space rotary joints overview & capability brief...space rotary joints overview & capability...

Diamond Antenna and Microwave Proprietary Document

Approved for Global Viewing

SPACE ROTARY JOINTSOVERVIEW &

CAPABILITY BRIEF

Prepared By: Charlie LusherDirector of Space Programs and Lead RF Design EngineerDiamond Antenna and Microwave

WHY USE A ROTARY JOINT IN SPACE?

PRODUCT/MISSION RELIABILITY

LONG LIFE

DESIGN FLEXIBILTY

EXCELLENT RF PERFORMANCE (MUCH BETTER THAN CABLE WRAPS)

STABLE THERMAL & VACUUM PERFORMANCE

HIGH MULTIPACTION MARGINS

VERY LOW TORQUE

NO ROTATION LIMITS (MORE ROBUST THAN FLEXIBLE WAVEGUIDE AND CABLE WRAPS)

LOW OUTGASSING MATERIALS USED

Diamond Antenna and Microwave Proprietary Document 2

ROTARY JOINT MISCONCEPTIONS:

ROTARY JOINTS SHOULDN’T BE USED FOR SPACE-FLIGHT USE

Diamond has delivered qualified products to multiple worldwide programs

POOR RELIABILITY Diamond has never experienced a Space product test failure

HIGH TORQUE

Typical ambient temperature values are < 4 inch ounces

ROTATIONAL RF CHANGE

RF change (Wow) with gimbal rotation is typically <.05 in VSWR & Insertion Loss

CABLE WRAPS or FLEXING A WAVEGUIDE IS A BETTER CHOICE

Why take the chance of a failure?

Several customers have selected Rotary Joints after test failures of a cable wrap or flexible waveguide


BEARING and LUBRICATION SELECTION:

BEARING SELECTION

Customers have final approval of bearings & lubricant selected

Some customers choose to supply bearings as CFE (Customer Furnished Equipment)

If required, Diamond personnel can be sent out for assembly and testing at the customer’s location

COMMON LUBRICANTS FOR SPACE BEARINGS

Penzane

Rheolube Family

Moly Disulfide (MOS2) Dry Film

Braycote 601EF

Customer Proprietary Lubricant

LUBRICANT LOSS

Rotary joints are designed to minimize lubricant loss, through the combination of bearing design,housing labyrinths, and the use of barrier film coating


Diamond Antenna & Microwave

Proprietary Document

DIAMOND ANTENNA SPACE ASSEMBLY AREA:

5Diamond Antenna and Microwave Proprietary Document

Class 10,000 Clean Room

Black Light Cleanliness Inspection RF Testing in Clean Room

Class 100 Laminaire Flow Bench

DIAMOND ROTARY JOINT DESIGN PROCESS:

(Typical)

RF Modeling Design

Mechanical Assembly Model

AnalysisPeriod

Mechanical Manufacturing

Package

Final RF Modeling

VerificationDrawing Package

Release

RF Modeling of Transient, Frequency, Thermal &

Mechanical Deformation Solvers Available

Design Cycle Repeated as Required


RF DESIGN SOFTWARE (MICROWAVE STUDIO)

MODELING CAPABILITY

Virtual Prototypes

Full RF Analysis

High Power Thermal Analysis

Mechanical Distortion Analysis

Multipaction Analysis

Ionization Analysis

Highly Accurate RF Prediction

Diamond Antenna & Microwave Proprietary Document 7



RF MODELING ACCURACY: (WR-34 Waveguide Design)

EXAMPLE 1No Tuning NeededVSWR Model

Prediction

Initial Measured

VSWR


Initial Measured

Actual VSWR



RF MODELING ACCURACY: (Coaxial Design)

EXAMPLE 2No Tuning Needed

CST Predicted

VSWR

Initial Measured

VSWR

3/5/2020 9Diamond Antenna and Microwave Proprietary Document

TYPICAL PROGRAM SDRLS:

Quality/Program Related:

1) MIP/KIP Plan

2) Quality Plan

3) PA Conformance Plan

4) PID Document

5) Configuration Control Plan

6) Cleanliness Control Plan

7) Critical Item List

8) Risk Management Plan

9) Risk Register

10) Schedules & WBS

11) Product Tree

12) Progress Reports

Meetings:

1) Kickoff Meeting

2) Preliminary Design Review

3) Critical Design Review

4) Manufacturing Readiness Review

5) Test Readiness Review

6) Pre-Ship Review

7) Weekly Progress Meetings

Documentation:

1) Materials/Process List

2) Log Books

3) Assembly Travelers

4) Photographic Inspection

5) Verification Test Plan

6) End Item Data Packages

7) Test Procedures

8) Test Reports

SDRL’s and ANALYSES TYPICALLY COMPRISE NEARLY 50% OF A CONTRACT’S VALUE

PROPER SELECTION CAN IMPROVE SCHEDULE & REDUCE COST


TYPICAL RF & MECHANICAL ANALYSES:

RF Analyses:

1) RF Design Modeling

2) High Power Thermal

3) Multipaction

4) EMI

5) PIM

6) RF Data Trending

7) Worst Case Dimensional

Mechanical Analyses:

1) Bearing

2) Structural (Vibration/Shock)

3) Thermal

4) Thread Engagement

5) FMEA

6) Reliability

7) Lubrication Loss

8) Life

9) Reliability




TYPICAL FINITE ELEMENT ANALYSES


Sinusoidal Vibration

Random Vibration

Shock

Quasi-Static

Thermal Loads

Bearing & Life

Bolted Joints

Lubricant Loss



TYPICAL RF ANALYSES


RF Analysis

Average Power

Peak Power

Multipaction

Ionization

Thermal Effects on RF

Worst Case Analysis

Distorted Geometry

RF Leakage



DIAMOND ANTENNA SPACE HERITAGE


Customer Satisfaction:

• Leading worldwide space rotary joint supplier

• Exceptional customer service

• Many repeat orders

• Other vendor product refurbishment/legacy replacement

Design & Manufacturing Experience:

• Performs 100% of the required activity (Prog Mgmt, QC, Design, Assy, Test, Shipment)

• Core team has worked together for over 15 years

International Customer Base:

• North America

• Europe

• Asia Pacific



DIAMOND ANTENNA SPACE PROGRAM HERITAGE

15

Rotary Joint Heritage: (Pre 2013)

Mars Observer: X-Band WR-90 Waveguide

DSCS-3: X-Band WR-90 Waveguide

Land Sat 5: X-Band Coaxial

Land Sat 7: X-Band Coaxial

CRSS: X-Band Coaxial

Earthwatch: X-Band Coaxial

Orbview: X-Band Coaxial

Quickbird: X-Band Coaxial

Stereo: X-Band Coaxial

Rotary Joint Heritage: (2013 – Current)

NASA Program: WR-34 Single Channel Waveguide

NASA Program: WR-34 Single-Axis

Military Program: WR-51 Multi-Axis Waveguide

Military Program: X-Band Coaxial Single Channel

WR-51 Program: WR-51 Dual Channel

ESA Program: WR-112 & WR-28 Dual Channel, Dual-Axis

Military Program: Coaxial Single Channel

WR-51 Program: WR-51 Single Channel, Dual Axis

Military Program: Dual Channel Coaxial

Military Program: WR-51 & WR-22 Single Channel

NASA Program: WR-34 Single Channel, Dual-Axis

Military Program: WR-28 Single Channel, Dual Axis

Military Program: Dual Channel Coaxial

NASA Program: WR-112 Single Channel

Mars 2020: X-Band Coaxial Single Channel Refurbishment




NEW IN-HOUSE TEST CAPABILITY

THERMAL VACUUM CHAMBER


Vacuum Chamber,

1 x 10-6 torr

Feedthroughs for

Waveguide, Coax,

Thermocouples,

and Wiring

Servo Motor

w/ Ferrofluidic

Rotary Seal

Torque Sensor,

Vacuum Rated

Rotary Joint Under Test

Thermal Platen-150⁰C to + 150⁰C


Approved for Global Viewing 17

Diamond Antenna and Microwave

SPACE HERITAGE EXAMPLES

DUAL CHANNEL DUAL AXIS WR-112 / WR-28:


+200o C / -80o C Temperature Range

Very Severe Vibration

& Shock Environment

WR-112 ChannelWR-28 Channel



DUAL CHANNEL X-BAND COAXIAL:


7.9 – 8.5 GHz

(Both Channels)



SINGLE CHANNEL WR-34:


25.5 – 27.5 GHz

SINGLE CHANNEL - DUAL AXIS, WR-34:

26.5 to 26.8 GHz


SINGLE CHANNEL DUAL AXIS, WR-51:


20.2 to 21.2 GHz

DUAL CHANNEL COAXIAL:


7.9 – 8.5 GHz

(Both Channels)



SINGLE CHANNEL COAXIAL:


7.9 – 8.5 GHz



SINGLE CHANNEL WR-112:


7.9 – 8.5 GHz

PLEASE CONTACT:

Charlie Lusher

Director of Space ProgramsDiamond Antenna and Microwave

[email protected]

[email protected]

978-486-0039 (Ext. 134)

DESIGN OR PROGRAM QUESTIONS?


mailto:[email protected]

space rotary joints overview & capability brief...space rotary joints overview & capability...

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