CURRENT SKA TDP ANTENNA DESIGN 10
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Transcript of CURRENT SKA TDP ANTENNA DESIGN 10
CURRENT SKA TDP ANTENNA DESIGN 10
DVA1 Meeting at NSF Arlington VA
April 15-16, 2010
Matt Fleming
Contributions from
Jack WelchRoger SchultzGordon Lacy
Antenna Design Drivers
1 Must achieve survival. ( 100 mph wind )
2 Low cost per unit area of aperture. ( good sky coverage ) ( installed )
( low cost materials, low mass design, low fabrication labor ) ( favors symmetric )
3 Very low operational cost for a 30 year life( very few maintenance visits required )
4 Frequency range of 0.3 to 10 GHz with WBSPF( 3.5m Gregorian secondary ) ( favors offset )
5 Excellent Ae / Tsys.( accurate surfaces, controlled spillover, low diffraction ) ( favors offset )
6 Exceptional dynamic range.( very rigid surfaces, very good pointing, )
pt source sensitivity
survey survey speed
Performance vs Cost
Tradeoffs
These will lead to specifications: ???
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 2 of 43
Basic fabrication cost drivers
Raw material costs. ( fairly constant world wide )( a good design is light weight )
Labor cost. ( varies by type and location based on economic and social conditions )
Understanding these items for every design allows engineering shortcutsWe cannot do detailed design on every possible design approach
For some designs material is often traded for labor
Technology. ( application of intellect to use of material, labor & energy )
Number of units needed. ( investment in tooling )
Transportation. ( where made, where assembled, where installed )
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 3 of 43
Note on Transportation
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 4 of 43
Physical size of antenna elements will influence transport cost.Remote fabrication of smaller elements allows use of global labor competition.Remote fabrication usually means greater on site assembly labor.Onsite fabrication of large elements can allow lower on site assembly labor.
Non modal transport is also possible, but likely more expensive.
Types of Reflectors & Support
This is an arbitrary identification systemjust for discussion
This slide just a reminder about initial choices
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 5 of 43
•Single piece reflectors often have low labor cost relative to alternate designs.•Reflector edge support by itself preserves accuracy extremely well.•The reflector surface can act as the structural front side of a deeper system.•Rim edge and center support works better if the center has axial flexibility.•The concept can work for symmetric or offset designs.
Primary as a monocoque elementSingle shell or stressed skin
Jump to single shellOn Az-El mount
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 6 of 43
•A frame & spar system gives good edge & center support with an open center.•Wind & gravity moment loads are reduce with Az & El near the shell center.•The support system allows a compact turret head to be nested close to shell.•A compact turret head can contain almost all the precision machining needs.•A relatively simple pipe pedestal can support the turret head. ( wind & thermal )
ATA Implementation
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 7 of 43
•A 6.1m diameter symmetric shell can be made with only a 3mm thickness.•The surface accuracy can be quite high.•A study showed 3mm alum 3003 will have good repeatability in production .•Another study showed 3mm alum 3003 can be extended to a 12m symmetric.
JPL, DSN, Prototype
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 8 of 43
Identify 3 Optical Designs of Interest
B1
E2
D1E1
Data points for SKA cost modelInform Tradeoff symmetric vs offset
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 9 of 43
Select 3 Designs for Costing
FEA Design & Costing for HMR to meet survival requirements
HMR = Hydroformed Metal Reflector
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 10 of 43
Information from Composite Investigations
DRAO = Dominion Radio ObservatoryCART = Composite Application Radio Telescope
Prototype 10m complete.Symmetric with Core, Beams & Hub.SKA Memo 116 costing information
Starting to investigate Offset monocoque V3
Canada DRAO CART Project and South Africa MeerKAT Project have generated cost and performance information for composite on site reflector fabrication.
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 11 of 43
TDP Antenna Cost ( summary estimates )
8% 15%0% 0% 11%
Adding 15% 113,000 122,000 130,000 137,000 152,000
25%
( survival design shown )( add 15% for performance design )
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 12 of 43
TDP Antenna Cost (summary estimate )
a little more detail
Masses are low
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 13 of 43
Optics 42 used for costing
2 Gregorian feeds with rotary indexer & possibly a PAF
Shown with Feed Up but optics can be the same with Feed Down
Costing Allows Selection
PAF = Phased Array Feed
Preffered mechanical configuration Acceptable optical configuration
Note feed support locations
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 14 of 43
HM & FRP shells are similarBoth hydroformed metal and fiber reinforced plastic create good monocoque structures
FRP can replace HM reflectors and can provide edge support
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 18 of 43
Beginning to work on details
Rain snow ice
Survival wind
Security and vandalism
Ease of maintenance
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 21 of 43
Structural Simplicity
Triangular deep trusses goodCured beams and curved shells bad
Tubular structures are very efficient at handling bending and torsion
More about PAF position later
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 23 of 43
Deliverable Antenna Elements
Primary not shownIt is an on sitefabrication
Pedestal Turret head
Secondary
Primary center frame
Electronics enclosures
Secondary and feed support
Feed and indexer
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 25 of 43
Pedestal Fabrication
Consider use of ring forgings
Machined Flange
Alternate foundation concepts are still under consideration
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 26 of 43
Transport Check
Looks good for global sourcing
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 27 of 43
Turret Head Assembly
Deliverable AssemblyIncludes az drives, bearings, encoders, electronics
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 28 of 43
Transport Check
Note 3.1 m secondary shown
Looks like a little larger is possible.
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 29 of 43
Primary Center Frame
Pentagonal frame shown
Machining of this portion may be necessary and a little expensive
Tubes all have parallel end cuts
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 30 of 43
Transport CheckNot so good
Design for assembly or ship prepared kit to near site fabricator for final weld and paint then transport to site.
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 31 of 43
Secondary Support Frame
FRP fabrication may be ideal for rear section from the primary lower rim to the feed support plane.
If made from metal, we will consider some on site assembly.
More information is needed about feed support requirements.
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 32 of 43
Transport CheckNot goodDensity very poorReconsider this
Design for assembly or ship prepared kit to near site fabricator for final weld and paint then transport to site.
Electronics enclosure shown
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 33 of 43
Turret Head & Az drives
Deliverable Assy
Double row ang contactOr crossed rollerWith oil bath
Lubrication 60 months
Machinedfabrication
Az drivemodules
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 34 of 43
Azimuth Drives
Dual idler supported pinion
Multiple modular drives
Access to drives
Full oil bath lubrication for 60 month period
RFI control
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 35 of 43
El Bearings & El driveGravity loading helpful.Low clearance importantBearing choices tuff.
Currently envision a custom actuator
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 36 of 43
Encoders & Pointing
Attachment to reflector surface away from loaded areas
Long light weight tube might be problematic
Both encoders can be interior to the turret head allowing environmental protection and easy cabling.
Limit switch gearing
Az tube could extend to ground for higher accuracy, but …….
Addition of tilt meter and accelerometer devices may enhance performance
Unatainium box on back of dish is the best option
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 37 of 43
Cable Wraps & Enclosures
Cooling is important to consider early in the design
Current Az wrap 540° and envisioned with only 5 elements Power 1, Power 2, Ground, Control fibers, Signal fibers
Security, access, swapping
Current El wrap 75°envisioned with many elementsPower 1, Power 2, Ground, Control fibers, Signal fibers
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 38 of 43
Feeds and Indexer 1
Space for PAF implies two leg support frame
Pivot & structural support
Lindgren in canATA in glass
Track ?
PAF shown1m x 1m x 1m
Maybe sector not turntable
PAF at secondary focus
still under consideration
Min angle on wraps
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 39 of 43
Feeds and Indexer 2
Some comments:
It will be expensive.It will introduce additional deflection.It will introduce additional pointing considerations.It will require more cables and cable wrap loading.
Is it really possible to imagine future feed upgrades?
I look at the ATA WBSPF with 1.0 to 10.0 GHz, weighing 40 Kg and wonder If we gave 0.3 to 1.0 GHz to another solution then the dish is much simpler.
DVA1, NSF, Arlington, 2010-04-16 Matt Fleming slide 40 of 43
Issues to rememberand questions remaining
For the DVA-1Diameter Primary ( 12 15m )( done )Diameter Secondary ? ( 4m ) go to ( 3.5 )Optics design – shaping – illumination angle ?High shrouding concept.Analysis high shroud ?High Low decision ?Diffraction from secondary support braces and other items ?Tolerances on component positions ?Determine spec for high performance
US SKA Consortium, Madison, 2008-11-17 Matt Fleming slide 42 of 35