuth/Elevation Rotary Actuatorn Redundant Absolute 14-bit Optical Encodersn Redundant Coaxial and Power/signal Cablesn Mechanical Stops: Az ± 202°, El -29° & + 97°n Titanium and Aluminum Structuren 36 lbs. Total Weightn 1.2 Deg/sec Slew Speedn Life Test– 10 Yr Duty Cyclen Delivered September 1995
Honeywell designed and built the Stepper-Gimbal Assembly for the Earth ObservingSystem Satellite (EOS) AM high gain antenna.
The two-axis gimbal pivot the craft’s antennadish and electronics, which gathered andtransmitted data.
EOS was among the first NASA spacecraftsusing Honeywell’s stepper-gimbals.
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Advanced Gimbal System (AGS)n Control torquen Elevation: 34 N-mn Lateral: 34 N-mn Roll: 14 N-m
n Angular rangen Elevation: +100/-60 degn Lateral: ±60 degn Roll: ±60 deg
n Pointing accuracyn Using ideal inertial
sensor: 0.1 arcsecn Using gimbal resolvers:
27.7 arcmin
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DMSP Scan Drive Assembly (SSMIS)
n 31.6 RPMn 7 year lifen 50 Slipringsn Redundant Optical
Encodern 2.9 ArcSec Accuracyn Redundant Motorsn 25 lbs
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SeaWinds Scatterometer Antenna Subsystem
n Major Subassembliesn Spin Actuator Assemblyn Antenna Assemblyn Electronics Assemblyn Base Structure Assembly
n Selectable 18 or 20 rpm spinrates
n Redundant 15 bit encodern Redundant brushless DC
motorsn Dual Channel RF rotary
jointn 4.5 year design lifen Delivered 6/97 for ADEOS IIn Delivered 4/98 for QuikScat -
launched 6/99
Mech_over_aug01.ppt 19SpaceSystems
ISS Assembly/Contingency Subsystem (ACS)Antenna Gimbals
Stepper Motor30:1 Anti-Backlash Spur Gear80:1 harmonic Drive-1 deg to +135 deg (Elev.)±236 deg (Azim.)0.018750 to 9 deg/sec9 in-lbs15,000 in-lbs/rad8.5” x 8.5” x 13.0”22 lbs8 lbs1 TS Quad1 Coaxial19.5 years18.9 (106) deg motion@ 0.06 deg/sec550 (106) deg motion@ 9 deg/sec190,000
Drive Config
Coverage
Output Step SizeAngular RateHolding TorqueTorsional StiffnessEnvelopeWeightPayload CapabilityConnections
Life
Direction Changes
Characteristics
Two-axis Pointing Gimbal forthe ISS High-gain Antenna
Application: Primary Communicationfor ISS to Ground
Mech_over_aug01.ppt 20SpaceSystems
ISS Space-to-Ground Subsystem (SGS)Antenna Gimbals
Stepper Motor19:1 Anti-Backlash Spur Gear160:1 harmonic Drive±121 deg(Elev.)±48 deg (Cross Elev.)0.0050 to 5 deg/sec90 in-lbs375,000 in-lbs/rad12” x 12” x 25.0”70 lbs75 lbs1 Two Axis Rotary Joint14 bit Optical Encoder19.5 years18.9 (106) deg motion@ 0.06 deg/sec293 (106) deg motion@ 3 deg/sec400,000
Drive Config
Coverage
Output Step SizeAngular RateHolding TorqueTorsional StiffnessEnvelopeWeightPayload CapabilityConnections
Life
Direction Changes
Characteristics
Two-axis pointing gimbal for the ISS parabolic antenna
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APS Antenna Gimbal Drive
n Redundant Brushless DCMotors
n Direct Driven 40 W Peak Powern 20 in.-Oz Output Torque
n Redundant Single-speed Resolversn ± 4 Arcmin Accuracyn Duplex Bearing Pairs - 1 Fixed, 1
Floatingn Flex Capsule for Power and
Telemetry Transfern Low Loss RF Rotary Couplern Lubrication Type Determines Life
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Explorer Platform (EP) Modular AntennaPointing System (MAPS)
Antenna Gimbals with Deployed MastSteering Control Electronics (2) and
Remote Interface Units (2) on Mast Canister
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Gimbal Torquer Drives (GTD)
n Roll and pitchdrives
n 3.8 ft-lb, 24 poleBDC, low ripplemotors
n Resolvercommutation
n Output torquen Roll: 74 ft-lbn Pitch: 243 ft-lb
n System weightn Roll: 28 lbn Pitch: 31 lb
Delivered for a Restricted Program
Mech_over_aug01.ppt 24SpaceSystems
PMIRR
Honeywell designed, developed and builtthe Optical Chopper Assembly (OCA)for the Pressure Modulated InfraredRadiometer (PMIRR), a scientificinstrument that flew aboard the MarsObserver.
Honeywell’s OCA functioned as anoptical switch alternating beam pathsbetween detectors within the PMIRRinstrument.
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Control Electronics Heritage
nAGS Yes Yesn SeaWinds Yes YesnAMSR Yes Yesn STAPS Yes NonHGAS/MAPS/TOPEX Yes YesnGalileo SAS/SBA Yes YesnDMSP SSMIS No NonQuikScat Yes Yesn EOS-AM No NonACS No Non SGS No No
Drive Electronics Control Electronics
Mech_over_aug01.ppt 26SpaceSystems
Flex Capsule and Cable Wrap AssemblyHeritage
nGalileo SAS - 200 channel flexcapsuleassembly - +/- 100 degreesn ISS SGS - Two axis cable wrap including 6
coaxial cablesn ISS ACS - Two axis cable wrap, coaxial
cablesnAPGS - Optical fiber cable wraps
Mech_over_aug01.ppt 27SpaceSystems
RF Rotary Joints
nDual Channel RotaryJoint (SeaWinds, &QuikScat @ 12 GHz)
n Single Channel RotaryJoint (STAPS, HGAS,TOPEX, & MAPS @ 3GHz)
Dual Channel RF Rotary Jointfrom SeaWinds
Honeywell worked with RF rotary joint suppliers to qualify the designHoneywell furnished the bearings and lubrication system
Mech_over_aug01.ppt 28SpaceSystems
Deployment Systems Heritage
nControlled Deployment - Velocity controlled withan eddie current damper, latched into place(TOPEX)nDeploy/Retract Mechanisms - Controlled with a
redundant drive motor (HGAS & MAPS)nLaunch Retention - Several designs using pyro
devices, flangibolts, paraffin actuators (VISS,TOPEX, Polar Laboratory)
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Position SensorsnSingle & Multi-Speed ResolversnCMG’s/HGAS/STAPS/AGS/TOPEX/APS
n InductisynsnAPGS
nOptical Encodersn Incrementaln Iridium/ACS
nAbsoluten Galileo/EOS-AM/SGS
Honeywell has experience with all types of sensors
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Expanded Production Capabilityn State-of-the-art assembly,
integration & test area (Class100,000 and 100 flow hoods)nGrand Opening of enhanced
facility (March ‘99)
nAccommodates productionof various types of actuators(linear, rotary, solar arraydrives, and gimbals)
Mech_over_aug01.ppt 31SpaceSystems
On-Line Work Instructionsn On-line database:
n Each work station has a monitor which has access to the electronic workinstructions
n Each necessary record is referenced in the work instructions and hyperlinked toan input table. All information is stored on a database by end item serial number.
n Paper back-up system is in placen Information is entered by keyboard or bar code.n All prints and Mspecs are accessible on line
Mech_over_aug01.ppt 32SpaceSystems
Automated Test Equipment Console
n Automated Multi-channel test console inplace.
n Capable of testing 8 units simultaneously.n Lab View based operating systemn Modular hardware and software design
n Replaceable stepper motor drivers (3-phase or 2-phase)
n Same application software can be activated to test upto 8 units.n One application simplifies software change
process.n Minimizes possibility of errors
n Expandable to test power / signal data transfer assemblies(Solar Array Drives) - Planned for the future
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Concurrent Data Reduction
n Real Time Data Reductionn Numerical print outn Graphical print outn Real time data evaluation (PASS /
FAIL criteria)
n Data Trending Capabilityn Currently being implementedn “In Family” data comparisonn Simplification of data packages for
internal and customer review
Program PTAG File Name:Test Name 5.1 Test Time: 8:00 amTest Paragraph 5.1 Test Date: 1/1/1999IT Document IT12345678 Software Rev. psXXXXXXX-XXXTester Rick Self Total Test Time
Part Number: 9999999-999 Pressure AmbientSerial Number: 123456789 Temperature Ambient
T e s t I n f o r m a t i o n
4525 - post vibe mechanical/electrical measurements at 23C (0-240 steps in 1 step increment)
P r e T e s t C o m m e n t s
Parameter Max Min Units Spec Max Spec Min Pass/Fail
Mechanical Output Position Error 0.0003 -0.0069 deg 0.035 -0.035 Pass
Fine Primary Potentiometer - Deviation 0.0113 -0.0145 volts 0.0782 -0.0782 Pass
Fine Secondary Potentiometer - Deviation 0.0196 -0.0042 volts 0.0782 -0.0782 Pass
Coarse Primary Potentiometer - Deviation 0.0000 -0.0018 volts 0.0316 -0.0316 PassCoarse Secondary Potentiometer - Deviation volts 0.0316 -0.0316 N/A
R e s u l t s
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B a c k u p
F i n e P o t e n t i o m e t e r P l o t t e d D a t a ( V D C )
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R E F T M R ( I f R e q u i r e d ) : _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
E n g r S i g n a t u r e : _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ D a t e : _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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P r i m a r y
B a c k u p
C o a r s e P o t e n t i o m e t e r P l o t t e d D a t a ( V D C )
Angle (deg)
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M e c h a n i c a l O u t p u t P o s i t i o n E r r o r ( d e g )
Angle (deg)
Angle (deg)
Mech_over_aug01.ppt 34SpaceSystems
Multiple Unit Test Capability
n Thermal Vacuum Testingn Multiple unit test capability
n 4 rotary actuators simultaneouslyn Quick set up test fixturesn Test console has been programmed
to perform standard test routines
UNITS BEING MOUNTED ON TEST FIXTURES
ONE SHIP SET OF ACTUATORS READY FOR THERMAL /VACUUM TESTING
ACTUATORS IN THERMAL VACUUM
Mech_over_aug01.ppt 35SpaceSystems
Conclusions
nModular Product Designn Interchangeability of parts / Component and subassembly
performance characterization / Low part countn Multiple applications
nAdvances in Production Capabilityn On-line work instructions / Automated Test Console /
Expanded facilities
n Customer Emphasisn Customer tailored testing profiles and sequencing /
Expanded thermal operational range translates to a morereusable design (better suited for Hall thruster application)