spacecraft mechanisms product catalog

Moog Inc. is a worldwide supplier of precision fluid and motion control products and systems foraerospace and industrial applications. Founded in 1951 by William C. Moog, the company nowhas operations worldwide.

Moog Inc. traces its origin to the company’s original patent for the electrohydraulic servovalve, adevice that helped control the flight of America’s earliest missiles and rockets. Today, Moogdesigns and manufactures a range of electrohydraulic, electropneumatic, electronic andelectromechanical control products. These products address the precise control requirements ofspacecraft , aircraft , jet engines,missiles, and industrial machinery.

The Corporate headquarters are locatedin East Aurora, New York, about 20miles from Niagara Falls. Also locatedin East Aurora is the bulk of Moog’sdomestic operating capability.

Internat ional operat ions inc ludemanufacturing and/or sales facilitiesin 18 countries in Europe, Asia,Australia and South America.

Moog is more than a hardwaremanufac tu re r. It ’s a company ofinnovation and ideas; one that takespride in developing creative solutionsand high-quality products that meetcustomers’ requirements.

Schaeffer Magnetics became part ofthe Moog family in February of 1998. Schaeffer Magnetics was founded in 1967 on the vision ofa growing need for ultra-reliable motion control equipment designed specifically for spaceflight.Schaeffer Magnetics started as a supplier of quality electric motors and has continued to grow tomeet the increasingly complex and demanding requirements of a worldwide market. With designheritage back to Apollo and Pioneer, Schaeffer spaceflight experience and Schaeffer’s record ofmission success are unparalleled in the industry.

Schaeffer Magnetics Division

About Moog Inc.

On March 3, 1972, a probe carrying two smal lelectromechanical actuators left earth for rendezvouswith Jupiter, Uranus, and interstellar space. More than adecade later, that spacecraft — known as Pioneer 10 —was still on course, still responding to NASA commands.By June of 1984, in its 12th year of flight, Pioneer 10had achieved celebrity status as the first man-madeobject to escape our solar system.

Vital to the operation of Pioneer 10’s imaging system,two precision actuators on board that distinguishedexplorer continue to perform — even though they werethe first significant products of a small Chatsworth,California firm founded just a few years prior toPioneer’s liftoff. That Chatsworth firm was SchaefferMagnetics, a technology-based company organized forthe express purpose of producing motors, actuators,and actuation systems for spaceflight.

The performance of the hundreds of individual Schaefferdevices that have seen operational spaceflight servicehas been excellent. Acknowledging that record, theheavyweights of spaceflight have become Schaeffercustomers — NASA, TRW, Lockheed Martin, JPL,Hughes, Loral, Sandia, Ithaco, Matra Marconi,Alcatel, Ball, Spectrum Astro, Boeing, OrbitalSciences, and Alenia; along with several ofAmerica’s leading universities including JohnsHopkins, University of Iowa, Caltech, MIT...andmore.

Schaeffer motors and actuators have dominatedAmerica’s exploration of the outer planets, flying tothe moon and to every NASA planetary target.Following the success of Pioneer 10 and 11,Schaeffer was selected as exclusive supplier ofmotor drives for the life science instruments aboardthe two Viking Mars Landers. In addition, the taperecorder drives for the companion Viking MarsOrbiters were provided by Schaeffer — 16 motors inall. The company’s motor drives then returned toJupiter on Voyagers 1 and 2, and to Venus on Pioneer12 and 13, and on the subsequent Venus Multiprobe.

In 1979, the firm earned orders for 57 diverse actuatorsaboard the Hubble Space Telescope, NASA’sLockheed/Perkin-Elmer 43 foot long, 24,000 pound“permanent window” to the universe. Essential functionsserved by the Schaeffer actuators include deployment,latching, primary mirror optical figure control, secondarymirror pointing, optical filter selection, and tape recorderdrives. Schaeffer has since provided an additional filterwheel assembly for the replacement of the Wide FieldPlanetary Camera.

Schaeffer products have also been favored for use inEarth mapping and weather satellites such as NimbusE, F and G, and Tiros N. The highly publicized Multi-Spectral Scanner and Thematic Mapper aboard theLandsat series operate with the help of Schaeffermotors. Meteorological platforms for Schaeffer unitshave included GOES, DMSP, TIROS, TOPEX andSEASAT1.

Scientific and research missions have been well servedby Schaeffer’s ability to design and produce specialhardware. These include COBE, Dynamics Explorer,SBUV/TOMS, CERES, MODIS, ADEOS and many others.

Antenna pointing aboard many satellites is also wellrepresented by Schaeffer actuators. Prominent examplesinclude the six gimbal drives used for the steerablespace and ground link antennas of TRW’s Tracking andData Relay Satellite (TDRS) which relay signals fromthe Hubble Space Telescope and the Shuttle to scientistson Earth. Schaeffer has met similar two-axis requirementsfor Intelsat 6 through 9, Telecom 2, ITALSAT, HISPASAT,

COMETS, ADEOS AND SOHO.

More recent Schaeffer Programs include the Iridium™Solar Array Drive Assembly, GLI Scanner, SpaceStation Pan-Tilt Unit, and ILAS2 Scanner. Solar arraydrives are another important established Schaefferproduct, with many systems having been successfullyflown on domestic, international, and classif iedprograms. These include Magellan, Explorer Platform,Clementine, and the recent large production run forIridium™.

Schaeffer’s long involvement in the spaceflight field,dating from the time when a corporate capability



dedicated to spaceflight hardware production was anew concept, has led to the growth of a unique, focusedcapability — one that can serve as the base forcontinued innovation.

SCHAEFFER RESOURCESSchaeffer’s operations are vertically integrated, andinclude design, manufacturing, test and inspection/qualitycontrol capabilities. This, combined with a demonstratedproblem-solving approach to spaceflight motion controlapplications and a company-wide commitment to thehighest values and standards, contribute to the growthand success of Schaeffer Magnetics. We strive to selectthe most competent and talented people to design andbuild quality products and provide outstanding service toour customers. We take pride in demonstrating responsiblecorporate citizenship and regard for our community. Bypracticing care and reinvesting in our facilities, we providean environment in which members of our team arechallenged to reach their highest potential.

ENGINEERINGThe core of our application-oriented design team is anexceptional group of electrical, mechanical, electronics,and controls engineers. These hardware-orientedindividuals are knowledgeable in the design, fabrication,assembly and test functions.

Schaeffer utilizes the most advanced hardware and soft-ware tools available for the engineering process. Westart with full concept design, using a parametric solidmodeling system. Solid model data is utilized to performdetailed finite element modeling for structural, thermaland magnetic analysis to achieve optimal designs.Similarly, conceptual design of electronics and control

systems are modeled and simulated using P-SPICE andMATLAB, respectively.

This information is also employed to perform 3Danimation during product development. Virtual Realityprototypes provide tools and methods for the shortestpath to new product generation by combining innovationwith cost effectiveness.

ASSEMBLYOur facility is equipped to perform precision mechanicaland electronic assembly in our Class 100,000 cleanroom along with Class 100 certified laminar flow workstations. Quality and conformity of workmanship areensured by skilled and well-trained technicians.

FABRICATIONSchaeffer uses the most up-to-date computer controlledmanufacturing machinery. Highly skilled machinistswork with a variety of materials. High volume machiningcapabilities exist through the extensive Moog resourcesavailable to Schaeffer.

TESTINGEvery Schaeffer product is thoroughly tested to verifyconformity with specification requirements. Schaeffer’senvironmental test laboratory is equipped with an arrayof modern thermal vacuum chambers with capacity upto 10 feet long and 6 feet in diameter. The vibration testlab is a clean, well-equipped facility with random andsine vibration capability, and can generate forces up to6000 pounds.

DEDICATED LIFE TEST LABSchaeffer’s technically advanced bearing and lubricantlife test laboratory provides validation of the life capabilityof our products when exposed to high vacuum envi-ronments. The laboratory provides real time mea-surements and simulated constant operation for periodsof 10 years or longer.

MOOG ACQUIRES SCHAEFFER MAGNETICSIn February of 1998, Moog Inc. completed the acquisitionof Schaeffer Magnetics. Since the acquisition, Moog hasmade several significant investments in the Schaefferinfrastructure. Most notably, the Schaeffer Division hasmoved into a modern 70,000 square foot facility (addingalmost 30,000 square feet).

Ernie SchaefferFounderSchaeffer Magnetics

Moog Rotary Actuators are based on the geometry andconfiguration of the Rotary Incremental Actuator whichevolved more than two decades ago at SchaefferMagnetics, in response to the needs of the spaceflightcommunity. The capabilities of this device were founduseful in many spaceflight applications; and the devicebecame a de facto standard in the industry. In recognitionof this, Schaeffer developed a family of basic units,whose size progression reflects the size range of theharmonic drive transmissions on which the units arebased. The following pages tabulate dimensions and thenormal ranges of performance parameters for standardconfiguration Rotary Actuators. Performance data aregiven as ranges in order to serve as a guideline in thepreparation of Buyer specifications for these devices.

The Rotary Actuator consists of a small-angle permanentmagnet stepper motor coupled to a Harmonic Drive speedreducer, with a large, rotating flange output member.Advantages of this configuration include:

• Short, rigid, “pancake” configuration• High gear ratio in a single pass• Small output step• Power-off holding capability• No backlash• High stiffness and structural load capability

Units produce high output torque for their size, withouthigh-speed members or excessive gear ratios. Theconfiguration of the harmonic drive allows a clear boreon the center line of the actuator, permitting accessorieson the rear of the actuator to be driven at output speed.The through-bore itself is also useful in many applications.

Spaceflight motion control applications generally aretypified by the unique and highly mission-specific natureof the requirements. However, within a given applicationcategory (e.g. solar array drive; antenna positioner), it isbecoming more and more possible to take advantage ofthe growing application history and make use of heritageunits. Few or no changes may be needed- especially ifthis course is adopted early in a program. Heritage unitsare described in the pages that follow. Their data sheetssupplement the generic configuration and performance datatabulation, to further guide the preparation of specifications.

Simply selecting a unit from the preferred heritage designs,when possible, will confer the following advantages:

High Performance- These units have been engineeredfor optimum performance, to meet stringent customerspecifications.

Significant Flight Heritage- The record of success ofMoog is unequalled. A great amount of flight time hasbeen amassed by these units, and their applicationenhances confidence and reduces program risk.

Previous Qualification- Costs of a qualification programcan frequently be avoided.

Lower Cost- Non-recurring costs are minimized with apreferred design. Standard parts are manufactured andstocked, with resulting cost savings.

Reduced Delivery Time- Critical long-lead componentsfor the actuators shown, including subassemblies suchas motor rotors and stators, are stocked. Schedule riskis thereby minimized.

A review of the preferred heritage designs will serve toillustrate many of the options and accessories that canbe incorporated in the Rotary Actuator. These includecenterline through-bores, enhanced torsional stiffness,electrical redundancy, hard stops, cable wraps, sliprings, modified step angles, brushless DC motors, andposition feedback devices (potentiometers, encoders,resolvers). The possibilities are further illustrated in thesections of this catalog listing applications of the RotaryActuator, such as Biaxial Gimbals and Solar ArrayDrives.


Rotary Actuators


Type M8 Rotary Incremental Actuator

Type M8

Design

Actuator Dimensions


The Moog Type M8 actuation system was specificallydesigned to replace other types of deployment release actuatorssuch as paraffin actuators (wax motors) and Electro ExplosiveDevices (EEDs). The M8 Actuator allows synchronous operationof multiple actuators and provides simple powered- resetcapability in the installed system. This actuator can providerelatively fast deployment or caging release that is independentof ambient temperatures. Also, this device is very insensitive

to electromagnetic interference and therefore does not requirelarge shielding cables and extreme safety precautions. ThisMoog actuation system offers linear or rotary motion bysubstitution of three components. The M8 is fully reversibleand resettable, does not represent a contamination hazard,and is not life-limited for ground system operation andprolonged on-orbit operation.

3X .138-32UNC-2B .240 MIN©

3X .32 MAX

Ø1.772

.39 MAX

3.20 MAX

Ø1.69MAX

.19

.18.151.1413XØ

Ø2.30 MAX

Ø2.000

Ø1.80 MAXØ1.65 MAX

2.0872.077

1.111.08

Ø

The performance data is intended to serve as a guide. Most of the dimensional and performance parameters reflect the typical capabilities and not the design limitations of the actuator.

Note: Optional position feedback encoder shown


Heritage Applications

Heritage Programs

Performance Specifications


21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] M8DS 4/99

SICRAL • ASTRO E • MUSES C • MARS 98

SPECIFICATION UNITS BASIS DATA SPECIFICATION UNITS BASIS DATA

Output Step Angle Degrees Standard 0.05

Output Torque:

lb-inTypical 5

Steps/Revolution — Standard 7,200 High 7

Harmonic Drive Ratio — Standard 100:1N-m

Typical 0.56

Motor Step Angle Degrees Standard 5.0 High 0.79

Max. Output Step Rate Step/Sec(Deg/Sec) Maximum 400

(20)

Holding Torque:Powered

lb-in

Low 5

Torsional Stiffness

lb-in/radTypical 2,000

Typical 7Enhanced N/A

N-m/radTypical 226

High 9Enhanced N/A

Shaft Load Capability Axial

lb Maximum 289

N-m

Low 0.56

N Maximum 1,286 Typical 0.79

Transverselb Maximum 422 High 1.0

N Maximum 1,878

Holding Torque:Unpowered

lb-in

Low 2

Momentlb-ft Maximum 5.5 Typical 4

N-m Maximum 7.4 High 7

Power Watts

Low 3

N-m

Low 0.23

Typical 5 Typical 0.45

High 7 High 0.79

Inertial Capability

Slug-ft2Typical 0.05

Total Assembly Weightlb Typical 0.7

High 0.5 kg Typical 0.3

Kg-m2Typical 0.07 Please contact Moog application engineers to discuss

optional actuator performance capabilities.High 0.7

Thru Hole Capabilityinches Maximum N/A

mm Maximum N/A

THRUSTER GIMBAL • ANTENNA POINTING MECHANISM • FILTER WHEEL


Type 1 Rotary Incremental Actuator

Type 1

Design

Actuator Dimensions


The Moog Type 1 rotary incremental actuator is a compact, closelyintegrated design made up of two key elements…a motor and aharmonic drive speed reducer. The motor is a small angle perma-nent magnet stepper with high holding torque. The harmonic drivespeed reducer offers large reduction ratios, high load capability,low weight, zero backlash and high torsional stiffness. Coaxialnesting of the motor and harmonic drive elements allows use of

large, high capacity output bearings and gives the unit a low-profile geometry. The actuator can be made available with optionalfeatures such as brushless DC motor and encoder/potentiome-ter/resolver output position feedback. All of the electrical elementssuch as motors and position sensors can be redundant with littleor no change in actuator envelope.

4X .138-32 UNC—2B .25 MIN©

Ø1.940

Ø2.500 6XØ THRU.143.137

Ø2.85 MAX

.21

.20

1.141.09

2.192.18

2.80 MAX

Ø2.182.17

Ø2.13 MAXØ

(1.66 MAX)


Note: Optional potentiometer depicted

MIRROR DRIVES • MECHANISM DRIVES • SOLAR ARRAY DRIVES • OPTICALMECHANISM DRIVES • OPTICAL FILTER POSITIONER • SCANNER BRAKE ACTUATOR

CONTAMINATION COVER ACTUATOR • DOOR OPENER • MASS ADJUSTER CYROGENIC OPTICAL POSITIONER • SHUTTLE DOOR OPENER



Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] T1DS 4/99

DYNAMICS EXPLORER • AXAF • GEOLITE • COMETS • STARLAB TELESCOPE MARS OBSERVER • CERES/EOS • SSTI • EOC • STEP 4 • MIGHTYSAT • AIRS

TIROS • VUE • UVIE • LACE • INTELSAT • GGS POLAR SPACECRAFT • TRMM/VIRS



Output Torque:

lb-inTypical 12



Typical 1.3

Motor Step Angle Degrees Standard 3.75 High 2.7


(31.25)


lb-in

Low 5

Torsional Stiffness


Typical 10Enhanced 5,000

N-m/radTypical 339

High 13Enhanced 565


lb Maximum 1,100

N-m

Low 0.6

N Maximum 4,900 Typical 1.1

Transverselb Maximum 1,100 High 1.5

N Maximum 4,900


lb-in

Low 3

Momentlb-ft Maximum 45 Typical 5

N-m Maximum 61 High 8

Power Watts

Low 4

N-m

Low 0.3


High 8 High 0.9

Inertial Capability

Slug-ft2Typical 0.1


High 1 kg Typical 0.5

Kg-m2Typical 0.14 Please contact Moog application engineers to discuss

optional actuator performance requirements.High 1.4

Thru Hole Capabilityin Maximum 0.25

mm Maximum 6.35

©Ø4.144

Ø3.100

6X .164—32UNC—2B

8X Ø.194.187

Ø4.46 MAX



Type 2

Design

Actuator Dimensions

Type 2 Rotary Incremental Actuator*

The family of Moog rotary incremental actuators is basedon a compact coaxially-nested motor and harmonic drivegear system. The actuator design is flexible and canaccommodate a variety of motor, gear and positionsensing options. The Type 2 design can provide additionaltorque and inertial capability over the Type 1 with a smallincrease in weight and envelope. Redundancy, hard stopsand a wide variety of design options can be incorporated

into the standard Type 2 design shown above. Otherdesign options for consideration are brushless DC motors,alternate gear drive systems and cable wrap accessories.Motors for all Moog actuators are designed and manufacturedat the Schaeffer facility. Stepper motors can be of 2 or 3phase construction, depending on the application. ContactMoog application engineers for assistance with actuatorselection and design options.

1.821.78

Ø3.56

3.67 MAX

Ø 3.8423.841

Ø3.34 MAX

.35 MAX


Note: unit pictured with optional bracket and potentiometer



Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] T2DS 4/99

CLASSIFIED • UARS • MSTI • CLEMENTINE • GFO • PTU • SSTI • ROCSAT INDOSTAR • KOMPSAT • DEEP SPACE 1 • GEOLITE • VCL • AXAF

MARS GLOBAL SURVEYOR • QUICKBIRD • JEM ICS

DEPLOYMENT ACTUATOR • MAST DRIVE UNIT • CYROGENIC ACTUATOR DUAL AXIS SOLAR ARRAY DRIVE • SINGLE AXIS SOLAR ARRAY DRIVE

DUAL AXIS CAMERA POINTING MECHANISM • ANTENNA POINTING MECHANISM


Output Step Angle Degrees Standard .0200

Output Torque:

lb-inTypical 80



Typical 13.5

Motor Step Angle Degrees Standard 2.0 High 20


(9.00)


lb-in

Low 40

Torsional Stiffness



N-m/radTypical 678

High 150Enhanced 1470


lb Maximum 1,750

N-m

Low 4.5

N Maximum 7,800 Typical 11

Transverselb Maximum 1,600 High 17

N Maximum 6,700


lb-in

Low 10



Power Watts

Low 4

N-m

Low 1.1


High 10 High 5.6

Inertial Capability

Slug-ft2Typical 5



Kg-m2Typical 7 Please contact Moog application engineers to discuss

optional actuator performance requirements.High 28

Thru Hole Capabilityinches Maximum 0.5

mm Maximum 12.7



Type 3

Design

Actuator Dimensions


The Type 3 actuator is one of our more popular designs, withhundreds of units delivered and successfully operatingon-orbit. The standard design is based on the heritage actuatorconcept, a compact coaxially-nested motor and harmonicdrive gear system. The most popular version incorporates apotentiometer for position sensing with a redundant 3 phasemotor. As with all Moog actuator products, incorporatingoptional equipment based on the application is possible. This

flexible design can accommodate hard stops, 2 or 3 phasestepper motors, brushless DC motors, a variety of positionsensors, cable management systems or other application-specific options. These actuators are commonly used inAntenna Pointing Mechanism applications. The actuators canbe incorporated into a biaxial gimbal configuration to fit yourapplication. Contact Moog application engineers for assistancewith actuator selection and design options.

6X .164—32UNC—2BX .246 MIN

©Ø4.75 MAX Ø4.350

Ø3.600

6XØ THRU.192.184

.26

.25

1.451.43

3.953.94

3.50 MAX

Ø4.00Ø3.93MAX

Ø


Note: unit pictured with optional feedback potentiometer and rotary stops



Heritage Programs




TELECOM 2 • INTERNATIONAL SPACE STATION • MUSES B • HISPASAT • SOHO • MARSGLOBAL SURVEYOR • INTELSAT • MSX • HOTBIRD • W24 • THAICOM • PANAMSAT

SIRIUS • ASTRA • AXAF • SEASAT • JEM ICS • STENTOR • EURASIASAT • AVNIR II • TIMED

ANTENNA POINTING MECHANISM • PAN-TILT UNIT DOOR DRIVE • SOLAR ARRAY DRIVE



Output Torque:

lb-inTypical 150



Typical 17



(3.75)


lb-in

Low 100

Torsional Stiffness



N-m/radTypical 11,300

High 800Enhanced 16,900


Maximum 2,500

N-m

Low 11



N Maximum 9,400


lb-in

Low 50

Momentft-lb Maximum 150 Typical 100


Power Watts

Low 6

N-m

Low 5.5

Typical 10 Typical 11

High 18 High 23

Inertial Capability

Slug-ft2Typical 25 Total Assembly Weight

(with potentiometer)

lb Typical 4.3



optional actuator performance requirementsHigh 100


mm Maximum 15.8

6X .164—32UNC—2B

Ø 5.450

6X Ø THRU.182.177

Ø4.37 MAX

Ø3.272

Ø 5.78 MAX



Type 5

Design

Actuator Dimensions


The Type 5 actuator has unmatched on-orbit heritage in avariety of applications, most notably as a solar array drivemechanism. As with the other standard Moog actuators, thedesign is based on a compact coaxially nested motor andharmonic drive gear system. This design can be provided witha variety of options, depending on the application. Moog engineersare available to assist in design trades as required. This unitcan be provided with 2 or 3 phase stepper motor,

redundant/non-redundant, brushless DC or stepper motors.Stand-alone drive electronics designed and manufactured byMoog can also be provided. If the application requiresincreased output stiffness, this design can be provided withadded capability with little weight or envelope impact. As withall standard actuators, this unit can be delivered with a through-hole to pass cabling for special applications.

B.21.19

2.021.97

3.673.65

5.49 MAX

Ø 5.10MAX

Ø4.34MAXØ


Note: unit pictured with optional potentiometer



Heritage Programs




ANTENNA POINTING MECHANISMS • MIRROR DRIVES • DEPLOYMENT MECHANISMSLATCH DRIVES ANTENNA DRIVE GIMBALS • DEPLOYMENT ACTUATORS • SOLAR

ARRAY DRIVES • INSTRUMENT DRIVES • SUNSHIELD ACTUATORS • MECHANISM DRIVES



Output Torque:

lb-inTypical 500

Steps/Revolution — Standard 48,000 High 1,000


Typical 56



(2.25)


lb-in

Low 200

Torsional Stiffness




High 1,000Enhanced 16,900


lb Maximum 3,000

N-m

Low 23



N Maximum 11,000


lb-in

Low 80



Power Watts

Low 7

N-m

Low 9


High 20 High 35

Inertial Capability

Slug-ft2Typical 100



Kg-m2Typical 136 Please contact Moog application engineers to discuss optional

actuator performance requirements.High 545


mm Maximum 22.2

TDRS • ANIK • HUBBLE SPACE TELESCOPE • ACTS • MAGELLAN • ERBE • EOSCLASSIFIED • IRIS • DIFFUSE X-RAY SPECTROMETER • EXPLORER PLATFORM • MIRTOPEX-POSEIDON • IRIDIUM™ • OICETS • FUSE • XTE • TRMM • DRTS • QUICKBIRDADEOS I • ADEOS II • COMETS • LANDSAT • GPS • MARS OBSERVER • GLI • ASAR



Type 7

Design

Actuator Dimensions


The Type 7 actuator is currently the largest rotary incrementalactuator within the Moog family of space qualified products.Applications for this unit can include solar panel drive, antennapointing, or custom uses. This unit provides significant capabilityin a relatively compact design. The through hole is the largest ofMoog’s harmonic drive based systems. The unit has all of theoutstanding features of a Moog actuator: high load capability, zerobacklash, high torsional stiffness. In addition, the Type 7 actuator

provides significant output torque and unpowered holding torque.The unit can be provided with redundant electrical elementssuch as motors and position sensors with little or no change inactuator envelope size. The unit shown in the photo above anddetailed below does not have a position sensor incorporated.Contact Moog applications engineers for assistance and additionalinformation.

.44

.41

6.356.33

Ø7.91MAX

Ø7.03MAX

Ø7.00MAX

5.71 MAX

3.573.50

5.055.04

Ø

3.923.91

Ø

Ø12XØ

Ø7.475

.195

.188

6X .190 -32UNF-3B

Ø4.500


Note: optional rotary stops are depicted



Heritage Programs






Output Torque:

lb-inTypical 1,400



Typical 158



(0.8)


lb-in

Low 800

Torsional Stiffness


Typical 1,800Enhanced 480,000




lb. Maximum 12,000

N-m

Low 90


Transverselb. Maximum 9,300 High 294

N Maximum 41,500


lb-in

Low 400

Momentlb-ft Maximum 1,200 Typical 800

N-m Maximum 1,627 High 1,400

Power Watts

Low 12

N-m

Low 45


High 30 High 155

Inertial Capability

Slug-ft2Typical 500

Total Assembly Weightlb. Typical 17.0

High 1,700 kg Typical 7.7


optional actuator performance requirements.High 2,300


mm Maximum 31.75

ANTENNA POINTING MECHANISM • SOLAR ARRAY DRIVE

CLASSIFIED



Type 6

Design

Actuator Dimensions


The Type 6 actuator has been specifically designed for applicationsthat require high stiffness and output torque along with the abilityto handle significant inrtial loads. The design is well suited tomove large antennaes or solar panels. The unit is comparable tothe other Moog rotary incremental actuators in that the design isbased on a coaxially nested motor and harmonic drive speedreducer. The standard design includes the large center hole for

RF conductors or solar panel power transfer. The unit can beprovided with a variety of position sensing devices such as opticalencoders, potentiometers or resolvers. The unit shown in thephoto above and detailed below does not have a position sensorincorporated. As with all Moog actuator designs, this unit hasmany other available options that can be discussed with Moogapplication engineers.

.38

.36

5.605.58

Ø7.33MAX

Ø6.39MAX

Ø6.37MAX

5.08 MAX

3.253.18

4.764.75

Ø

3.403.39

Ø

Ø

6X .190—32UNF—3B

12XØ THRU

Ø6.855

.195

.188

Ø4.000




Heritage Programs




CLASSIFIED • IRIS

ANTENNA POINTING MECHANISM • SOLAR ARRAY DRIVELATCH ACTUATOR • MECHANISM DRIVE



Output Torque:

lb-inTypical 800



Typical 90



(1.20)


lb-in

Low 400

Torsional Stiffness


Typical 1,300Enhanced 250,000




lb. Maximum 7,800

N-m

Low 45


Transverselb. Maximum 5,400 High 226

N Maximum 24,000


lb-in

Low 200



Power Watts

Low 10

N-m

Low 23


High 23 High 70

Inertial Capability

Slug-ft2Typical 150

Total Assembly Weightlb. Typical 9.0



optional actuator performance requirements.High 1,290


mm Maximum 25.4


Rotary Incremental ActuatorPerformance Data

ACTUATOR PERFORMANCE

SPECIFICATION UNITS BASISACTUATOR TYPE

M8 1 2 3 5 6 7

Output Step Angle Degrees Standard 0.05 0.0625 .0200 0.009375 0.0075 0.0060 0.0040

Steps/Revolution — Standard 7,200 5,760 18,000 38,400 48,000 60,000 90,000

Harmonic Drive Ratio — Standard 100:1 60:1 100:1 160:1 200:1 200:1 200:1

Motor Step Angle Degrees Standard 5.0 3.75 2.0 1.5 1.5 1.2 0.8

Max. Output Step RatesStep/Sec(Deg/Sec) Maximum

400(20)

500(31.25)

450(9.00)

400(3.75)

300(2.25)

200(1.20)

200(0.8)

Power Watts

Low 3 4 4 6 7 10 12

Typical 5 5 8 10 12 14 16

High 7 8 10 18 20 23 30

Inertial Capability

Slug Ft2Typical 0.05 0.1 5 25 50 150 500

High 0.5 1 20 75 400 950 1,700

Kg-m2Typical 0.07 0.14 7 35 70 205 680

High 0.7 1.4 28 100 545 1,290 2,300

Output Torque

lb-inTypical 5 12 80 150 500 800 1,400

High 7 24 120 330 1,000 2,000 2,600

N-mTypical 0.56 1.3 9 17 56 90 158

High 0.79 2.7 13 37 113 226 294


lb-in

Low 5 5 40 100 200 400 800

Typical 7 10 100 300 600 1,300 1,800

High 9 13 150 800 1,000 2,000 2,600

N-m

Low 0.56 0.6 4.5 11 23 45 90

Typical 0.79 1.1 11 34 70 145 200

High 1.0 1.5 17 90 113 226 294


lb-in

Low 2 3 10 50 80 200 400

Typical 4 5 25 100 200 400 800

High 7 8 50 150 300 600 1,400

N-m

Low 0.23 0.3 1.1 5.5 9 23 45

Typical 0.45 0.6 2.8 11 23 45 90

High 0.79 0.9 5.6 23 35 70 155

Torsional Stiffness

lb-in/radTypical 2,000 3,000 6,000 100,000 100,000 150,000 350,000

Enhanced NA 5,000 13,000 150,000 150,000 250,000 480,000

N-m/radTypical 226 339 678 11,300 11,300 17,000 39,500

Enhanced N/A 565 1,470 16,900 16,900 28,000 54,200


lb. Maximum 289 1,100 1,750 2,500 3,000 7,800 12,000

N Maximum 1,286 4,900 7,800 11,000 13,400 35,000 53,500

Transverselb. Maximum 422 1,100 1,600 2,100 2,500 5,400 9,300

N Maximum 1,878 4,900 6,700 9,400 11,000 24,000 41,500

Momentlb-ft Maximum 5.5 45 78 150 220 660 1,200

N-m Maximum 7.4 61 106 203 298 895 1,627

Thru Hole Capabilityinch Maximum N/A 0.25 0.5 0.625 0.875 1.0 1.25

mm Maximum N/A 6.35 12.7 15.8 22.2 25.4 31.75

Total Assembly Weightlb. Typical 0.7 1.3 2.8 4.3 4.8 9.0 17.0

kg Typical 0.3 0.6 1.3 2.0 2.2 4.1 7.7

Contact Moog application engineers to discuss optional actuator performance requirements.

Rotary Incremental Actuator

Dimensional Comparison


21339 Nordhoff St. • Chatsworth CA • 91311Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] P/DDS 4/99

GENERAL ACTUATOR DIMENSIONS

ACTUATORDIMENSIONS

Ø A B C D Ø E Ø F Ø G H J

TYPEM8

in. 2.0872.077

1.111.08

2.31MAX

0.190.18

1.69MAX

N/A 2.30MAX

0.138-32UNC-2B X 0.24 DP(MIN) 3PL EQ SP ON Ø1.772

Ø0.151/0.141 THRU3PL EQ SP ON Ø2.000

mm 53.0052.76

28.227.4

58.7MAX

4.84.6

42.9MAX N/A 58.4

MAX 3 PL EQ SP ON Ø45.01 3 PL EQ SP ON Ø50.80

TYPE 1

in.2.192.18

1.141.09

2.25MAX

0.210.20

2.13MAX 2.18

2.85MAX

.138-32UNC-2B X 0.25 DP4PL EQ SP ON Ø1.940

Ø0.143/0.137 THRU6PL EQ SP ON Ø2.500

mm55.655.4

29.027.7

57.2MAX

5.35.1

54.1MAX 55.4

72.4MAX 4PL EQ SP ON Ø49.28 6PL EQ SP ON Ø63.50

TYPE 2

in. 3.573.55

1.821.78

3.15MAX

0.270.26

3.18MAX

3.842 4.46MAX

.164-32UNC-2B X 0.25MIN DP6PL EQ SP ON Ø3.100

Ø0.194/0.187 THRU8PL EQ SP ON Ø4.144

mm 90.790.2

46.245.2

80.0MAX

6.96.6

80.8MAX 97.6 113.3

MAX 4PL EQ SP ON Ø107.77 8PL EQ SP ON Ø105.26

TYPE 3

in.3.953.94

1.451.43

3.81MAX

0.260.25

3.93MAX 4.00

4.75MAX

0.164-32UNC-2B X 0.24 DP(MIN) 6PL EQ SP ON Ø3.600

Ø0.192/0.184 THRU6 PL EQ SP ON Ø4.350

mm100.3100.1

36.836.3

88.9MAX

6.66.4

99.8MAX 101.6


TYPE 5

in. 4.384.37

2.021.97

3.75MAX

0.210.19

4.65MAX

5.10 5.78MAX

0.164-32UNC-2B X 0.25MIN DP6PL EQ SP ON Ø3.272

Ø0.182/0.177 THRU6PL EQ SP ON Ø5.450

mm 111.3111.0

51.350.0

95.3MAX

5.34.8

118.1MAX

129.5 146.8MAX

6PL EQ SP ON Ø83.11 6PL EQ SP ON Ø138.43

TYPE 6

in. 5.605.58

3.253.18

5.08MAX

0.380.36

6.37MAX 6.39 7.33

MAX0.190-32UNF-2B x 0.45/0.40 DP

6PL EQ SP ON Ø4.000Ø0.195/0.188 THRU

12PL EQ SP ON Ø6.855

mm142.2141.7

82.680.8

129.0MAX

9.69.1

161.8MAX 162.3


TYPE 7

in.6.356.33

3.573.50

5.71MAX

0.440.41

7.00MAX 7.03

7.91MAX

0.190-32UNF-2B X 0.45/0.40 DP6PL EQ SP ON Ø4.500

Ø0.188/0.195 THRU12PL EQ SP ON Ø7.475

mm 161.3160.8

90.788.9

145.0MAX

11.210.4

177.8MAX

178.6 200.9MAX

6PL EQ SP ON Ø114.30 12PL EQ SP ON Ø189.86

Notes:1. Maximum diameter over ears.2. Basic length with no accessories.3. Basic body diameter exclusive of flanges or ears.4. Many designs do not have pilot diameter.

D

A

B

C

E

F

Note 1 Note 3

Note 2

Note 4

G

H

J


Rotary Incremental ActuatorHarmonic Drive Comparison

Rotary Incremental Actuator Options

ACTUATORTYPE

M8 1 2 3 5 6 7

SPECIFICATION UNITSMotor StepDegrees 5 3.75 2 1.5 1.5 1.2 0.8

MAX PPS 400 500 450 400 300 200 200

HD RATIO

50 0.100 0.0300 0.0300 0.0240 0.0160 Output Step Size Degree

50 2.5 46 120 200 350 Output Torque lb-in

50 40 12 9 4.8 3.2 Max. Speed Deg/Sec

60 0.083 0.0625 0.0333 0.0250 0.0250 0.0200 0.0133 Output Step Size Degree

60 3.0 12.0 48 56 150 240 420 Output Torque lb-in

60 33 31.25 15 10 7.5 4 2.67 Max. Speed Deg/Sec

72 0.0278 0.011111 Output Step Size Degree

72 57 500 Output Torque lb-in

72 12.5 2.22 Max. Speed Deg/Sec

80 .063 0.0469 0.0250 0.0188 0.0188 0.0150 0.0100 Output Step Size Degree


80 25 23.44 11.25 7.5 5.63 3 2 Max. Speed Deg/Sec

100 0.05 0.0375 0.0200 0.0150 0.0150 0.0120 0.0080 Output Step Size Degree


100 20 18.75 9 6 4.5 2.40 1.60 Max. Speed Deg/Sec

120 0.0125 0.0125 0.0100 0.0067 Output Step Size Degree

120 112 300 480 840 Output Torque lb-in

120 5 3.75 2 1.33 Max. Speed Deg/Sec



160 3.75 2.81 1.50 1.00 Max. Speed Deg/Sec



180 3.33 2.5 1.33 0.89 Max. Speed Deg/Sec

200 0.0075 0.0060 0.0040 Output Step Size Degree

200 500 800 1400 Output Torque lb-in

200 2.25 1.20 0.80 Max. Speed Deg/Sec

255 0.0059 Output Step Size Degree

255 637 Output Torque lb-in

255 1.76 Max. Speed Deg/Sec

Note: Preferred ratios are highlighted.


21339 Nordhoff St. • Chatsworth CA • 91311Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] HDDS 4/99

The units shown on the following product data sheetsrepresent a very popular and versatile application of thespaceflight qualified Moog Rotary Incremental Actuator.When there is a need to move a payload on two orthogonalaxes, two actuators can be combined ito provide thiscapability. The gimbals are designed in modular fashion,making it easy to create units of either elevation-over-azimuth or cross-axis configuration- the difference is inthe design of the interaxis and/or interface bracket orbrackets.

GIMBAL CONSTRUCTIONThe key to the simplicity and economy of forming a gimbalwith Moog actuators is the strong, cantilever-mountedoutput of the actuators- the actuator output bearings arethe gimbal bearings.

APPLICATIONSMoog biaxial gimbals are well suited for performingspaceflight tracking, scanning, and positioning functions.Applications include solar array drives, antennapositioners, and optical telescope and instrument drives.

CORE ACTUATORSThe core actuators employed in biaxial gimbals aretypically Moog standards. One or more accessories orcustom features may be added to them; and the gimbalbrackets may be standard or special for the application.Accessories routinely used include position feedback

devices (potentiometers, encoders, or resolvers), cablewrap assemblies, slip rings, and RF rotary joints. Specialfeatures frequently found useful in gimbals are motionlimiting stops (up to 680 degrees total rotation) on theactuator outputs, cable management features such asclamps and guides, and launch lock devices.

THROUGH-GIMBAL CONNECTIONSWhen the gimbal’s driven load is electrically active,cable and conduit management is an important part ofgimbal design. To accommodate continuous rotation onone or both axes, slip ring assemblies and rotary RFjoints are used. These are integrated as modules withthe actuators at the actuator level, becoming anotherbuilding block in the construction of the gimbal. Onlimited-rotation axes, at least four different approachesare available for these connections.

SPECIAL CONSTRUCTIONSThe size of the driven load, or dynamic requirements,may indicate a full yoke construction on one of the gimbalaxes. In that case, minor changes can be made to theactuator output section to enable it to operate smoothlywith the additional outboard bearings. Special load orstiffness requirements may indicate a gimbal of mixedconstruction; i.e. the combination of a Type 2 actuatorwith a Type 1 actuator, a Type 6 and a Type 7; etc.Such combinations have been made

DRIVE AND CONTROLThe rotary actuators in the biaxial gimbals are driven bythe standard Moog driver circuit; and driver circuits arecombined in the same modular fashion as the actuators,to create a multi-channel control box matched to theconfiguration and redundancy scheme of the gimbal.

Specifications shown on the following pages are typical,and are meant to illustrate how construction andperformance parameters are addressed. The range ofstandard actuator sizes available, and the variety ofaccessory devices that can be applied, mean that a Moogbiaxial gimbal can be designed for virtually anyapplication.


Biaxial Gimbals


Type 11 Biaxial Gimbal

Type 11 Biax

Design

Gimbal Dimensions


The Type 11 biaxial gimbal as shown consists of two Type 1 actuators inan orthogonal combination. The Type 1 actuators can be provided with avariety of options. Baseline Type 1 Actuator characteristics may be foundin the Rotary Actuator data sheets. These gimbals can be used for two-axisantenna or solar array drive. A variety of application-specific options canbe implemented, including slip rings, RF rotary joints, cable management

systems, hard stops, and launch locks. Interfaces can be adapted to fitthe application both mechanically and electrically. Where the Type 1actuator is not suitable for both axes, please keep in mind that actuatorsof different sizes can be mixed in a biaxial configuration (such as a Type 21Biax for instance) if required. Please contact Moog engineers to discussthe specifics of the application.

R1.60MAX

4XØ

Ø2.550

.18

.17

(5.70)

(R1.43)

Ø2.16 MAX

4X 4-4O UNC-2B THD .36 .34

©.151.145

Ø2.85MAX

Ø2.16MAX

Ø2.25MAX

4.31

2.96

2.29MAX

Ø1.940

The performance data is intended to serve as a guide. Most of the dimensional and performance parameters reflect the typical capabilities and not the design limitations of the mechanism.



Heritage Programs





Output Step Angle* Degrees Standard 0.0625Moment Stiffness In the AZ-EL Plane

lb-in/rad Typical 30,000

N-m/rad Typical 3,390

Steps/Revolution* — Standard 5,760 Perpendicular to Planelb-in/rad Typical 2,500

N-m/rad Typical 282

Harmonic Drive Ratio* — Standard 60:1 Output Flange Load Capability Axial

lb Maximum 200

N Maximum 890

Output Step Rate* Step/Sec(Deg/Sec)

Maximum 500(31.25)

Transverselb Maximum 200

N Maximum 890

Power* Watts Nominal 5 Momentlb-ft Maximum 45

N-m Maximum 61

Inertial Capability*Slug ft2 Typical 0.1


kg-m2 Typical 0.14 kg Typical 1.4

Output Torque*lb-in Typical 12 * Each Axis

Please contact Moog application engineers to discuss optional actuatorperformance requirements.

N-m Typical 1.4

Holding Torque Powered*

lb-in Typical 10

N-m Typical 1.1

Unpowered*lb-in Typical 5

N-m Typical 0.6

SOLAR ARRAY DRIVE

MIGHTYSAT



Type 22 Biax

Design

Gimbal Dimensions


The Type 22 Biaxial Gimbal offers increased output torqueand greater stiffness. The center through-hole allows standardRF rotary joints to be easily incorporated for antenna pointingapplications. For solar array drive applications, power andsignal lines are passed through the actuator and transferred to

the spacecraft by way of slip rings or twist capsules. A widerange of position sensors, cable management systems andlaunch/caging options are available. Please Contact Moogengineers to discuss application options.

Ø3.20

Ø4.52

Ø3.65

2.67

(7.67)

5.40

.25

R2.26

Ø4.15

Ø2.83

6X 0.112-40 UNC — 2B

4.10




Heritage Programs





Output Step Angle* Degrees Standard 0.0200Moment Stiffness In the Az-EL Plane




N-m/rad Typical 621

Harmonic Drive Ratio* — Standard 100:1Output Flange Load Capability Axial

lb Maximum 250

N Maximum 1,112

Output Step Rate*Step/Sec(Deg/Sec) Maximum

450(9.00) Transverse

lb Maximum 250

N Maximum 1,112


N-m Maximum 106

Inertial Capability*Slug ft2 Typical 5


Kg-m2 Typical 6.8 kg Typical 2.8


Please contact Moog application engineers to discuss optionalperformance requirements.

N-m Typical 9.0


lb-in Typical 100

N-m Typical 11.3


N-m Typical 2.8

SOLAR ARRAY DRIVE ASSEMBLY • ANTENNA POINTING MECHANISM PAN-TILT UNIT

VCL • QUICKBIRD • SPACE STATION • MSTI



Type 33 Biax

Design

Gimbal Dimensions


The Type 33 Biaxial Gimbal is of a size appropriate for manyantennas, and it has become by far our most popular AntennaPointing Mechanism configuration. Available in eitherElevation/Azimuth or X/Y, these units have proven their reliabilityand versatility many times over. The actuators of the unitsincorporate centerline through-holes for RF rotary joint orcable management implementation. The actuators are based

on Moog’s heritage Type 3 actuator design with significanton-orbit experience. The gimbals can incorporate a widerange of options. Launch locks, caging mechanisms, cablemanagement systems, position sensors and waveguidebrackets/mounting features are some examples of the optionsavailable to the designer. Please contact Moog engineers forassistance when evaluating options for your application.

6X .164—32UNC—2B X.25 MIN©

Ø3.600

8.81 MAX

4.36 MAX

.26

.25

R 2.40

3.953.94

Ø

1.451.43

2.052.03

X

Ø3.94 MAX

Ø4.750

4.0003.998Ø




Heritage Programs





Output Step Angle* Degrees Standard .009375Moment Stiffness In the AZ-EL Plane






lb Maximum 420

N Maximum 1,868


Maximum 400(3.75)


N Maximum 1,868


N-m Maximum 203



kg-m2 Typical 34 kg Typical 4.4



N-m Typical 17


lb-in Typical 300

N-m Typical 34


N-m Typical 9.0

TELSTAR • TELECOM 2 • MUSES-B • MGS INTELSAT VIIA • HOTBIRD III & IV • W24 • PANAMSAT

THAICOM • SIRIUS • ASTRA 2B • INTELSAT KTV

ANTENNA POINTING MECHANISM

8.98

5.80 MAX

1.35



Type 55 Biax

Design

Gimbal Dimensions


The Type 55 Biaxial Gimbal is currently the largest standardMoog biaxial gimbal with flight heritage. The Type 55 is capableof handling large loads with high torsional stiffness. If desired,added load capability can be achieved by enhancing the actuatoroutput section. The standard design has been optimized to behighly producible at a reasonable price. The actuator used isbased on the design of the Iridium™ Solar Array Drive actuator.

Moog has manufactured over 400 of these actuators used inthis Biaxial configuration. Although the standard designincorporates potentiometers as position sensors, resolvers orencoders can be accommodated as well. Moog engineers canimplement a number of design options to meet your programrequirements.

1.50

5.80 MAX

4.65

4.73




Heritage Programs





Output Step Angle* Degrees Standard 0.0075Moment Stiffness In the AZ-EL Plane






lb Maximum 550

N Maximum 2,446


Maximum 300(2.25)


N Maximum 2,446


N-m Maximum 298



Kg-m2 Typical 68 kg Typical 4.8



N-m Typical 56


lb-in Typical 600

N-m Typical 68


N-m Typical 23

SOLAR ARRAY DRIVE ASSEMBLY • DEPLOYMENT DRIVEANTENNA POINTING

IRIDIUM™ • ACTS • CLASSIFIEDADEOS I & II • COMETS


Active Universal Joint Biaxial Gimbal

AUJ Biax

Design

Gimbal Dimensions


The Active Universal Joint (AUJ) Gimbal is functionally anelevation-over-azimuth biaxial gimbal. A novel method is usedto achieve the motion, however. Rather than the usual orthogonalarrangement of two rotary actuators, a coaxial arrangement oftwo motors is used. Both motors are mounted in stationarystructure, and no inter-axis gimbal wiring is needed.

AUJ axes are referred to as the outer and the inner axisrespectively. The outer axis output is a cup-shaped member

carrying a slant-mounted ball bearing. The inner axis memberrides in the slant-mounted bearing, and is driven independentlyby a motor coaxial with the outer axis motor, through a universaljoint. Pointing of the output line of sight of the antenna or mirrormounted on the AUJ output is the resultant of the motions ofthe inner and outer axes, and can be characterized as elevationand azimuth motions. Angular position outputs from precisionresolvers on both drive axes are used with coordinate transformationalgorithms for control of the motion.


1.90

4.66

5.87

3.75

3.17

Reverse Type


Functional Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] AUJDS 4/99

The AUJ gimbal offers a line-of-sight coverage area which isan annulus symmetrical about the rotation axis of the motors.The elevation range is determined by the slant angle built intothe gimbal and the angularity of the antenna or mirror mountrelative to the gimbal output. Particularly fine control of theelevation motion (where optical doubling of the motion isfrequently involved) is offered by the AUJ, because of thelarge-angle rotary motion of the motor required to produce a

small motion in elevation. If oversize bearings are used, theAUJ also offers a central volume for an optical path on therotational centerline of the motors. This version is picturedbelow.

Perhaps no other gimbal design offers the same angularcoverage in such a compact, lightweight, symmetrical packageas the AUJ.

4.00

1.35

10°

7.76

Ø6.80

6X M4 THDEQ SP ON Ø6.40 BC

ZERO POSITION

SPECIFICATION REVERSE TYPE CLEAR BORE TYPE

Azimuth Range 125° No Limitation

Azimuth Track Rate 5°/sec max 5°/sec max

Elevation Range -12° to -1° -12° to -1°

Elevation Track Rate 0.5°/sec max 0.5°/sec max

Life 10yr/5,000,000 cycles 10yr/5,000,000 cycles

Weight 3.1 kg approx. 6.5 kg approx.

Power (@25°C) <10 watts with 200% margin TBD

Please contact Moog application engineers to discuss optional performancerequirements.

Clear Bore T ype

The AUJ is the result of a joint effort betweenMoog and NEC of Yokohama, Japan. TheAUJ is covered under U.S. patent number4,683,406 issued to NEC.

BIAX PERFORMANCE

SPECIFICATION UNITS BASISBIAX TYPE

11 22 33 55

Output Step Angle* Degrees Standard 0.0625 0.0200 0.009375 0.0075

Steps/Revolution* — Standard 5,760 18,000 38,400 48,000

Harmonic Drive Ratio* — Standard 60:1 100:1 160:1 200:1

Output Step Rates* Step/Sec(Deg/Sec) Maximum 500

(31.25)450

(9.00)400

(3.75)300

(2.25)

Power* Watts Nominal 5 8 10 12

Inertial Capability*Slug Ft2 Typical 0.1 5 25 50

kg-m2 Typical 0.14 6.8 34 68

Output Torque*lb-in Typical 12 80 150 500

N-m Typical 1.4 9.0 17 56

Holding Torque: Powered*lb-in Typical 10 100 300 600

N-m Typical 1.1 11.3 34 68

Holding Torque: Unpowered*lb-in Typical 5 25 80 200

N-m Typical 0.6 2.8 9.0 23

Moment Stiffness In the AZ-EL Plane

lb-in/rad Typical 30,000 70,000 150,000 250,000

N-m Typical 3,390 7,910 16,950 28,250

Perpendicular to Planelb-in/rad Maximum 2,500 5,500 35,000 85,000

N-m/rad Maximum 282 621 3,960 9,600

Output Flange Load Capability Axial

lb Maximum 200 250 420 550

N Maximum 890 1,112 1,868 2,446

Transverselb Maximum 200 250 420 550

N Maximum 890 1,112 1,868 2,446

Momentlb-ft Maximum 45 78 150 220

N-m Maximum 61 106 203 298

Total Assembly Weightlb Typical 3.1 6.2 9.6 10.6

kg Typical 1.4 2.8 4.4 4.8

* Each Axis

Please contact Moog application engineers to discuss optional biax performance requirements.


Biaxial Gimbals

Performance Data

Linear actuators are used in spaceflight applicationstypically to produce fine linear adjustments (e.g. opticalmounts), small-angle tilting motions (e.g. “tilt table”gimbals; thrust vector control), to operate lever-crankmechanisms (e.g. scanners; positioners), to operatemechanisms (e.g. launch locks; movable covers), andgenerally wherever linear motion is needed.

Linear motion may be required either directly as an outputmotion, or as input to other mechanisms. Prime movers,on the other hand, are almost invariably rotary in operation.The most simple device with linear output is the screw-nutpair; and it integrates very well with the motor as a compact,symmetrical element of the unit. This close integration ofthe rotary and linear elements is the key to the compactdesign of the Moog linear actuator, making it a “plug-in”source of linear motion.

DESIGN FEATURESMany design features of linear actuators are stronglyapplication-dependent, and there are typically severalchoices to be made. Moog has experience with all thedesign variations, and can assist in matching an actuatordesign to the application. Two constructional variationsare significant: either the screw or the nut may be therotating element; and the anti-rotation feature for thetranslating member may be either internal to the unit, ora part of the driven load. The geometry of the applicationis the primary determinant of the optimum actuatorconfiguration.

LINKAGE OPTIONSLinear actuators may be body mounted- and may becalled upon to carry side loads as well as thrust- or maybe articulated in order to serve as extendable links.In the latter case, any column loading of the unitsis considered in the design.

SCREW-NUT OPTIONSThe screw-nut pair used in the actuator may beeither plain (lead screw), or a ball screw-ball nutcombination. Moog has extensive experience withboth. The ball screw offers higher efficiency, whilethe lead screw has the advantage, frequently important,of being generally non-backdriving under load andoffering a greater choice of thread pitches.

ACCESSORIESOptional accessories include rotational stops to limitlinear output travel, and a variety of position feedbackdevices. Potentiometers, resolvers, encoders, andLVDTs are commonly used. A popular combination is

an encoder on the motor rotor and a linear potentiometeron the output; the combination offering absolute linearposition knowledge. Discrete output position indicationin the form of Hall Effect devices or optical flags may beincorporated as well.

GEAR-REDUCED LINEAR ACTUATORSThe standard linear actuator, including any of theaccessories and constructional variations describedabove, consists of motor and screw-nut pair. A powerfulmechanical advantage is afforded by the screw andnut- output step increments much less than 0.001 inch(0.025 mm)- are easily achieved. When microinch-sizedsteps are needed, or when very large forces are to begenerated, the screw can be paired with a Moogharmonic drive actuator- the overall reduction ratio isthen very high, and extremely fine output motion can beachieved.

DRIVE AND CONTROLMotors can be electrically redundant, and steppers canbe driven by the standard Moog driver circuit. Systemsusing multiple linear actuators can be configured withmulti-channel driver modules as desired.

HERITAGE DESIGNSSpecifications shown on the following pages will beseen to illustrate most of the many constructionaldetails and variations involved in the specification of aspaceflight linear actuator. Whether the application callsfor a simple, existing unit, or requires unique geometryand an unusual combination of features, a Moog linearactuator can meet the requirement.


Linear Actuators


Type M8 Linear Actuator

Linear Actuator

Design

Actuator Dimensions

M8 LinearActuator

The M8 Linear Actuator uses a ball screw to translate therotary motion of a stepper motor to linear output motion. Thetorque transmitted to the ball screw is amplified through aharmonic drive transmission. The motor is a 2-phase,15-degree permanent magnet stepper design. Position ismonitored through potentiometers located on both the rotaryand linear elements of the actuator. Both position sensors are

redundant. The unit shown has a 6 TPI (Threads Per Inch) ballscrew, and non-jamming stops at both the deployed andretracted positions. Thermistors, heaters and thermostats arealso incorporated into this design. Two versions of this designexist, and differences between the two are depicted on thePerformance Specification table as min/max or low/high.

.81

.79

1.121.10

1.68 MAX

.840

2.362

6.68 MAX

1.53 MAX

2.21 MAX

1.089

4X M3 X .12 MIN. ©

1.661.64

.525

.60 MAX 4X M3 X .5 .16 MIN. ©


Type M8 Linear Actuator


Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] TLM84/99

ANTENNA POINTING MECHANISM • THRUSTER GIMBAL • FILTER WHEEL • RF SHUTTER

SICRAL • MUSES C

SPECIFICATION UNITS BASIS DATA

Output Step micro in. Standard 69

Steps/Revolution — Standard 2,400

Harmonic Drive Ratio — Standard 100:1

Motor Step Angle Degrees Standard 15

Max. Output Step Rate Step/sec(in/sec) Maximum 600

(0.04)

Temperature Degrees C Typical -45 to +80

Linear Motion in.Minimum 0.25

Maximum 1.96

Motor Phases — 2

Motor Resistance ohms — 53

Power Watts Maximum 10

Output Forcelbs Typical 7

N Typical 30


Kg Typical 0.50

Please contact Moog application engineers to discussoptional actuator performance requirements.


Figure Control Linear Actuator


Design

Actuator Dimensions

Figure ControlLinear Actuator

The HST (Hubble Space Telescope) Figure Control Actuator(FCA) consists of a small angle stepper motor whose output isconverted to linear motion by means of a recirculating ball nutand ball screw. The ball screw is coupled to a 10 lb/in loadingspring such that each motor pulse corresponds to a constantforce increment of 0.01 lb. The linear actuator consists of amotor, motor housing, frame, ball screw, output member,non-jamming rotational stops, optical encoder for rotary position

and a potentiometer for linear position. The motor is a 3°, 6-phase permanent magnet stepper design. The ball screwdesign is designed for 20 TPI (Threads Per Inch), with thepreloaded rotating ball nut directly attached to the motor rotor.The rate-calibrated spring on the output of the actuator wasdesigned and fabricated by Moog. The encoder providedsingle-step accuracy, confirmation of the motor excitationstate and a once per revolution absolute position indication.

Ø3.438

2.94 SQMAX

Ø.207.203

.250 MAX

(8.19 MAX)

Ø2.21MAX

Ø2.88MAX

Ø1.000

.138 - 32UNC - 2B

Ø3.875 MAX

Ø1.705MAX

2.572.56

2.75 MAX5.62 MAX



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] FCA DS 4/99

This linear actuator is used on the Hubble Space Telescope(HST). A major concern with the large optics was the possibleloss of correct optical figure of the large primary mirror (2.4meters in diameter). The mirror was tested for proper figure in1g conditions, however there were concerns that slightdistortions would occur in the 0g environment of space. Tocounteract this problem, Moog was contracted to provide the

Figure Control Actuator (FCA). Each FCA can produce a pointload of 10 pounds maximum, either push or pull, on the rearface of the massive primary mirror. A total of 24 FCA’s aremounted in concentric rings behind the primary mirror. TheFCA’s were instrumental in the troubleshooting and formulationof corrective measures that were necessary prior to theHubble Servicing Mission.

SPECIFICATION DATA

Weight 0.9 kg

Power 16.5 W maximum

Temperature Range + 15°C to +27°C

Linear Motion ±0.4 in

Step Rate 0.0208 in/sec maximum

Output Step 0.000416 in

Linear Force 0 to 10 lb (0 to 44.5 N)

Accuracy one step, 0.0004°

Backlash 0.005 in maximum

Motor Voltage Resistance Phases

18 - 30 V155 ohms nominal6-phase

Please contact Moog application engineers to discussoptional linear actuator performance requirements.

Hubble Space Telescope


Large Angle and Spectrometric Coronagraph Linear Actuator

LASCO Linear Actuator

Design

Actuator Dimensions

LASCO LinearActuator

The LASCO (Large Angle and Spectrometric COronagraph)linear actuator consists of a motor, motor housing, frame, ballscrew, output member, non-jamming rotational stops and posi-tion feedback elements. The motor is a 4°, 6-phase permanentmagnet stepper design. The ball screw pitch is 20 TPI(Threads Per Inch), with the preloaded rotating ball nut directlyattached to the motor rotor. The output member incorporates

spherical rod ends and an adjustable locking nut feature.Rotating lugs on the motor rotor engage non-rotating lugs onthe traveling screw, stopping the rotation directly, and preventingjamming of the screw and rotating nut. The position encoderprovides center, end and direction telemetry with a simplewiper and track design. This linear actuator was based onheritage designs and has performed exceptionally well on-orbit.

2X M6X1

1.601.59

1.301.29

2.07MAX

± .222 TRAVEL

Ø2.26 MAX

.627

Ø2.60 MAX

2.10 SQ MAX(7.00 MAX)

NOM POSITION6.786.77

(4.10 NOM)

6.366.35

3.812

2X M3X0.5N.S. — F.S.

1.252


LASCO Linear Actuator

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] LASCO 4/99

This linear actuator is used on the LASCO (Large Angle andSpectrometric Coronagraph) instrument, which is one ofeleven instruments on board the SOHO (Solar andHeliospheric Observatory) spacecraft. The SOHO spacecraftis designed to study the internal structure of the Sun, its outeratmosphere and the origin of the solar wind. This informationwill help scientists understand the complex interactionsbetween the Sun and the Earth’s environment. SOHO waslaunched in December of 1995. The LASCO instrument is one

of three coronagraphs that image the solar corona from 1.1 to32 solar radii. A coronograph is a telescope that is designed toblock light coming from the solar disk, in order to see theextremely faint emissions from the region around the Sun,called the corona. LASCO is designed to address the followingscientific issues:• How is the corona heated?• Where and how is the solar wind accelerated?• What causes coronal transients?

SPECIFICATION DATA

Weight 1.0 kg

Power 10 W maximum

Temperature Range -10°C to +50°C

Linear Motion ± 5mm

Step Rate 100 pps (0.556 in/sec) maximum


Output Force 5 lb. (22.2 N)

Accuracy <0.1 mm


28 V nominal70 ohms nominal6 phase with center tap


5.74

4.502.532.47

Ø3.75MAX

.71

.69

1.81

1.79


Microwave Limb Sounder Linear Actuator

MLS Linear Actuator

Design

Actuator Dimensions

Microwave Limb SounderLinear Actuator

1.701.67

9.769.74

9.769.74

14.50MAX

1.44

1.70


The MLS (Microwave Limb Sounder) linear actuator providedscanning motion to a large microwave antenna. The linearactuator consists of a permament magnet stepper motor, aball screw ball-nut pair, and a system of linear guides. Rotaryand linear encoders provide position feedback. The actuator isconfigured as an articulated link, with a ball joint at one end

and a universal joint at the other. The encoder electronics aremounted in the pivot joint bracket. The unit also has heatercircuits, thermistor and a vent screen as accessories. Thislinear actuator has performed exceptionally on-orbit, exceedinglife requirements.

Microwave Limb Sounder Linear Actuator

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] MLS 4/99

This linear actuator is used on the MLS (Microwave LimbSounder) instrument, which is one of nine instruments onboard the UARS (Upper Atmosphere Research Satellite)spacecraft. The UARS spacecraft is the first of the Mission toPlanet Earth series of NASA missions. UARS was deployedfrom the shuttle Discovery in September 1991. Shortly afterbeing deployed from the shuttle, MLS was able to map ClO(chlorine monoxide, an ozone-depleting chemical) over thearctic zones. The data confirmed earlier aircraft measurements

and also provided insight into the extent of the ozone-depletedareas. UARS continues to monitor both the Arctic andAntarctic late winter-spring ozone depletions. The NorthernHemisphere depletion in January-March 1996 was the largestever recorded. Another use for the MLS instrument wasdiscovered while on orbit. The MLS instrument can measureupper tropospheric water, even if ice clouds are present. Thismeasurement is being used to study how cirrus clouds impactclimate.

SPECIFICATION DATA

Weight 5.3 lbs.

Power 6.4 W maximum

Temperature Range +35°C to +85°C

Linear Motion 3.10 in

Step Rate 0.16 in/sec maximum


Linear Force 25 lb nominal (111 N)

Accuracy 0.022° to 0.044°


28 V nominal157 ohms nominal3 phase bipolar


UARS Satellite

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Rubicon™ Linear Actuator


Design

Actuator Dimensions

Rubicon™ LinearActuator

This linear actuator is the result of a joint effort between Moog engineeringand Alson E. Hatheway Inc. (AEH). The Rubicon actuator is capable ofproviding accurate and repeatable position control with a resolution of 2.5nanometers. Moog’s rotary motor technology is combined with AEH’spatented Rubicon transducer to create a linear micro-positioningmechanism which is small, robust, and power-efficient. The device isinherently mechanical, using the linear stiffness and elasticity ratio of the

materials to produce motion, thereby avoiding the linearity and reliabilityproblems associated with other micro-positioning devices that use smartmaterials. Also, no continuous power is required to hold a position.Coarse position capability gives the actuator a 10 mm stroke with .64micron resolution. Fine positioning can be achieved within a 25 micronrange anywhere inside that 10 mm stroke. The unit is designed forcryogenic operation.

Ø.650 X .2 Deep

Ø1.375

.090 Square On

.110 Dia. Shaft

3.750 0.0 To 10.0 MM (0 To .39 In.) .112-40 UNC X .188 DeepOn 1.000 Dia. Circle3 PLCS



Applications



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] RUBDS 4/99

SPECIFICATION DATA

Resolution (nanometer) 2.5

Stroke (mm.) 10

Operating Temperature Range 20° to 300°K

Mass 180g to 200g

Outside Diameter 3.175 cm

Creep OM (nm/day) 0.0

Thermal Stability, OM 0.0 to ± 49.5 (nm/K°)

Axial Force, Set & Hold, OM (N) ± 4

Power Consumption CM .00033 (watt)

Power Consumption OM 0.0 (watt)

Axial Stiffness 1.06 (N/micron)

Stowed Axial Length < 10 (cm)

Note: OM = Observatory Mode, CM = Calibration Mode

MICRO-POSITIONING • OPTICAL COMPONENT CORRECTION INDUSTRIAL METEROLOGY AND NANOMETER CALIBRATION MAGNETIC AND OPTICAL READING/RECORDING MACHINES

Rubicon is an AEH trademark.

The Rubicon™ transducer is covered underU.S. patent 5,187,876

Moog has experience with solar array drives, for both Earthorbit and planetary missions, stretching back to 1980. Thesolar power application is one of the most mature for Moogactuators and biaxial gimbals. Solar array drives havetraditionally been very mission-specific in their configuration;a fact that will be well illustrated in the data sheets that follow.However a standard line is in place now as a result of ourprevious constellation work. Engineers can specify a previouslyqualified design for a new application, or a modified designhaving extensive heritage at the component level can be produced.

CONFIGURATIONSSolar array drives may have one or two axes of rotation, mayinvolve continuous rotation capability on one or both of thoseaxes, and may drive one or two solar panels. The most frequentlyused configurations are the following:

• Body mounted on spacecraft pitch axis; continuous rotation in pitch. Limited angle capability on an orthogonalaxis.

• Boom mounted, with double-ended output for two solar panels. Continuous rotation on outer (spacecraft pitch) axis; partial rotation capability at each solar panel interface.

Essentially any single or two-axis pointing of solar arrays canbe accommodated by a Moog gimbal, probably with acombination of actuators already having spaceflight heritage.

CABLE MANAGEMENTCable handling is a major part of solararray drive design. On continuous rotationaxes, the electrical connections to the solarpanels are generally carried on slip rings.Limited rotation axes may also use sliprings, but more commonly use simple flexloops of cable. Slip rings of both compositeconstruction (silver-graphite brushes on silverrings) and gold-on-gold (wireform brushesin vee grooves) have been used. Slip ringsare typically integrated with their actuatorsin modular fashion, so that, for manyapplications, it will be possible to use apreviously qualified unit.

For most applications, slip ring assembliesare mounted on the actuator as an accessory,on the rear face. Conductors enter the unitthrough the brush blocks, and exit via therotating cable bundle from the rotor. Thehollow shaft feature of the rotary actuator isused, to allow the cables to be passedthrough the actuator on the center line ofrotation. This arrangement is used whether

the continuous rotation axis is the outer axis, the inner axis, orboth. For limited angle applications, twist capsules can beused.

When the required number of slip rings is too great to permitthis approach; i.e. integrating the slip ring assembly as anaccessory to the actuator, then the slip ring housing becomesa relatively larger part of the assembly, and the actuator ismounted to the slip ring housing. Some examples of thisapproach, for large solar array drives, will be seen in thefollowing data sheets.

OPTIONS AND ACCESSORIESOther constructional variations in solar array drives involve theuse of DC motors rather than steppers, when torquedisturbances to the spacecraft are a concern. In this case,closed loop control is used for solar panel positioning, anddrive may be direct rather than through harmonic drive gearing.Position feedback devices can be integrated with the actuatorsto facilitate control.

Other accessories commonly used in solar array drivesinclude potentiometers, sine-cosine resolvers, and encoders.Limited-rotation axes are equipped with hard stops, to limit themotion at the actuator outputs.

Motors are easily made redundant; and steppers can be drivenby the standard Moog driver circuit. Multi-axis and multi-panelsystems can be matched with multi-channel driver boxes.These options are illustrated by several of the systemsdetailed on the following data sheets.


Solar Array Drives


Type 2 Solar Array Drive Assembly

Type 2 SADA

Design

SADA Dimensions


The single axis Type 2 Solar Array Drive Assembly (SADA) isbased on the Type 2 Rotary Incremental Actuator. The standardactuator has varied over many applications to meet missionrequirements, and examples of the modifications are reflectedin the performance specification table on the reverse side ofthis data sheet. Generally, the items that tend to vary are interfaceparameters and power transfer requirements. All of therepresented Type 2 SADA designs are configured withharmonic drive gear sets, potentiometers, encoders, or

resolvers for position sensing and a slip ring assembly forpower transfer. As with all Moog mechanisms, a variety ofdesign options are available. Custom power transfer requirementsare easily accommodated upon request. The designsrepresented on this data sheet are qualified and provide anoption that has cost and schedule benefits. The Type 2 SADAeasily interfaces with the Moog 2 or 4 channel ElectronicControl Unit for a complete system solution. Contact Moogengineering for assistance with your application.

6XØ

Ø5.88 MAX

Ø5.375 1.391.36

3.523.51

9.87 MAX

Ø5.05MAX

Ø

.185

.180

Ø3.000

6X.164-32UNC-2B

.30

.28

Ø2.00MAX


Note: Optional optical encoder shown.


Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] SAD2DS 4/99

SPECIFICATION UNITS 1 2 3 4 5*

Output Step Angle Degrees .02 .02 .02 .02 .02

Harmonic Drive Ratio — 100:1 100:1 100:1 100:1 100:1

Motor Step Angle Degrees 2 2 2 2 2

Output Torquelb-in 100 100 100 100 100

N-m 11 11 11 11 11

Holding Torque Poweredlb-in 80 80 80 80 80

N-m 9 9 9 9 9

Holding Torque Unpoweredlb-in 40 40 40 40 40

N-m 4.5 4.5 4.5 4.5 4.5

Slip Ring

# Power# 53 22 20 16 12

Amps 1.75 2.0 3 3.6 3

# Signal# 18 12 17 36 10

Amps 0.5 0.5 1.0 1.2 0.5

Voltage Volts 75 135 65 75 65

Position SensorAccuracy Degrees ± 3.6 ± 0.08 ± 0.2 ± 1.0 ± 3.6

Type — Pot Opt. Enc. Pot Pot Pot

Total Assembly Weightlb 5 6.6 5.3 5 6

kg 2.27 3.0 2.40 2.27 2.72

* Incorporates a twist capsule ± 170°Please contact Moog application engineers to discuss optional SADA performance requirements.

DEEP SPACE 1 • SSTI • INDOSTAR • KOMPSAT • ROCSATMSTI-3 • GFO • DSPSE • GEOLITE • VCL

The following table depicts performance specifications of several qualified Type 2 Solar Array Drive Assemblies:



Type 5 SADA

Design

SADA Dimensions

Type 5 Solar Array DriveAssembly

The Type 5 actuator used in the single axis Type 5 Solar ArrayDrive Assembly is based on the large production volume Type55 SADA. This SADA has significant heritage, including thesuccessful completion of a life test at 86,000 revolutions (testedunder vacuum and temperature conditions). The actuatordesign has been optimized over many programs to the currentconfiguration through design for manufacturing/cost initiatives.This SADA has been supplied with slip rings or twist capsules

for power transfer. The number of rings and the selectionbetween slip rings and twist capsules is application dependent.Other options such as position sensors, range of motion andmotor configuration are available with this design. A modifiedversion with additional stiffness/load capability is also available.Designers are encouraged to utilize one of the existingproducts shown on this data sheet. Contact Moog engineeringfor assistance with your application.

.21

.19

3.673.65

(11.66 MAX)9.41 MAX

6.865.49

Ø5.10MAX

Ø4.34

Ø2.96

Ø2.00

Ø3.272

Ø

2X2.25MAX

Ø5.450

Ø5.78 MAX

6X .164—32UNC—2B

6XØ.182.177



Heritage Programs




SPECIFICATION UNITS 1 2* 3 4

Output Step Angle Degrees .0094 .0075 .0075 .0075

Harmonic Drive Ratio — 160:1 200:1 200:1 200:1

Motor Step Angle Degrees 1.5 1.5 1.5 1.5

Output Torquelb-in 350 435 435 435

N-m 39.6 49.5 49.5 49.5

Holding Torque Poweredlb-in 600 600 600 600

N-m 70 70 70 70

Holding Torque Unpoweredlb-in 200 200 200 200

N-m 23 23 23 23

Power Transfer

# Power# 27 64 53 30

Amps 3 5 3 3

# Signal# 15 34 18 15

Amps 1 0.5 1 1

Voltage Volts 65 N/A 82 65

Position SensorAccuracy Degrees ±1.2 ±1.8 ±1.8 ±3.6

Type — Resolver Pot Pot Pot

Total Assembly Weightlb 7 7 12.6 8.8

kg 3.2 3.2 5.7 4.0

* Incorporates a twistcapsule ± 150°Contact Moog application engineers to discuss optional SADA performance requirements.

QUICKBIRD • QUICKSCAT • GPS BLOCK2F • OICETS • ICESAT • FUSE • EO1 • TRMM • XTE • CLASSIFIED

The following table depicts performance specifications of several qualified Type 5 Solar Array Drive Assemblies:



Type 11 SADA

Design

SADA Dimensions

Type 11 Solar Array DriveAssembly

The two-axis Type 11 Solar Array Drive Assembly utilizes twoMoog standard Type 1 actuators in a two-axis configuration.Power transfer is accomplished through the use of a slip ringassembly. Each actuator has potentiometers installed for posi-tion sensing. The slip ring utilizes gold rings and gold platedcontacts with a “V”-groove ring-brush interface. The brushblock assembly incorporates redundancy with two separateassemblies. The ring configuration is a brass substrate with anickel diffusion barrier and a gold surface finish. The unit

pictured above was configured for a specific application. Thedesign incorporates hard stops on the elevation axis at ±90°.By using heritage actuator designs for this application, theadvantage of significant on-orbit experience was immediatelygained by the end user. By selecting existing design configurations,cost, and schedule savings can be realized. Please contactMoog engineering to discuss your application. Variations onthis design are available.

Ø3.76

6X.138-32UNC-2B

Ø3.450

2.77 MAX 6.65 MAX

Ø2.13MAX

(9.42 MAX)

2.8432.842

Ø

4.704.64

.23

.21

Ø1.940

2.192.18Ø 4X .138-32UNC-2B

.300 MIN©



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] SAD114/99

SPECIFICATION UNITS DATA

Weight kg 4.2

Power watts 4W max per axis

Operating Temperature degrees -30°C to +61°C

Rate pulses per second 20 pps typical

Potentiometer linearity ± 1%

Slip Ring

# Power# 12

Amps 2

#Signal# 6

Amps 1

Voltage Volts 45

Motor Step Size Output Step Size Phases Holding Torque

degreesdegrees

—lb-in

3.75°0.0375°

3Ø, 6 state20 lb-in minimum

Range of Rotation Azimuth Elevation

degreesdegrees

360°± 90°

Please contact Moog application engineers to discuss optional SADAperformance requirements.

Mightysat is an Air Force Research Laboratory (AFRL) programthat demonstrates new technologies on-orbit. The Mightysat IIspacecraft is a 300-pound satellite designed for launch fromeither the Space Shuttle or the Minotaur launch vehicle.Following Mightysat II, additional launches are planned every18-24 months. Mightysat II’s primary objective is to provide anaffordable space-based platform for demonstrations ofadvanced space system technology. This demonstrationprocess will expedite the transition of technology from the labto operational spacecraft.

There are two classes of payloads on Mightysat II. They areExperimental Bus Components and Stand-Alone Experiments.The payloads for each class are as follows:

Experimental Bus Components:

• Solar Array Concentrator

• Water Resisto-Jet Thruster

• Ground Link System Transponder

• Multi-Functional Composite Bus Structure

Stand-Alone Experiment Payloads:

• Fourier Transform Hyperspectral Imager

• Satellite Command and Control using Iridium™ Link

• Quad-C40 Processor

• Shaped-Memory Alloy Thermal Tailoring Experiment

• Solar Array Flexible Interconnect

• Plume Diagnostic Experiment

Ø4.562

.26

.24

.75

.72

2X 1.00 MAX

6.01 MAX

14.53MAX

7.787.72

5.00MAX

7X Ø.198.196



Type 55 SADA

Design

SADA Dimensions


The Type 55 Solar Array Drive Assembly (SADA) shown wasconfigured specif ical ly for a high-volume productionprogram. Over 200 of these units have been delivered, andthe actuator is the basis for the single axis Type 5 SADA. Thelower axis of this unit (elevation) provides 360° of rotation andpower transfer through the use of a slip ring device. Positionsensing is accomplished with a sine-cosine resolver. The crossaxis (azimuth) provides ± 90° of travel and incorporates a simpleflex loop for power transfer. As shown in the photo above, the

cross axis actuator is located on the right side of the mechanism.The position sensor is housed on the left side of the unit. Theactuator and position sensor sides are connected through thetwo flat paddles. The paddles are attached to the solar panel,which provides the mechanical path to join the two sides of theazimuth axis. Variations of this design are available forconsideration. Please contact Moog engineering specialistsfor assistance with your application.

Ø5.200MAX

(14.53)MAX

2X 1.750

16.40 MAX

13.38 MAX

9.929.91

2X 2.750



Mission Description





Output Step Angle Degrees .009375

Harmonic Drive Ratio — 160:1

Motor Step Angle Degrees 1.5

Holding Torque Poweredlb-in 600

N-m 70

Holding Torque Unpoweredlb-in 200

N-m 23

Slip Ring

# Power# 27

Amps 3

# Signal# 15

Amps 1

Voltage Volts 65

Position Sensor Accuracy Degrees 1.2

Total Assembly Weightlb 18.9

kg 8.57

Contact Moog application engineers to discuss optionalSADA performance requirements.

The I r i d i u m Constellation is comprised of 66 satellites thatform a cross-linked grid above the Earth. The system is in aLow Earth Orbit and provides wireless telephone service.Some applications for the I r i d i u m system are commercialmobile telephone service, aircraft phone systems, and paging.I r i d i u m is especially effective for wireless communications inremote areas. The I r i d i u m satellites orbit the Earth at analtitude of 780-km (485 miles). Messages are routed through acomplex system of both satellite and ground-based gateways.

Transfer of data between satellites is accomplished via RFgateways. The handheld transceiver can be operated incellular mode, using ground based data links, or in satellitemode. In satellite mode, one of the 66 LEO based satelliteswill relay the call from satellite to satellite until the call reachesits destination. The entire constellation of satellites (72 total,66 operational units plus 6 on-orbit spares) was launched andplaced into service in a little more than 1 year, a truly amazing feat.

I r i d i u m Satellite

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Topex Solar Array Drive Assembly

Solar Array Drive Assembly

Design

SADA Dimensions

TOPEX SADA

The TOPEX Solar Array Drive Assembly is based on acombination of existing Moog technology and application-specific elements. The actuator used is the standard Type 5,which incorporates a small angle stepper motor and aharmonic drive gear assembly. The output position wasmonitored through the use of a potentiometer. The high powerrating of the solar panel (worst case 20 kw) required a specialslip ring assembly for power transfer. The power requirementand number of power/signal rings was a major design driver.

To accommodate the large slip ring, the actuator output drivesa torque tube that in turn interfaces with the SADA outputsection. The slip ring is installed over the torque tube and themain housing supports the brush block assembly. The slip ringis of composite construction, utilizing redundant silver graphitebrushes and silver coated rings. Redundancy was incorporatedin the motor, slip ring brushes and brush blocks and thepotentiometer. The unit has exceeded the required on orbit lifeand continues to function as specified.

Ø8.625

Ø10.75MAX

6.636.54

8.49MAX

16.8516.84

(33.44 MAX)

9.509.47

5.20

11.00MAX

Ø6.18MAX

Ø

6X .250—28UNF—3B


Topex Solar Array Drive Assembly

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] TOPDS4/99

Topex/Poseidon

TOPEX/Poseidon measures the precise shape of the ocean’ssurface and how this surface changes over time. The TOPEXsatellite is located in an orbit 830 miles above the Earth’s surface.TOPEX measures sea level along the same path every 10days. This information is used to relate changes in ocean currentswith atmospheric and climate patterns. Combined instrumentmeasurements allow scientists to chart the height of the seasacross ocean basins with an accuracy of better than 5 inches!During its first three years in orbit, TOPEX/Poseidon has:

• Continuously observed global ocean topography• Produced the first global views of seasonal changes of currents• Monitored El Niño and large-scale features such as Rossby

and Kelvin waves• Provided global data to validate models of ocean circulation• Mapped year-to-year changes in heat stored in the upper ocean• Produced the most accurate global maps of tides ever• Improved our knowledge of Earth’s gravity field


Weight kg 27.2

Power Watts 17.5

Operating Temperature Degrees C -30°C to +85°C

Rate — 0 to ± 90°/min

Potentiometer linearity ± 0.1%

Slip Ring

# Power# 16

Amps 23

# Signal# 72

Amps 3

Voltage Volts 127 max

Motor

Step Size Degrees 1.5

Output Step Size Degrees 0.0075

Phases — 3Ø, 6 state

Holding Torque lb-in 264 min

Please contact Moog application engineers to discuss optionalSADA performance requirements.

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Antenna Pointing Mechanisms

A common movable element on spacecraft is thecommunication (or radar/microwave) antenna. AntennaPositioner Mechanisms (APMs) have long been used toperform the vital function of pointing the antenna boresightto its target, and tracking to maintain the RF link to thespacecraft.

GIMBAL TYPESAPMs are typically two-axis (and, very rarely, three-axis)gimbals. Antenna motion relative to the spacecraft isproduced in either an elevation-over-azimuth or across-axis format. The el-az format can yield fullhemispherical coverage, while the cross-axis format isuseful for producing def ined angular motion inspacecraft coordinates; e.g. North-South and East-West.

Antenna positioning is a popular application of the Moogbiaxial gimbal (see “Biaxial Gimbals”). The basic cantilevergimbal construction lends itself well to both el-az andcross-axis formats, with the primary difference betweenthe two being the configuration of the gimbal interfacebrackets and the angles between the travel-limitingrotational stops. Biaxial APM gimbals have beenproduced in sizes from Type 11 to Type 55 for numerousprograms.

CABLE AND RF MANAGEMENTAPM gimbals are distinguished by their cable managementfeatures. In addition to the motor and feedback leads tothe inner axis of the gimbal itself, electrical conductorsand/or coaxial cables and RF waveguides to the antennamay be accommodated. It can be seen in the followingdata sheets that management of the electrical and RFfeeds is sometimes the driving factor in determininggimbal basic size and configuration.

SPECIAL CONFIGURATIONSAPMs of special configuration have been produced,especially for applications featuring small angularranges. Most common of these is the tilt-table or platformtype APM, which actually uses a set of fine-incrementlinear actuators to tilt the antenna mount on crossedaxes, typically over angular ranges of 3 to 5 degrees(see data sheet).

SPECIFYING AN APMThe following product data sheets depict actual hardwareillustrating many of the features described above. Theyillustrate qualified configurations which might be usedas is, or with modifications. Whether existing hardwareis used or a specification is created, some of the importantpoints to be considered in matching a gimbal to theapplication are as follows:

• Electrical Feed: Cables, or coax/waveguide?• Gimbal type: el-az, or x-y? • Angular Ranges?• Launch Latching: if needed, and will it be part of

the gimbal?• Antenna package mass properties, including

CG location • Are spacecraft disturbance torques important?• Angular position feedback: type and accuracy

needed?

Addressing these considerations, and others which maybe relevant to the application, will result in a specificationfor successful APM hardware. The qualified APMconfigurations in the following data sheets will serve asexamples to facilitate that process.

11X .164-32UNC-2B

6.30

(11.41)

8.16

8.16

7.224.003.80Ø6.52 MAX

3.18

.86Ø1.14

2X 149°

Ø6.00


Type 22 Antenna Pointing Mechanism

Type 22 APM

Design

APM Dimensions


This 2-axis gimbal subsystem is used to position an X-bandantenna installed on an Earth observing platform. The gimbalis arranged in an X/Y configuration and provides an RFtransmission line that interfaces to the spacecraft and antennavia two RF rotary joints. Redundant potentiometer assembliesprovide position telemetry. A caging mechanism is used forlaunch lock. This is accomplished with a single paraffin actuatorand redundant micro switches. Each actuator is based on theMoog standard Type 2 Rotary Incremental Actuator. The

actuators incorporate integral interface bracketry to reduceoverall part count and weight. The Gimbal Drive Electronics(GDE) receives a 16-bit serial command from the spacecraftand positions the actuators to the proper commanded anglesor releases the launch lock mechanism. The GDE also providesstatus information, such as position and temperature. TheGDE is fully redundant and incorporates the Moog standard3-phase hybrid driver.

4.24

Ø6.60

7.52

4.93

4.93

Ø4.70

4.87

5.215.08

10.9710.73

(14.00 MAX)

16.99

3.032.97



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] 22APMD4/99

The Type 22 Antenna Pointing Mechanism is used on anEarth observation satellite that features high spatial resolution,high geolocational accuracy and variable imaging collectiontimes. The spacecraft is capable of 1-meter panchromatic(black and white) and 4-meter multispectral (color) spatialresolution. This system provides satellite-derived geodata ofsuperb quality and clarity previously not available to commercialusers. The spacecraft provides quality, large-scale maps

where ground surveys are costly or impossible. Images aretaken in swaths of 22 kilometers. The spacecraft operates in aunique non-sun-synchronous, non-polar orbit, providing Earthimages at different times of the day under different lightingconditions. A second spacecraft operates in the industry-standard,sun-synchronous near polar orbit. Applications for the systeminclude agriculture forecasting/assessment, mapping,environmental (pollution, runoff, floodplains) and forestry.

SPECIFICATION DATA

Weight 5.44 kg

Power 10 W maximum per axis

Temperature Range -40° C to +60° C

Range of Motion Minimum ± 98.0°

Step Rate 198.5 pps (3.97°/sec) maximum

Output Step Angle 0.02°

Pointing Accuracy ±1.4°

Pointing Resolution 12 bit

RF Interface Frequency Avg. Power VSWR Insertion Loss

8.0 - 8.4 Ghz10W (in vacuum)2.1 max1.3 dB max

Please contact Moog application engineers to discussoptional APM performance requirements.

SPECIFICATION DATA

Weight 4.76 kg

Power 10 W maximum


Input Voltage 24-35 Volts DC

Interface 16-bit Serial

In-Rush Current 3 amps at 300° sec

Reliability 0.9997

Electron Dose 20 Krad

Analog Sensor Interface 0 to 5.12 VDC

Please contact Moog application engineers todiscuss optional performance requirements.

Gimbal Drive Electronics

Antenna Pointing Mechanism



Type 33 APM

Design

APM Dimensions


The Type 33 is by far the most popular Moog Two-AxisAntenna Pointing Mechanism. These units have proven theirreliability and versatility many times over. The actuators arebased on Moog’s heritage design with significant on-orbitexperience. The unit can be provided in the standard configurationor can incorporate a wide range of options. Launch locks,caging mechanisms, cable management systems, position

sensors, and waveguide brackets/mounting features are someexamples of the options available to the designer. The standarddesign incorporates potentiometers for position sensing andhard stops for limited angle applications. Integral interfacebrackets are also included in the standard design. ContactMoog engineers for assistance when evaluating options foryour application.

5.905.88

4.814.79

8.98MAX

4.854.79

6.596.55

6.62 MAX

6.97 MAX

2.912.895.51

5.49

3.513.49

4XØ.21.20

4XØ.19.18

4.854.79

Antenna Interface

S/C InterfaceAxis 1

Axis 2



Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] 33APM4/99

INTELSAT VIIA, IX • TELECOM 2 • HISPASAT • SOHO •MSX • HOTBIRD III & IV • W24 • INTELSAT KTV • SEASAT •

THAICOM • SIRIUS II • PAS 7, 8, 8R

SPECIFICATION DATA

Weight 4.6 kg

Power 17 W maximum per axis

Temperature Range -45°C to + 80°C

Range of Motion Axis 1 Axis 2

12.6° typical12.6° typical

Step Rate Tracking Slew

2.3 pps (0.02°/sec) typical8.0 pps (0.075°/sec) typical


Mechanical Accuracy ± .01°

Potentiometer Coarse Fine Accuracy

10 K ohm8 K ohm0.01° combined


Ø5.750

16.24MAX

15.94MAX

8.06

9.10 MAX

6XØ.250-28UNF-3B



Type 55 APM

Design

APM Dimensions


The Type 55 Antenna Pointing Mechanism provides two-axiselevation-over-azimuth pointing capability for a very largeantenna package. The design is based on Moog standardType 5 rotary incremental actuators with redundant opticalencoders for position sensing. The two actuators are identicalin design with the exception of the respective range of rotation.Due to the operational requirements, redundant heaters andthermistors are incorporated. The encoders are 16-bit

absolute with redundant read heads and amplifiers. The unitincorporates a cable management system that includes 180pass-through conductors/shields and 78 dedicated APMconductors/shields. Cable and RF management areapplication-specific features that are easily modified. Pleasecontact Moog engineers to discuss Antenna PointingMechanisms for your application.

1.90 .71

11.170

5.31MAX

Ø

9.33 MAX

6.386.36



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] 55 APM 4/99

The Type 55 Antenna Pointing Mechanism has been used onthe ADEOS project as part of the Inter Orbit CommunicationsSystem. The main objective of ADEOS is to monitor Earth’sgeophysical parameters using a number of sensors. The mainparameters observed are 1) energy flux between the atmos-phere and ocean, 2) 3-D distribution of temperature and watervapor, 3) aerosol distribution over the oceans, 4) chlorophylldistribution in the oceans, 5) sea surface temperature, 6)

ocean winds and 7) vegetation distribution. In addition to thescientific data, the information collected by ADEOS can beused in a number of terrestrial applications such as weatherforecasting and land surveying. ADEOS is the first satellite toobserve the Earth in such an integrated manner, providinglong-term data in order to fully understand the Earth’s globalenvironment.

SPECIFICATION DATA

Weight 16.42 kg

Power 6.4 W maximum per axis


Range of Motion Azimuth Axis Elevation Axis

±175°±120°


100 pps (0.75°/sec) maximum400 pps (3.0°/sec) maximum


Tracking Resolution ± 0.015°

Encoder Resolution Accuracy Power

0.0055°0.0001°2W maximum


Adeos

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DA

R4.740

7.76 MAX

8.16 SQ

8.83 MAX

5.30MAX


Inter Orbit Link Antenna Pointing Mechanism

Inter Orbit Link APM

Design

APM Dimensions


The Inter Orbit Link Antenna Pointing Mechanism (IOL) pro-vides two-axis pointing capability in an x-y or cross-axis gim-bal format. The design is based on Moog standard Type 5rotary incremental actuators with redundant optical encodersfor position sensing. The actuators are identical in design withthe exception of the respective range of rotation. Due to theoperational requirements, redundant heaters and thermistorswere added. Thermal control is implemented with a white thermal

control paint (emissivity .85 min, absorptivity .23). Theencoders are 16-bit absolute with redundant read heads andamplifiers. Special attention to stiffness and load capabilityhas been considered in this design. The unit is capable ofhandling loads of 210 Kg and inertia of 250 Kg-m2 maximum.Contact Moog engineers for detailed input on AntennaPointing Mechanisms for your application.

12.56 MAX

11.74

10.94

8.53MAX

6.96 7.76MAX

5.54

6.30 3.13



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] LINKAPM4/99

This unit is currently operational on the COMETS satellite aspart of the Inter Orbit Link Antenna. COMETS stands forCOmmunications and broadcasting Engineering Test Satellite.COMETS is an R&D satellite designed specifically to verifynew technologies in the communications and broadcastingfields. COMETS will conduct various experiments, such asinter-orbit communications, advanced satellite broadcastingand advanced mobile satell i te communications.Communications between satellites (including GEO to LEO to

ground stations) will be tested. COMETS will also be testingbroadcast capabilities in the Ka-band of frequencies. Thiscapability will allow a larger volume of data to be transferredand will help with the development of High Definit ionTelevision (HDTV) broadcasts. COMETS will also seek todevelop advanced technology for mobile communications viasatellite in the high frequency Ka-band. COMETS is one ofJapans largest geostationary satellites, weighing over 2-tonsand standing almost 3 meters high.

SPECIFICATION DATA

Weight 15.6 kg

Power 14 W maximum (slew)


Range of Motion X Axis Y Axis

±15°-35°, +1°


10 pps (0.06°/sec) maximum70 pps (0.40°/sec) maximum



Encoder Resolution Accuracy Power

0.0055°0.011°2W maximum


Comets

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R1.53

9.20

6.99

2X 37.5°

8.95

6.81

5.66

2X 4.10


Fine Adjustment Antenna Pointing Mechanism

Fine Adjustment APM

Design

APM Dimensions

Fine AdjustmentAntenna Pointing Mechanism

The Fine Adjustment Antenna Pointing Mechanism consists ofa gimballed platform which pivots about center and is supportedby zero-backlash flex members on the outputs of two linearactuators. The unit drives and positions in the X and Y axesaccurately, and maintains position when power is removed.The center pivot and linear actuators are rigidly mounted onthe unit base. A wax motor activated caging mechanism provides

structural support during launch. The actuators are based onthe Moog standard Type 1 configured as a linear device. Themotors as well as the position sensing optical encoders areredundant. A low friction ball screw - ball nut combination isused. The antenna sub reflector is mounted directly to theplatform shown, which is manufactured to 0.001 mm/mmflatness.

4.74

2X 3.87

2X 2.89

1.00

Antenna Interface

S/C Interface


Fine Adjustment Antenna Pointing Mechanism




21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] FA APM 4/99

This unit is currently operational on the COMETS satellite aspart of the Feeder Link Antenna (FLC-ANT). COMETS standsfor COMmunications and broadcasting Engineering TestSatellite. COMETS is an R&D satellite designed specifically toverify new technologies in the communications and broadcastingfields. COMETS is designed to conduct various experiments,such as inter-orbit communications, advanced satellitebroadcasting, and advanced mobile satellite communications.

Communications between satellites (including GEO to LEO toground stations) will be tested. COMETS will also be testingbroadcast and mobile communications capabilities in the Ka-bandof frequencies. This capability will allow a larger volume ofdata to be transferred and will help with the development ofHigh Definition Television (HDTV) broadcasts. COMETS isone of Japans largest satellites, weighing over 2-tons andstanding almost 3 meters high.

SPECIFICATION DATA

Weight 2.97 kg

Power 6 W maximum

Temperature Range -51° C to +70°C

Range of Motion X Axis Y Axis

±1.5°±1.5°

Step Rate 2.5pps (0.2°/sec) maximum


Accuracy ± 1 step


Comets

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R 2.49MAX

5.000 MAX

6.360 MAXØ5.64 MAX

Ø3.995 MAX

Ø3.600

4.744.71

6X Ø.164-32UNC-2B


Type 33 Large Range of Travel Antenna Pointing Mechanism

Type 33 Large Range of Travel APM

Design

APM Dimensions

Type 33 Large Range of TravelAntenna Pointing Mechanism

This Antenna Pointing Mechanism was designed for a largeangle of rotation application. The actuators are Moog standardType 3’s with internal optical encoders on the motor shaft andoutput shaft. The actuators are based on Moog’s heritagedesign with significant on-orbit experience. On the AzimuthAxis, a cable drum assembly has been incorporated toaccommodate the angle of rotation required. The internalcable is a ribbon cable fashioned in a spiral clock-spring

arrangement. Redundancy was incorporated in both the motorand the optical encoder. As with all Moog actuation systems,standard products are used where possible with slightmodifications that are application specific. This configurationcan be provided with potentiometers, RF rotary joints, alongwith many other options. This particular unit has performedexceptionally well on-orbit. Please contact Moog engineers forassistance when evaluating options for your application.

Ø3.955MAX

(7.23 MAX)

9.8

4.45 MAX

1.94MAX


Type 33 Large Range of Travel Antenna Pointing Mechanism

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] MUAPM 4/99

This Antenna Pointing Mechanism is currently operational onJapan’s orbiting radio telescope, HALCA. This satellite wasformally known as Muses-B-as it was the second Mu SpaceEngineering Satell i te. Renamed the Highly AdvancedLaboratory for Communications and Astronomy (HALCA), thesatellite will be used to study super-dense black holes. Themain observation targets are active galactic nuclei, which is

the bright radiation caused by gaseous clouds falling intoblack holes. HALCA will also investigate intense microwave-emitting sources called Masers. HALCA was launched inFebruary 1997 and is now in an orbit with an apogee altitudeof 21,400 km and a perigee altitude of 560 km. The MoogAntenna Pointing Mechanism on this mission provides antennapointing for satellite to Earth communications.

SPECIFICATION DATA

Weight 5.23 kg

Power 17 W maximum


Output Step Size 0.009375°

Range of Motion Azimuth Elevation

±200.0°±165.0°

Slew Rate Tracking Slew

10.67 pps (0.1°/sec) typical320 pps (3.0°/sec) maximum



Encoder Accuracy 0.01°


MUSES - B

Solar Panel Antenna for Data Downlink and Phase Transfer

Sub-ReflectorMain Reflector

Schaeffer Type 5Solar Array Drive

Schaeffer Type 33Antenna Pointing Mechanism


Instruments And SystemsMoog devices and systems find application on spacecraftpayloads in a broad spectrum of uses. These are looselydefined as Instrument applications, since such applicationsmost frequently support the operation of various sensorsystems which are part of the spacecraft payload.Hardware furnished for these uses has run the gamutfrom simple stepper motor positioners to completeclosed loop scanning systems. The common thread isthe need for precision motion control with spaceflightheritage.

APPLICATIONSMoog devices may be found at the heart of the spaceinstrument, where their high performance parametersand precision motion control contribute materially to thequality of the science performed; or in more peripheralroles such as aperture door opening and closing. Or wemay furnish complete control systems which constitutemajor instrument subsystems in their own right. In everycase, reliability is a major concern- and a reason forusing proven Moog components and systems.

MOTORS AND POSITIONERSSmall positioners and calibration devices exploit the finepositioning increment and power-off holding capability ofthe small-angle stepper; either directly driving, drivingthrough a harmonic drive reducer, or used in conjunctionwith a ball or lead screw. A particular illustration of the

innovative uses which can be made of this versatiledevice is the direct drive filter wheel, wherein the motorrotor is fitted with pockets for a set of optical filters, andbecomes the active output of the device.

UTILITY APPLICATIONSUtility applications on scientific payloads may involvereduced speed and accuracy requirements, but typicallyare no less critical to the mission. In general, a Moogdevice can be applied to any instrument utility functionrequiring rotary or linear motion.

SPECIAL UNITSAdaptations of Moog hardware to accommodate specialapplication parameters have occurred most often ininstrumentation uses. Modification of units for operationat cryogenic temperatures is a good example, as illustratedby the AIRS mirror positioner described in one of thedata sheets following. A door opener actuator for theUARS mission was subject to the same design requirement.Special requirements of this nature are common withinstrumentation applications, and illustrate the Moogdesign flexibility which can be used to great advantagein designing an optimum space instrument system.

INSTRUMENT SYSTEMSOptimum configuring of interfaces within the instrumentsystem may be such that an entire subsystem is most

reasonably allocated to the motion controlsupplier. This has been the case onprior Moog programs, two of which areillustrated in the data sheets following.Moog can supply the drive and feedbackcircuits associated with the motors andactuators, or, can supply completeclosed-loop control systems. In thiscase we can work interactively with thecustomer during all program phases, toinsure a smooth integration of the instrumentsystem at the top level.

6.94

8.56

5.95 MAX

5.03

3.40

3.98

.26


Atmospheric Infrared Sounder

AIRS

Design

Instrument Dimensions

Atmospheric Infrared SounderSchmidt Mirror Adjuster

As part of the AIRS instrument, Moog provided the SchmidtMirror Adjuster (SMA). The SMA utilized three Moog Type 1actuators configured for linear motion through a screw/nutassembly. Due to the cryogenic temperature requirement,Dicronite dry lubrication was applied to the bearings, leadscrew and harmonic drive assembly. As part of the SMA

assembly, Moog also provided the mirror support structure,mirror suspension and mirror mounts. The mirror supportstructure is spring loaded to the SMA housing through astabilizing diaphragm spring. Due to the extremely small stepsize, specialized equipment was developed for testing thisinstrument.

4.13

2.38

Ø10.6 MAXØ10.000

3 X Ø THRU.286284


Atmospheric Infrared Sounder

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] AIRSDS 4/99

The AIRS instrument will make measurements of the Earth’satmosphere and surface that will allow scientists to improveweather prediction and to observe changes in the Earth’sclimate. AIRS is a high spectral resolution spectrometer withcoverage in nearly 2400 bands in the infrared and visibleranges. These ranges have been specifically selected to makethe measurements of temperature and humidity. AIRS obtainstemperature and moisture profiles by observing the presenceof carbon dioxide at certain wavelengths. To determine thetemperature or humidity at a specific altitude, AIRS takes the

signals from many different spectrally narrow bands, assignspre-determined weighting functions to each band based onprevious observations, and uses them to derive a verticalprofile that fits the signal. The data retrieved from the AIRSinstrument will help improve global modeling efforts, numericalweather prediction, study of the global energy and watercycles, detection of greenhouse gases and climate variationand trend monitoring. Typical data from the AIRS instrument isshown below.

SPECIFICATION DATA

Weight 4.0 kg

Power 5 W Maximum

Operating Temperature -128°C to -113°C

Step Size X-Rotational Y-Rotational Z-Translational

3.38m rad3.38m rad0.118m m

Repeatability X- Rotational Y- Rotational Z- Translational

±6.8m rad±10.0m rad±3.4m rad

Minimum Speed 23.6mm/sec

Mirror Mass 1.28 kg

Please contact Moog application engineers to discuss this orsimilar applications


Fine Pointing Mechanism

FPM

Design



The Fine Pointing Mechanism (FPM) is a two-axis pan/tiltmechanism designed for small angular excursions of ±3degrees or less. If desired, the moving platform can also bepositioned linearly along the centerline axis, providingvergence or zoom control in optical applications. Unlike typicaldesigns, which use voice coil actuators, the FPM has no moving

coils or electrical connections, and uses an electromagneticcircuit which is inherently more size- and power-efficient.Noncontacting inductive sensors provide position feedback.Two sensors mounted on each axis of motion provide adifferential signal which results in extremely high thermalstability and position resolution.

Ø.59 (Mirror)

1.64 Sq.

Ø1.58

1.89

1.74

1.59

4X.125

4X R.120Ø1.64

4X Ø.14 Thru Hole(.15)



Applications



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] FPMDS 4/99

SPECIFICATION DATA

Weight .22 kg

Travel ± 3°

Power 2w/axis

Bandwidth 100-300 Hz

Accuracy ± 9.9 m rad

Resolution ± 0.009 m rad

Contact Moog application engineers to discussoptional instrument performance requirements.

Mirror Positioning • Beam Steering • Sensor Pointing

The unit depicted on this data sheet has been developed internally at Moog Schaeffer Magnetics. The proof of concept unitshown has many applications, such as mirror positioning for Optical InterSatellite Links, beam steering and sensor pointing. Thisdevice can be used in conjunction with other Schaeffer products to form a complete coarse/fine mechanism. Please refer to ourAUJ (Active Universal Joint) data sheet for a coarse pointing mechanism concept that can be used for laser communicationapplications. Closed-loop drive electronics can also be provided with this design. Contact Moog engineering to discuss designoptions for your application.

FlexureDiaphragm

Mirror Platform

Mirror

Magnets

Coils

Fine Pointing MechanismCross-SectionPatent Pending

(1.5)

8.96MAX

33.04MAX

21.2421.22 18.03

17.97

18.0317.97


Global Imager Scan Mirror Gimbal

GLI

Design



The GLobal Imager instrument is a two-axis gimbal designedspecifically for the ADEOS-II satellite. The gimbal is a classicElevation over Azimuth configuration with a fully redundant,class S-level electronic control unit. The Azimuth axis utilizesa stepper motor configured as a Type 5 actuator with enlargedand spaced output bearings for enhanced stiffness. The Azimuthaxis also includes a 21-bit resolver for position sensing. The

Elevation axis is configured with a Brushless DC Motor and aMoog-designed 20-bit incremental optical encoder. The basematerial is beryllium, the yoke aluminum and the mirrorsubstrate is also beryllium. The electronic control unit providespower conditioning, resolver to digital conversion, motor drive,microprocessor-based bookkeeping and closed-loop servo control.

21.65MAX

(23.81MAX)

13.0112.97

10.80MAX



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] GLIDS 4/99

The GLI instrument will be launched on the ADEOS-2spacecraft. GLI is an optical sensor designed to measure thereflected solar radiation from the earth’s surfaces (land,ocean, clouds) and infrared radiation for measuring surfacetemperature, vegetation distribution, vegetation biomass andthe distribution of snow and ice. Analysis of the GLI data will

be used to understand the global circulation of carbon,monitoring cloud, snow, ice and sea surface temperatures,and grasping marine production. GLI has 22 bands in the visibleand near-infrared region (VNIR), 5 bands in short-wave lengthinfrared region (SWIR) and 7 bands in the middle and thermalinfrared region for its multispectral observation tasks.

SPECIFICATION DATA

Weight Scanner Electronic Control Unit

42.5 kg18 kg

Power Standby Scanning

7.0 W nominal35 W nominal

Temperature Range -10°C to +40°C

Tilt Axis Range of Motion Operation Safety Position Accuracy Motor Type Phases Position Sensor Max Rate

± 20°+ 54°± 0.08°

1.5° Stepper3 Ø2 Speed resolver1.3°/sec

Scan Axis Rotation Speed Accuracy of Rotation Velocity Rotation Linearity Repeatability Encoder Resolution Motor Type

16.716 RPM± 0.015°/sec± 0.003°± 34msec± 0.000343°/ 20 bit2Ø Brushless DC

Contact Moog application engineers to discuss your similarrequirement..

Adeos

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Improved Limb Atmospheric Spectrometer Scan Mirror

ILAS

Design



The ILAS scan mirror gimbal is a two-axis gimbal designed tobe used as a fine pointing mirror assembly. Both the azimuthand elevation axes incorporate Brushless DC Motors with 21-bitresolvers for position sensing and motor commutation. Eachaxis also has a friction brake for launch restraint and to lockthe gimbal position between track acquisitions. Cabling is routedthrough each axis with specialized cable wrap assemblies to

accommodate the gimbal motion. The electronic control unit isa microprocessor-based design incorporating power conditioning,resolver excitation and conversion, motor drive/commutation,and closed-loop servo control. Specialized materials such asberylium and magnesium were used in the gimbal along withradiation hardened S-level components in the electronic controlunit.

15.75MAX

11.8111.73

6.385

14.51 MAX

3.70MAX

12.28 MAX

MIRROR DIM7.9 X 6.7


2x Ø

6.766.74

4.994.89

Ø

7.68 MAX


Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] ILASDS 4/99

The ILAS instrument initially was used on the ADEOS-1mission and will also fly on the ADEOS-2 spacecraft. Theinstrument mission is to observe the ozone layer and to profilegases in the atmosphere. This is accomplished by using thesolar occulation technique shown below. The sensor detectsand spectrally disperses the light from the sun coming throughthe atmosphere. The resultant is the absorption spectrum ofthe atmosphere. Each gas in the atmosphere has its owncharacteristic absorption in the infrared region (IR), thusmaking it possible to identify each gas component and its

concentration level. The tracking mirror gimbal is inactive untilthe satellite is in position to view the “sunrise” through theatmosphere. Prior to the “sunrise” the gimbal is activated andpositioned near the anticipated track start location. Once atrack has been initiated, the sensor continuously measures thechanges of light intensity from the sun. The main gasesprofiled by the ILAS instrument are ozone (O3) and ozone-related species such as nitric acid (HNO3), nitrogen dioxide(NO2), nitrous oxide (N2O), methane (CH4) and water vapor(H2O). Some actual data from ILAS I is shown below.

SPECIFICATION ILAS I ILAS II

Power 29W Max 29W Max

Weight Gimbal & ECU 24kg Gimbal & ECU 24kg

Motor 64 Pole 64 Pole

Position Sensor 21-Bit Resolver 21-Bit Resolver

Track Mode Rate Accuracy

0.06°/sec± 20 arc sec

0 to ± 0.06°/sec± 20 arc sec

Position Mode Rate Accuracy

2°/sec± 6 arc sec

2°/sec± 6 arc sec

Scan Mode Rate Accuracy

NANA

0.02°/sec±0.002°/sec

Track Acquisition <4 sec <4 sec

Mirror Substrate Finish Type Surface Figure Wavelength

AluminumGold, electroplated

<2l (P-V)l =632.8 Nm

BerylliumGold, electroplated

<0.8l (P-V)l =632.8 Nm

Range of Motion Azimuth Elevation

± 45°±15°

± 45°±15°

Please contact Moog application engineers to discuss this or similarapplications.

Ø8.405

5.664MAX

.401 ±.001

4.2944.289

.050

.045


Selectable Optical Filter Assembly

SOFA

Design



The Selectable Optical Filter Assembly (SOFA) was designedspecifically for the Hubble Space Telescope (HST) Wide FieldPlanetary Camera. The design is a unique concept and hassubsequently been used on several other missions, such asCassini. The Moog design proved to be significantly lighter thanoriginally specified, and very simple in concept. The unit consistsof 12 separate rotor/stator motor combinations. Each rotorassembly carries 4 filters and one open aperture, providing 48total filters and many possible filter combinations. The unit featuresredundant ball bearings, and dry film lubrication throughout. The

electronic control unit tracked the angular position of each filterwheel by counting steps from a home position sensor located oneach rotor assembly. Since the rotor assemblies are not cagedfor launch, upon initialization the ECU rotates each filter wheeluntil the home position sensor is located. The unit has operatedflawlessly while on orbit. Moog engineers were given the uniqueopportunity to examine one of the SOFA units after several yearson orbit. The unit was found to be in excellent condition andrecertified for flight. In addition, a single wheel version of thisdevice was designed for the HST Fine Guidance System.

7XØ

Ø9.10 MAX

2.281 SQ. @ 45°

R4.904.89

.233

.238

8XØ.163.158

98°

3XØ.2.13.208

Ø8.700



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] SOFADS4/99

Hubble Space Telescope

The Selectable Optical Filter Assembly is an integral part ofthe Wide Field Planetary Camera II instrument on the HubbleSpace Telescope (HST). The instrument was installed on theHST in December 1993. The new camera included corrective opticsto refocus light coming from the telescope’s flawed primarymirror, and restores telescope performance to the originalspecifications. The Wide Field and Planetary Camera II comprisesfour camera systems: three wide field cameras having one

magnification and a planetary camera having a magnificationof about 2.2 times greater. The wide field cameras give thetelescope a panoramic view, providing the greatest sensitivityfor the discovery of faint objects. The planetary camera has asmaller field of view but facilitates high-resolution studies ofindividual objects such as planets, galaxies and stellar systems.All four camera systems are sensitive to light at wavelengthsranging from the ultraviolet to the near infrared.

SPECIFICATION DATA

Weight 11.8 kg

Power 26 W maximum

Voltage 28 V nominal

Step Angle 0.5°

Rate 25° per second

Temperature Range -15°C to + 35°C

Please contact Moog application engineers to discuss thisor similar Filter Wheel requirements.

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SM

D

12.91

(16.66)

2.400

3.600

3.15

5.06

7.82

8.85

Ø8.75

Ø5.56

5X .112-40UNC-2BBoth Sides

7X .138-32UNC-2BBoth Sides

14.94

6.75

11.18

12.98


Clouds and the Earth’s Radiant Energy System

CERES Biaxial Scan Assembly

Design


CERES Biaxial Scan Assembly

The Moog contribution to the CERES instrument is quiteextensive. Moog provides the entire Biaxial Scan Assembly,sans sensors. The Biaxial Scan Assembly is comprised of thefollowing components: Azimuth Drive Mechanism, ElevationDrive Mechanism, Azimuth Brake/Caging Mechanism, SensorDoor Mechanism and the Main Contamination Cover

Mechanism. The Azimuth and Elevation Drives incorporateBrushless DC motors, twist capsules and optical encoders forposition sensing (13-bit absolute). Each of the other threemechanisms incorporate Moog Type 1 actuators in both rotaryand linear configurations. Special attention was given bearinglubrication and life for this application.


Clouds and the Earth’s Radiant Energy System

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] CERDS 4/99

The Clouds and the Earth’s Radiant Energy System (CERES)instrument is part of the Earth Observing System of satellites. Thedata from the CERES instrument will be used to study theenergy exchanged between the Sun, the Earth’s atmosphere,surface and clouds, and outer space. CERES will measure theenergy at the top of the atmosphere, as well as estimate energylevels in the atmosphere and at the Earth’s surface. Using

information from very high resolution cloud imaging instrumentson the same spacecraft, CERES will also determine cloudproperties, including cloud amount, altitude, thickness, and thesize of the cloud particles. All of these measurements are criti-cal for advancing our understanding of the Earth’s total climatesystem and further improving climate prediction models.

SPECIFICATION DATA

Weight 18.19 kg

Power 35.1 W peak

Operating Temperature -10°C to +30°C

Azimuth Axis Range of Motion

elocity Accel/Decel

350° total± 4.6°/sec0.04 sec

Elevation Axis Range of Motion Velocity Fast Nominal Accel/Decel

255° total

255.5°/sec63.5°/sec0.03 sec

Please contact Moog application engineers todiscuss this and similar applications.

CERES

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Modis Scan Motor/Encoder

Scan Motor/Encoder

Design



The MODIS scan motor/encoder is an integrated assemblydesigned to drive a precision scan mirror. The unit consists ofa smooth running brushless DC motor and an extremely accu-rate 14-bit incremental optical encoder. The motor is based onstandard Moog designs, and is configured as redundantlywound 16 pole/2-phase. The unit is a compact design withhigh torsional st i f fness to help meet cr i t ical control

requirements. The encoder was designed and manufacturedby Moog and demonstrated 11 microradian accuracy. Anintegral aspect of this program was the bearing selection andlife test. As part of this contract, Moog developed a bearing lifetest program. Flight bearings and the qualification unit are inan extended life test, which will be run under orbital conditionsuntil mission launch (approximately 5 years total).

Ø4.375

7.917.81

9.47MAX

Ø8.15MAX

3.753.74

Ø7.650

2XØ.350.343

3XØ.285.278

Ø

Ø6.850MAX

Ø6.888MAX

.380MAX

3X .250-28UNF-2B



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] SM/EDS 4/99

MODIS is an optical instrument that will measure biologicaland physical processes on the earth’s surface and in the loweratmosphere. MODIS will provide long-term observations ofsurface temperature, cloud cover, ocean temperature, chlorophyllconcentration, vegetation, snow cover and aerosol properties.The instrument will also detect fires, providing data about theirsize and temperature and will gather information about the

global distribution of precipital water. To accomplish this task,the MODIS instrument is designed to provide high radiometricsensitivity (12 bit) in 36 spectral bands ranging in wavelengthfrom 0.4 mm to 14.4 mm. A ± 55-degree scanning pattern at anorbit of 705 km achieves a 2,330-km swath and provides globalcoverage every one to two days.

SPECIFICATION DATA

Weight 6.17 kg

Power Motor Encoder

1.0 W @ 20.3 RPM1.9 W max


Motor Type Phases Stall Torque Cogging Torque Margin

16 pole BDCM296.7 oz-in<3.6 oz-in p-p3:1

Encoder Accuracy Resolution Repeatability Temp. Drift

30mrad14 bit<5mrad<10mrad over temp range

Mirror Mass 4.3 kg

Scan Rate 20.3 RPM constantly

Please contact Moog application engineers to discussoptional instrument performance requirements.

Modis Bearing Life Test

14.51 MAX

5.125.08

Ø 2.18MAX

3.77MAX

14.118

3.00MAX 2.33 MAX


Pan-Tilt Unit

PTU

Design


Pan-Tilt Unit

The PTU provides 2-axis motion to position a video cameraand light assembly. It is comprised of two Type 2 actuators, alaunch lock mechanism, class ‘S’ control electronics and thelight/camera bracket assembly. The actuators uti l izepotentiometers and limit switches for position feedback. Theelectronic control unit provides DC power conversion (input is

120 VDC), and motor drive and control circuitry. The electroniccontrol unit is integral to the PTU. The launch lock is an integralpart of the gimbal. For a more detailed description of the Type2 actuators, please refer to the Actuator section of the Moogcatalog.

5.00

3.316

2.700

45°

3.300

11.51 MAX5.56 MAX 2.380

4.500

3.000

2.122

5.56MAX


Pan-Tilt Unit

Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] PTUDS 4/99

The PTU shown here will be been used on two InternationalSpace Station missions. The first application of the PTU is forthe Space Station Remote Manipulator System (SSRMS). TheSSRMS will be used to aid in the assembly of the SpaceStation on orbit. The SSRMS has two latching end effectors, isself-relocatable, and has 7-degrees of freedom. The PTU willallow the operator to view the location of the Manipulator duringassembly tasks. The second application is on the SpecialPurpose Dexterous Manipulator system (SPDM), also a SpaceStation project. The SPDM is designed to perform Extra-

Vehicular Robotics (EVR) maintenance on the Space Stationwhile on orbit. This includes tasks such as installing, inspecting,removing or replacing as many as 286 Orbital ReplacementUnits. The SPDM works autonomously or with SSRMS, otherrobots or astronauts to

• Manipulate small payloads and perform small tasks• Manipulate, install, and remove small payloads such as

batteries, power supplies and computers• Operate robotic tools such as specialized wrenches for

delicate maintenance and servicing tasks.

SPECIFICATION DATA

Weight 7.25 kg

Power 27 W Maximum

Input Voltage 120 VDC


Tilt Axis Fast Rate Slow Rate Range

6°/second1.2°/second± 92°

Pan Axis Fast Rate Slow Rate Range

6°/second1.2°/second±175°

Static Angular Oscillations ± 0.01° amplitude

Dynamic AngularOscillations

± 0.02° amplitude

Overshoot/undershoot >0.1°

Contact Moog application engineers to discussoptional instrument performance requirements.

Special Purpose Dexterous Manipulator

Pho

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ourt

esy

of C

SA

8.438.32

7.527.48

10.98 MAX

4.51MAX

2.99MAX


Pressure Modulator Infrared Radiometer

PMIRR

Design



The PMIRR scan mirror assembly provides two commandableaxes which are used to provide nadir, off nadir, limb, space,and target views. The elevation axis consists of a Moog TypeM8 actuator with an incremental disk encoder on the motor.The encoder is capable of resolving to one motor step and ishighly repeatable. The azimuth axis uses a standard MoogType 2 actuator with an integral disk encoder. To protect themirror surface during launch, the mirror is rotated 180° into itsprotective bonnet. The bonnet is a magnesium structure coatedwith a white thermal paint. The mirror is an aluminum substrate

with a silver finish and protective coating. During slewmotions, the motor is commanded to move at maximum rateswithout missing steps. In operation, slew rates exceed 500pps. Control electronics monitor the step command andencoder outputs to verify the actuators are operating withoutmissing steps. The actuators used on this instrument aremodified Moog products optimized for the application.Additional detail on the actuator capabilities can be found onthe Type M8 and Type 2 Rotary Actuator data sheets.

5.625.57

5.014.99

6.25MAX

9.90MAX

2.762.74



Mission Description



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] PMIRRDS4/99

The PMIRR instrument was launched on the Mars Observerspacecraft. The first mission was lost when the spacecraftarrived at Mars, and a second spacecraft was subsequentlylaunched. The spacecraft will be placed in a low, circular,polar orbit about Mars. The instrument performs continuousradiometric mapping of the atmosphere and surface of Marsthroughout its 687-day mission. Daily maps of the surfaceproperties and high vertical resolution, 3D maps of temperaturestructure, dust loading and water vapor distribution will be

derived from these measurements. PMIRR is a nine-channellimb and nadir scanning atmospheric sounder. PMIRRobserves in a broadband visible channel, calibrated by observationsof a solar target mounted on the instrument. Once deployed inthe mapping orbit, vertical profiles on atmospheric propertiesare constructed in 3 fields-of-view stepped across the limband onto the planet using the two-axis scan mirror located infront of the primary telescope.

SPECIFICATION DATA

Weight 2.25 kg

Power 7 W


Slew Rate >500 pulses per second

Mirror Substrates

Coating Surface Figure Roughness

AluminumSilver2 waves P-V @ 632nm>20Å

Please.contact Moog application engineers to discussoptional instrument performance requirements.

Mars Observer

Pho

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esy

of N

AS

A

The major climatology goals of the mission are:• Determine the time and space distribution, abundance

and sources of Martian volatile materials and dust over a seasonal cycle.

• Explore the structure and aspects of the circulation of the Martian atmosphere.

The major science goals of the mission are:• Map the thermal structure of the atmosphere from the

surface to 80-km.• Map the atmospheric dust loading and its global vertical

and temporal variation.• Map the atmospheric water vapor to an altitude of at

least 35-km.• Map the seasonal variability of atmospheric pressure.• Monitor the polar radiative balance.


ElectronicsSchaeffer Magnetics Division produces a line ofstandard stepper motor controllers, and customelectronics for systems. The stepper controller is thestandard for driving the Schaeffer three-phase motor,and system control and signal conditioning electronicsare generally mission-specific.

For the typical stepper motor application, simple openloop operation with appropriate power and commandinterface is most often used. The core unit ElectronicControl Unit (ECU) is designed such that its size,weight, and power con-sumption are mini-mized. A single DCpower input is required,and a minimum numberof commands to definemotor operation areused: ENABLE,DIRECTION, andSTEP. The DIRECTIONor DIR commanddefines motor rotationdi rect ion, and theSTEP input, a pulsetrain of the desired fre-quency, allows theuser to define motoroperating speed. TheENABLE (ENA) com-mand provides system design flexibility in allowingmotor operation to be defined separate from the STEPinput. Also frequently of great utility is the capability oftailoring the width of the power pulses applied to themotor phases. For low pulse rates, the ENA commandlevels can be asserted synchronously with STEP inorder to limit the time duration of the power pulses, andtherefore to tailor the power duty cycle. Average motorpower will be reduced accordingly.

The heart of the standard ECU is the Moog-developedhybrid circuit module (see Data Sheet). All the functionsdescribed above are implemented in a single hybridcircuit. In the ECU, functions added in discrete componentinterfacing circuitry are: conditioning of the input power,

generation of internal logic voltage, and motor currentlimiting. The level of current limiting is selectable at themotor interface connector, by means of jumpers on themating motor side of the connector.

Since many systems employ the Moog actuator in pairs,the standard ECU is configured as a two-channel (2X)unit; i.e. two actuators can be driven. The standard unithas a single power input and power conditioning circuit,and two independent motor drivers with two separatecommand interfaces. Alternatively, the 2X unit can be

used to drive oneredundant actuator.The standard 2X ECUis packaged as astackable module, sothat two of the unitscan be assembled toform a four channel or4X box. This unit issuitable for driving tworedundant actuators;for instance, in thecase of a biaxial gimbalusing redundant motors.

When a more high-levelcommand interface isrequired, the basicECU circuits are still

used, and interfacing front-end circuitry is added toconfigure the interface as needed. This approach hasbeen employed on many programs, wi th suchrefinements as digital interfaces and time multiplexingof a suite of actuators with a single control box.

Moog electronics capability extends also to morecomplex systems, with microprocessor control andclosed loop operation. The design of such systems is ofcourse very mission-specific; however, qualifiedsubsystem circuit designs are used in new systemdesigns, and advantage can be taken of Moog experiencewith these space-based systems. Some examples ofcomplex control systems can be seen in the instrumentdata sheets in Section Six of the Moog product catalog.


Electronic Control Units

2 and 4 Channel ECU

Design

ECU Dimensions

Electronic Control Unit

The Moog 2-channel Electronic Control Unit (ECU) is comprised of 2Schaeffer hybrid stepper motor controllers, an EMI filter, and 6 analogpass-throughs for telemetry. The ECU enclosure has been designed toallow 2 ECU’s to be stacked to form a 4-channel ECU. The ECU containsall power conditioning, pulse sequencing and output driver stages necessaryto drive two 3-phase motors. The system electrical interface consists ofpower and command input lines, output motor drive lines and telemetry

outputs. The required input commands are discrete for ENABLE andDIRECTION, and a pulse train on the STEP input. An initial discrete logicstate on the ENABLE line will activate the control unit for the desiredmotor. On the DIRECTION line, one logic state enables clockwise rotationand the other state enables counterclockwise rotation. Motion is initiatedby the application of a pulse train on the STEP command line.

3.43.2

1.37 MAX

1.51.3

3.80 MAX

6.70 MAX 5.45.2

2X 15 SOCKETCONNECTOR

44 PINCONNECTOR

4XØ.25.22

The performance data is intended to serve as a guide. Most of the dimensional and performance parameters reflect the typical capabilities and not the design limitations of the unit.

Electronic Control Unit


Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] ECUDS 4/99

Motor driver in a variety of spaceflight applications, such as solar array drives, door openers and antenna pointing.

OICETS • CLASSIFIED MISSION • QUICKBIRD • EO1 ORBVIEW • FUSE • INDOSTAR • SSTI • ROCSAT • DSPSE • STEP

KOMPSAT • TIMED • VCL • GEOLITE


WeightPounds Standard ≤ 2.2

kg Standard ≤ .99

Step Rate Hertz Standard 0-1000

Logic Power Watts Standard≤ 0.7W@22V

[email protected]@36V

Turn-On Surge Amps Standard < 3A for 300 µs

Power Insulation Mohms Mininum

>5 Megohmisolation betweenpower return and

ground

Temperature deg C Standard -55° to +60°

Please contact Moog application engineers to discuss optional ElectronicControl Unit performance requirements.

3.43.2

2.68MAX

.7

.5

1.51.3

5.45.2

4X 15 SOCKETCONNECTOR

2X 44 PINCONNECTOR

5

4 Channel Electronic Control Unit


3 Phase Stepper Motor Controller Hybrid

Hybrid

Design

Hybrid Dimensions

Hybrid Control Unit

This hybrid package has been designed specifically to drivethe Moog unique three-phase six state stepper motor. Thespaceflight qualified hybrid constitutes a significant advance inreduced size and weight to complement the compact size andlow weight of Moog’s stepper motor based products.

The hybrid is designed and tested to “K” level per MIL-H-38534. The device requires only three command operations(Enable-Step-Direction).

An internal regulator provides the 12 volt power for buffer andlogic circuits so that a single 22 to 36 volt input is all that is

required. The command interface supports and is compatiblewith optically isolated inputs (TTL, CMOS, Open CollectorSignals). A greater degree of motor control can be obtainedwith the current control circuitry which is included.

Level shifting and bipolar output switching are functionsperformed by the motor drive circuits. The output section is athree-phase, six leg bridge inverter which drives the motorwindings in bipolar mode. Back EMF diodes are providedacross each leg of the inverter. The hybrid is designed foreither surface or thru-hole circuit board mounting.

(1) (74)

(37) (38)

2.000±.005

1.25±.005

.250 MAX

The performance data is intended to serve as a guide. Most of the dimensional and performance parameters reflect the typical capabilities and not the design limitations of the device.

3 Phase Stepper Motor Controller Hybrid


Heritage Programs



21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] HYB 1 4/99

Motor driver in a variety of spaceflight applications, such as solar array drives, door openers, filter wheels and antenna pointing.

OICETS • CLASSIFIED MISSION • QUICKBIRD • EO1 • SSTI • ROCSAT • DSPSEORBVIEW • FUSE • INDOSTAR • ASTRO E • STEP • KOMPSAT •

TIMED • SPACE STATION • VCL • GEOLITE

OCCMD 1

OCCMD 2

OCCMD 3

OPTO-ISOLATORS

COMMANDRECEIVERS

ISO CMD 1

ISO CMD 2

ISO CMD 3

12 VREG

CURRENTLIMITER

V IN

PHASE A

PHASE B

PHASE C

DRIVERCIRCUIT

SEQUENCEGENERATOR

DIR

STEP

ENABLE

• Dashed Lines Indicate External Access• Solid Lines Indicate Internally Connected


Input Voltage Volts Standard 22-36

Step Rate Hertz Standard 0-1000

Drive Current Amps Max 1A per phase

Power Dissipation Watts Max 13

SizeInches

CentimetersStandardStandard

2.0x1.25x.255.0x3.0x0.8

WeightOuncesGrams

StandardStandard

128

Please contact Moog application engineers to discuss optional Hybridperformance requirements.


3 Phase Stepper Motor Controller HybridApplication Note

Application

Figure 1 Simplified Block Diagram

Hybrid Control Unit

Three-phase permanent magnet stepper motors driven in bipolar mode have become very popular in space-flight motion control applications. These units offer the advantage of high output, small step angle, brushless reliability, and good conductive cooling. The Schaeffer Stepper Motor Controller Hybrid Microcircuit Assembly was developed to offer the system designer a space-qualified, self-contained motor drive circuit module as an alternative to designs with discrete components. Pinouts are configured for application flexibility in areas where it is most commonly desired.

65 7 8 9 22 23ILIM SET ILIM OUT

–

+

FERRITE BEADF1832-1-Q1 OREQUIVALENT

Qlimit Rsense2N3749 OR EQUIVALENT

202112

64636566

34

6261

535251444241403938

50

46

45

60

59

55

56

57

58

353426251716

363728291918+V MTR

Q CONTROLCHASSISGROUNDCHASSISGROUND

ILIM IN

+V REG IN

+24V CLAMP

LOGIC RETURN

LOGIC RETURN

MOTOR RETURN

+12V OUT

+V LOGIC

OC CMD1

ISO CMD1

IC1 RTN

OC CMD2

ISO CMD2

IC2 RTN

OC CMD3

ISO CMD3

IC3 RTN

ILIM IN

C1~0.047 100V

Rbias301 3W

REQV. VR1

CURRENT LIMITER

LM113 1.22V

HOUSEKEEPINGVOLTAGE

REGULATORLM7812

CR181N4967 24V

+

–

FILTERED SPACECRAFTBUS VOLTAGE

+28VDC NOMINAL

1KREN

+5VDC

1KRDIR

1KRSTEP

+5VDC

+5VDC

CMD1

CMD2

CMD3




PHASE A

PHASE B

PHASE C

3 PHASE STEPPER MOTOR

SHOWN FORREFERENCE ONLY

MOTORDRIVERS

SA PH A

PH B

PH C

SB

SC

EN POL

EN CMD

DIR POL

DIR CMD

STEP POL

STEP CMD

89

12

56

4

3

10U3C

U3A

U3B

COUNTER

SEQUENCEGENERATOR

+12VDC

A1

A2

B1

B2

C1

C2

RA100

RB100

RC100

STEPPER MOTORELECTRONIC CONTROL UNIT

HYBRID MICROCIRCUIT ASSEMBLY

INPUT COMMANDOPTO-ISOLATORS

ENABLE

DIRECTION

QENNPN

INPUTCOMMANDS

QDIRNPN

STEP QSTEPNPN

4070B

4070B

4070B

Figure 1Stepper Motor Electronic Control Unit Simplified Block Diagram

1

3 Phase Stepper Motor Controller Hybrid: Application Notes

Circuit Description and Function

Current Limiter

The Stepper Motor Electronic Control Unit Hybrid Microelectronic Assembly (HMA) drives three-phase stepper motors with constant current pulses in response to input commands. The HMA is comprised of five functional circuits: the command input circuits, the current limiter, the sequence generator, the motor drivers, and the housekeeping regulator. Refer to Fig. 1 for the HMA simplified block diagram.

INPUT COMMANDS -Three input commands- Enable, Direction and Step- control the operation of the HMA. The Enable command applies power to the stepper motor windings. The Direction command establishes clockwise or counter-clockwise rotation of the stepper motor when step pulses are sent. A pulse on the Step command advances the position of the stepper motor rotor one step. Each command input is isolated from the source by an OLI400 opto-coupler. The command inputs are reverse polarity protected by parallel diode clamps. The minimum “ON” current through the opto-coupler Light Emitting Diode (LED) is 0.5 mA. The maximum opto-coupler “ON” current is 20 mA. The minimum pulse width for the opto-coupler input commands is 500 microseconds with a maximum frequency of 1000 Hz. The outputs of the command opto-isolators (CMD1, CMD2, CMD3) are open collectors with 20 K ohm pull-up resistors. If isolation is not required, open collector input commands can be accommodated via connections OC CMD1, OC CMD2, and OC CMD3. In that case, there is no connection to the opto-isolators. The open collector command inputs are each reverse polarity protected by a series diode. The command outputs are brought out and must be connected externally (as shown in Figure 1). They are connected to the Enable, Direction, and Step input of the Sequence Generator.

2

The current applied to the stepper motor windings is derived from the spacecraft power bus applied to the HMA (+28 VDC nomi-nal). The current limit value is established with an external current sense resistor. The voltage drop across the current limiting resistor is compared to a fixed voltage reference (VR1), approximately 1.22V. Current limiting action will occur when the voltage drop across the current sense resistor (Rsense) is equal to the reference voltage. Therefore ILIMIT = 1.22V/ Rsense. To mini-mize thermal dissipation, an NPN bipolar transistor, external to the HMA, should be used as the series regulator element in the HMA. Refer to Figure 1. The regulator transistor must have a capacitor connected between the collector and the base to ensure stability. A ferrite bead at the emitter of the regulator transistor improves stability and EMI compliance by reducing the high fre-quency content of the stepper motor drive pulses.


Sequence Generator

Motor Drivers

The sequence generator controls the excitation configuration (polarities) of the three motor windings. The Enable, Direction, and Step commands from the Command Input Circuits are applied to the Sequence Generator. The active state of these commands can be programmed via the polarity inputs of the CMOS Exclusive OR gates (U3A, U3B, U3C). A logic high on the polarity inputs of the U3 inverts the applied command signal.Non-inverting operation can be accomplished by applying a logic low on the polarity input of U3. There are six possible excitation states for the three phases of the stepper motor and one inactive state. In the inactive state applying the current limiter output (+V MTR) to the stepper motor is not allowed by the Sequence Generator as no motor cur-rent would flow. The Direction and Enable commands must be asserted at least 1 msec prior to applying a Step command pulse for current to flow to the motor. The Enable command must remain active at least 80 ms after the last Step pulse transition to ensure stepper motor positional accuracy. At low step rates (<20 steps/second) the stepper motor may be disabled via the Enable command for power savings. Fig. 2 shows details of the input command timing requirements and power savings option.

CW

CCWDIRECTION

ENABLE

ENABLE

STEP

STEP

PHASE A

PHASE B

PHASE C

MOTOR STATE DISABLED 1 2 3 4 5 6 1 2 2 DISABLED

1 mS MIN.

80 mS MIN.1 mS MIN.

1 mS MIN.

NORMAL OPERATION

POWER SAVING OPERATION AT LOW PULSE RATES

40 mS MIN.

COUNTERSTATE

SA(PHASE A)

SB(PHASE B)

SC(PHASE C)

1 + - -2 + - +3 - - +4 - + +5 - + -6 + + -

TABLE 1 MOTOR STATE TABLE

+=V MTR-+ MOTOR RETURN

Figure 2Command Timing Requirements

+ = V MTR - = Motor ReturnTable 1

Motor State Table

3

The Motor Drivers apply the current drive to the appropriate stepper motor phases in response to the Sequence Generator Counter outputs. The output of the Current Limiter is connected externally to the Motor Driver’s input. The excitation polarity of the stepper motor is shown in Table 1. The DIR input selects whether the counter states are stepped in ascending order (state 1 through 6), or descending order (states 6 through 1). External resistors RA, RB, and RC provide the bias current for the output drive switches SA, SB, and SC. Each of the output switches SA, SB, and SC are capable of supplying up to 1 amp of drive current. Ferrite beads at the outputs of Motor Driver switches are recommended to reduce the switching transients to the stepper motor.

MOTOR DRIVER EXTERNAL CIRCUITRY REQUIRED -External resistors RA, RB and RC provide the bias current for the output drive switches SA, SB and SC. Each of the output switches SA, SB and SC are capable of supplying up to 1 amp of drive current. Ferrite beads at the outputs of Motor Driver switches are recommended to reduce the switching transients to the stepper motor.


Housekeeping Voltage Regulator

The Housekeeping Voltage Regulator is an LM7812 that regulates the spacecraft bus voltage down to +12 VDC. Protection of the Voltage Regulator from spacecraft bus voltage transients is provided by zener diode CR18. The cathode of CR18 must be connected to the regulator input (+VREG IN) as shown in Figure 1. Rbias connects the Regulator input to the spacecraft bus voltage and provides current limiting for CR18. The +12 VDC output of the LM7812 is brought out to pin 62 of the HMA. The input power for the Sequence Generator logic and Opto-Isolators (+V LOGIC) is connected to pin 61 of the HMA. Connecting +12V OUT (pin 62) to +V LOGIC (pin 61) powers the Sequence Generator logic and the Input Command Circuits from the Voltage Regulator.

Pin Functional Descriptions

4

SIGNAL NAME

PIN # SIGNAL FUNCTION I/O CONNECTION

ILIM IL 1 & 2 Current limiter reference voltage biasVin max = 36Vlin max = 100mA

+ Spacecraft bus voltage

MOTOR RETURN

3 & 5 Stepper motor drive current return – Spacecraft bus voltage

Q CNTRL 5 Current limiter control voltage lout max = 30mA Base of regulator transistor

ILIM SET 6 & 7 Current limiter amplifier sense input Emitter of current regulator/RESENSE +

ILIM OUT 8 & 9 Current limiter reference input RESENSE –

PH A 16 & 17 Motor driver phase A output lout max = 1A Stepper motor phase A

A1 18 Phase A driver bias out A2 via 100 ohm 1/4W resistor

A2 19 Phase A driver bias in A1 via 100 ohm 1/4W resistor

CHASSIS GROUND

20 & 21 Chassis ground Hybrid case only

+V MTR 22 & 23 Input power to Motor drivers Vin max = 36V RESENSE –

PH B 25 & 26 Motor driver phase B output lout max = 1A Stepper motor phase B

B2 28 Phase B driver bias in B2 via 100 ohm 1/4W reisitor

B1 29 Phase B driver bias out B1 via 100 ohm 1/4W resistor

PHC 34 & 35 Motor driver phase C output lout max = 1A Stepper motor phase B

C2 36 Phase C driver bias in C2 via 100 ohm 1/4W resistor

C1 37 Phase C driver bias out C1 via 100 ohm 1/4W resistor

IC3 RTN 38 Command Opto-isolator input #3 return lon min = 0.5mA Open collector command source #1

ISO CMD 3 39 Command Opto-isolator input #3 bias Iin max = 20 mA +5VDC via 1K ohm resistor

OC CMD 3 40Optional open collector input (bypass opto-coupler #3)

Vlow max = 1.0V Open collector command source #3

IC2 RTN 41 Command Opto-isolator input #2 return Ion min = 5.5mA Open collector command source #2

ISO CMD2 42 Command Opto-isolator input #2 bias lin max = 20mA +5VDC via 1K ohm resistor

COMMAND BIAS

43+V LOGIC power supply via 1k ohm resistor

NC

OC CMD2 44Optional open collector input (bypass opto-coupler #2)


CMD3 45 Command Opto-isolator #3 output STEP CMD


Pin Functional Descriptions Continued

5

SIGNAL NAME

PIN # SIGNAL FUNCTION I/O CONNECTION

CMD2 46 Command Opto-isolator #2 output DIR CMD

COMP OUT 47 Spare NC

COMP + 48 Spare NC

COMP – 49 Spare NC

CMD1 50 Command Opto-isolator #1 output EN CMD

IC1 RTN 51 Command Opto-isolator input #1 return Ion min = 0.5mA Open collector command source #1

ISO CMD1 52 Command Opto-isolator input #1 bias lin max = 20mA +5VDC via 1k ohm resistor

OC CMD1 53Optional open collector input (bypass opto-coupler #1)


RCVR BIAS 54 LM139 negative input bias Vout nom = 3.2V NC

DIR POL 55 Direction command polarity selection Logic return for CCW operation

DIR CMD 56Sequence Generator Direction command input

CMD2

STEP POL 57 Step command polarity selectionLogic return for rising edge triggered operation

STEP CMD 58Sequence Generator Step command input

CMD3

EN CMD 59Sequence Generator Enable command input

CMD1

EN POL 60 Enable command polarity selectionLogic return for EN POL and EN CMD = output enabled

+V LOGIC 61Input power supply for Sequence Generator & Command Opto-isolators

lin max = 50mA +12V OUT

+12V OUT 62 Housekeeping Voltage Regulator input Pmax = 0.8W +V LOGIC

+24V CLAMP 63Transient protection diode for Housekeeping Voltage Regulator input

Pmax = 0.5W +VREG IN

+VREG IN 64 Housekeeping Voltage Regulator input Vin max = 36VSpacecraft bus voltage + via current limiting resistor

LOGIC RETURN

65 & 66Sequence Generator & Command Opto-isolator logic return

Spacecraft bus voltage - & MOTOR RETURN

70 Spare NC

71 & 72 Spare NC

73 & 74 Spare NC


HMA Outline Drawing

(1) (74)

(37) (38)

2.000±.005

1.25±.005

.250 MAX


21339 Nordhoff St. • Chatsworth CA • 91311 Phone (818) 341-5156 • Fax (818) 341-3884 • email: [email protected] APNT 1210

6

The Moog engineering team is internationally recognizedfor its innovative solutions to the most challengingspacecraft motion control applications. With designheritage tracing back to the infancy of the space industry,the engineering team can draw upon a wealth of flight-proven designs and well-established approaches to newproduct development. The engineering team is verticallyintegrated to offer complete solutions to spaceflightmotion control applications with experts in mechanical,electromagnetic, electronic, controls, software, andmaterials engineering. Close relationships are maintainedwith the manufacturing and quality assurance disciplinesthrough the use of integrated product teams, enablingthese groups to provide design input from the inceptionof development. Moog brings the full benefit of itsunmatched space flight heritage to bear through the useof this concurrent approach.

The mechanical engineering group offers tremendousexperience in mechanisms design and electronicspackaging. Particular emphasis is placed on bearingapplications and analysis, using the latest bearingsoftware and supported by a life test facility withmultiple vacuum stations and automated dataacquisition. Structures are analyzed for thedynamic spacecraft environments using finiteelement techniques supported by non-linear,fracture, and thermal stress analysis capability.Thermal analysis is performed using the latestversions of finite difference and finite elementsoftware. Moog has in-house materials engineeringand reliability analysis capability.

The electronic engineering area specializes inmotor controllers and encoders developed to meetthe unique requirements of spacecraft environmentsand reliability. Specialties include controller design,motor drivers, signal conditioning, encoder design, andcomponents engineering. The complete product designcycle can be performed by Moog from schematiccapture and printed wiring board layout and through allapplicable analyses including parts stress, worst case,and radiation.

Motors are the founding technology for Moog SMD.Combining 30 years of successful heritage, proprietarydesign software honed by years of experience, and thelatest finite element tools, Moog offers the mostexperienced and capable motor design staff in theindustry. Known for its proprietary 3-phase stepperdesign, Moog also manufactures many variations ofstepper and brushless DC motors along with numerousspecialty electromagnetic devices.

Moog has developed controllers to meet many exactingpositioning requirements for solar array, antenna, andmirror scanning and positioning applications. Using bothanalog and microprocessor-based designs, Moogcontrollers meet all aspects of electronic and softwarespaceflight requirements. Test stands and software arealso developed within rigorous configuration anddocumentation requirements.

The design group uses a combination of solid modellingand drafting software to produce mechanism andelectronics designs. Using the Integrated Product Teamapproach, representatives from the manufacturing andquality assurance organizations give input from theonset of development programs resulting in producible,cost effective solutions to the most complex customerrequirements. Configuration management is handledelectronically on a database common to the entire company,

so that the latest documentation is always on hand andall organizations are rapidly informed of changes.

Moog has a distinct advantage in new product developmentbecause of its dedicated Advanced Development group.Composed of several highly experienced individualswith talents ranging over the full spectrum of motioncontrol product design and manufacturing disciplines,the group is intimately involved in the development andmanufacture of new designs both for internal developmentand external customers. The group is involved withinternal research and development, joint research anddevelopment with customers and vendors, proof of conceptand prototype models for development contracts; and,in cases of extreme schedule pressure, flight qualitymodels.


Engineering

Moog manufacturing capabilities are extensive andgeared for spaceflight programs. The company hascomplete machining, assembly and test capabilities alllocated in the modern Chatsworth facility.

FABRICATION

Schaeffer Magnetics Division has 950 square meters offacility devoted to machine shop. The machine shopfeatures the latest in computer controlled manufacturingmachinery (EDM, lathe and milling machines), and acomputer based Coordinate Measurement Machine.

In addition to the in-house capability, the resources ofMoog Inc. are available to SMD. These extensivefabricat ion facilities and equipment increase thethroughput capacity of SMD manyfold. There are over500 machines and work stations in the Moog EastAurora Facility. The equipment ranges from $750,000CNC machining centers to fine tools for deburring.

The Moog SMD production facility reflects a conceptthat has been developed through the years, specificallyto produce the highest quality systems and relatedcomponents. Cleanliness is stressed throughout allMoog’s manufacturing facilities and environmentalcontrols are provided where necessary to controltemperature, humidity and/or air cleanliness.

In addition to the extensive machining capacity availableat the Moog East Aurora facility, the Moog facility locatedin Torrance California has a complete gear cutting andplating capability, also available to SMD.

ASSEMBLY

Moog SMD currently has over 900 square meters offloor space devoted to assembly, rated at class100,000, including a dedicated area for the assembly ofelectronic hardware. Class-100 flow benches supportassembly activity. Work is distributed and planned in acellular concept. Workstations are set up to allow theorderly flow of hardware through the assembly area.

The assembly area has all of the resources necessaryto provide for all assembly processes. The hardware kitdoes not leave the assembly area until it is a finishedproduct, ready for acceptance test. This philosophy hasreduced assembly times and costs.

Assembly technicians are cross-trained on all assemblyprocesses. This allows management flexibility in utilizingpersonnel.

Some of the key assembly processes maintained atMoog SMD are:

Motor Winding: The motor winding technicians atMoog have over 15 years experience on average. TheElectronic Assembly technicians have been cross-trained to provide support in this area during peak loadperiods. All motor winding technicians have been certifiedto NHB5300.4 (1C) soldering standards.

Bearing Processing: Moog emphasizes meticuloushandling and processing of ball bearings for all of ourproducts. Bearings are an especially critical componentin spaceflight mechanisms. All bearings are carefullyspecified to our approved suppliers. Once the bearingshave been received at Moog, traceability is established.They are inspected, cleaned and lubricated, and kept inprotective containers. The bearings are never againexposed unless in a class 100 laminar flow benchenvironment.

Electronic Assembly: Within Moog, low volumethrough-hole Printed Circuit Board assembly is available.All assemblers are certified to the NHB5300.4(1C)standards. All electronic circuit board assembly isperformed in an ESD approved, environmentallycontrolled room. Access to the room is restricted topersonnel that have successfully completed ESD training.Other Moog divisions have high-volume solderingcapabilities such as wave soldering and surface mountsoldering systems which are available to SchaefferMagnetics Division.


Manufacturing

Sensor Integration: Most of SMD’s productsincorporate position sensing. Moog has extensiveflight experience with most types of position feed-back devices, such as absolute encoders,incremental encoders, disk encoders, single andmulti-speed resolvers, fine and coarse potentiometers,LVDT, RVDT and Hall sensors.

Moog has the test equipment and fixturing necessaryto integrate these devices into our mechanisms.

Cabling: Moog has incorporated a wide variety ofcable management systems. Special attentionmust be paid to cabling as it is reliability-critical.Moog has incorporated flexible printed circuit(patented designs) wraps, clock-spring wraps, sliprings, twist capsules and molded circuits.

Moog technicians are trained on the various typesof cable management systems and their properinstallation/operation. Special care is taken when han-dling these devices to ensure proper operation and toprevent damage to any of the conductors or insulation atany point in the production process.

TEST

The 730 square meter test facility includes a 6000 lbfLing vibration table, six specially designed and instrumentedthermal vacuum chambers ranging in size from a 6’diameter x 6’ deep cylindrical vessel to a 2’ x 2’ box, andseven environmental ovens supporting manufacturingand test activities.

Some of the key test activit ies at Moog can bedescribed as follows:

Qualification Testing: Qualification testing is a verificationof design and also of methods, assembly procedures,and tooling. A performance baseline is established forthe later production models, with initial metrics for flightlevel units. Qualification is the first opportunity to accumulatedata on the flight design using flight-level proceduresand support tooling.

Acceptance Testing: For acceptance testing, Moogutilizes a streamlined procedure that provides highconfidence that passing units will be fully capable inflight. Acceptance test of all units is the reason, however,Moog has experience testing in both low and high volumeprograms. At times, extensive environmental testing ofevery unit is cost and schedule prohibitive. In these

situations, Moog can recommend a procedure ofreduced testing and statistical lot sampling.

Life Testing: Moog has extensive experience designing,fabricating and performing life tests on a wide variety ofcomponents. Our life test experience includes actuators,various mechanisms, slip rings, position sensingdevices, cable wrap assemblies and bearings. Many ofthese tests have been performed at actual on-orbitspeeds, making the tests run many years. Others havebeen performed at accelerated rates, depending on theapplication.

Moog currently has a dedicated multi-station life testroom established that is used for a variety of tests. Theroom currently contains 4 bell jar systems that arecompletely autonomous. Each test station has a dedicatedpump system, temperature control and automatedmonitoring system. The life test room is capable oftesting several additional mechanisms beyond thecurrent test plan.

PLANNING

Moog Schaeffer Magnetics Division currently operatesusing the Moog Business System MRP softwareprogram. This tool fully integrates all facets of thebusiness from accounting, payroll, scheduling, materials,in-process work, engineering, to cost estimating andforecasting.

Quality Assurance is an integral part of the overallorganization at Moog, and is involved in many facets ofthe daily operation. The emphasis is based on providinga highly controlled, yet cost effective program that isconsistent with the stringent reliability and criticalperformance requirements of customer needs andspace applications.

The Quality departmentsdaily involvement in theareas of receiving, inspection,procurement, suppliercontrol, SPC, systemsand operator audi ts ,customer reviews andapproval of engineeringdocuments are describedwithin the QualityAssurance Manual. Thisdocumented systemdetails the control of eachelement of the qualityfunction. The overall programcomplies with all therequirements of MIL-Q-9858, MIL-I-45208, andNHB 5300.4(1b). Theintegration of these systemrequirements along withspecific customer requirements,and integrating the businesssystem controls associatedwith ISO 9000 ensuresMoog to meet all customerneeds and produce asuperior quality product.

The structure and responsibilit ies of the Qualityorganization are described in detail as follows:

Quality Assurance Manual: The Moog QualityAssurance Manual outlines the timing and depth ofQuality involvement. It also outlines controls onProcurement, Fabrication, Inspection and Testing,Measuring and Test Equipment, Property, Handling andStorage of Hardware, and other aspects of the productionprocess. A Quality Engineer is assigned to the program,and preliminary Quality review of the program starts inthe proposal process, followed by initial Quality planningat program kickoff. The Quality Program Plan for theprogram is generated, defining program-specific proceduresand milestones.

Quality Audit System: The Quality audit system inplace at Moog requires that Quality conduct audits on arandom basis but no less often than monthly; withdetailed f indings and reports being generated.Management involvement is ongoing, with monthlyQuality status reports to management routine and activeManagement involvement available on an as-necessarybasis.

Inspection Planning:The Moog QualityAssurance Departmentconducts a comprehensivesystematic review of alldrawings, parts, materials,processes and proceduresto preclude the manufactureand/or inclusion of non-conforming material indeliverable product at theearliest stage possible.Through the establishedprocedures of review andapproval, Quality Engineeringprovides appropriateinput to the design andmanufacturing departments.Conformance verificationis included in the inspec-tion planning and detailedin the ManufacturingOutlines

Inspection Philosophy:It has always been partof the Moog culture thatemployees are given

responsibility for the quality of their own work. Individualmachine operators monitor the output of the processesthey are performing at established intervals based onmachine capability studies, piece part tolerances and lotsizes. When tolerances are out of limits, the operator isresponsible for stopping his or her own machine andtaking or obtaining corrective action before proceeding.The employee inspects his other work and stamps offthe completion of that inspection with his own individuallynumbered stamp. The employee maintains their inspectioncertification by passing random independent audits ofhis work. Therefore quality is monitored throughout theprocess rather than inspecting and rejecting parts at theend of the line.


Quality

Certified Operator Program: A certified operatorprogram has been instituted at Moog. This programtrains each of our manufacturing employees on thebasics of self-inspection. This action of empowering theemployee with the responsibility of checking their ownwork prior to moving on to the next step in the manufacturingcycle has had a tremendous impact on productivity. Bycatching errors at the source, both time and costsassociated with errors have been reduced.

The quality audit system is in place as a positive controlconcept that emphasizes auditing techniques andpersonal responsibility for the quality of work. This systemenables factors leading to poor quality to be identifiedas close as possible to their source.

Supplier Selection: Moog selects suppliers whooffer maximum value at affordable prices.Maximum value means that the supplier is offeringmuch more than a low initial price. We evaluatemany other factors such as historical qualityperformance, diligence toward effective correctiveaction, ISO registration, delivery performance,reliability predictions, extended warranties, on-siteengineering assistance, early supplier involvementactivities, long term pricing agreements, environmentaltest capabilities, compatible computer systems,SPC implementation, and analytical computertools. This evaluation is performed using atraditional multi-disciplined team approach thatincludes as a minimum Purchasing, SupplierQuality, Quality Engineering, Design Engineeringand Manufacturing Engineering.

Supplier Qualification: Supplier Quality SystemEvaluation checklists are established to assureconsistent evaluations of quality procedures andcontrols being employed by suppliers. The objectivesare a) to establish uniform standards for evaluatingthe degree and effectiveness of quality practicesand controls; b) to identify quality problems forevaluation and correction, and c) to permit evaluationof various methods of controlling a specific qualityarea.

Supplier Management: Moog is a world classcompany and supplier of precision motion controls, andmust be supported by a world class group of suppliers.In many companies, the supplier base reflected anaccumulation of individual “Ad-Hoc” needs being metover an extended period of time. At Moog, this processhas become a strategic one, with suppliers being selectedand developed to meet a broader range of needs.Although not an objectiv, a by-product of this strategyhas been that we require fewer and fewer suppliers tomeet the vast majority of our needs.

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