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SpaceSystems

Mechanisms Overview

August 2001

Mech_over__aug01.ppt

www.honeywell.com/space/CEM

Mech_over_aug01.ppt 2SpaceSystems

Space Systems Glendale Product Areas

CommercialProducts

Reaction Wheel Assembly

Larger VolumeStandardized Products

Standardized Mechanisms

Special Projects

Unique Low VolumeProducts

Control MomentGyros (CMG)

SpecialtyMechanisms

SpaceStation

Multiplexers/Demultiplexers

Software DevelopmentSystem

DisplaysData Storage

Data and VehicleManagement

HumanSpace

Displays andSoftware


Mechanisms Design Heritagen Over 30 Years experience in custom mechanisms for Military, NASA

and Commercial programsn Spin Systems Key Technologies and Heritagen Several Encoder Methodsn Power and Data Transfer Assembliesn Low ripple and jitter motors

n Gimbal and Pointing Systems Heritagen Precision Pointing Gimbals and electronicsn RF Rotary Joints and Flex capsulesn Deployment Systemsn Controls/Structure Interactions and Dampingn Disturbance Compensation/Reduction

n Commercial Rotary Actuators and Gimbalsn Communication Antennasn Thruster Controln Solar Array Drives


Rotary Actuator Typesn Ambassador Series:

n High volume production (1400+)n LEO Constellation tailored designn Application:

n Antenna dish deployment and pointing

n Galaxy Series:n Currently in productionn LEO / GEO tailored designn Applications:

n Subreflector rotationn Antenna dish deployment & pointingn Thruster pointing


Honeywell Mechanisms DesignPhilosophy

nDesign products with inherent modularityn Insure individual rotary actuators can be used

easily in single axis or two axis gimbal modesnMinimize part count for lower production costsnDesign for manufacturing and assembly

through close relationship with productionpersonneln Insure flexibility in the design to meet

customer specific requirements with minimalnon-recurring costs.


Galaxy Series Rotary Actuators and Gimbals

n Modular Packaging Conceptn Low part count (12)n 2.2 Kg (4.9 lbs) per axis weightn Precise step accuracy (0.0075 deg)

n Theoretical step size versus actual step size

n Small step size ( 0.009375 deg)n Non-redundant coarse potentiometern Conductive track for ground path across

output bearingsn Redundant Fine potentiometer for

position telemetry

n Target Applicationsn Antenna deployment and pointingn Thruster pointing


Assembly of GX-090221 ActuatorSTOPRING

MOTOR & FINEPOTENTIOMETERASSEMBLY

HARMONICDRIVEASSEMBLY

OUTPUTFLANGE

BEARINGSPOTENTIOMETER

MOUNTINGFLANGE


System Applications of Galaxy SeriesRotary Actuators

Two Axis Gimbal Leveln Reflector Deployment and

Pointingn Thruster Deployment and

Pointing (Proposed design)

Two Axis Gimbal w/ Interfacen Spot Beam Antenna

Deployment and Pointingn Thruster Deployment and

Pointing (Proposed design)

Features:n Primary and Secondary

Circuits Separated on TwoConnectors

n Modularityn Extended Thermal

Environmentsn Non-Op: -60degC to +117 degCn Op. (Flight): -45degC to 105 degC

Features:n Primary and Secondary

Circuits Separated on TwoConnectors

n Modularityn Extended Thermal

Environmentsn Non-Op: -60degC to +117 degCn Op. (Flight): -45degC to 105 degC

Rotary Actuator Leveln Subreflector Rotationn Single Axis Deployment

& Positioning


Specialized Mechanism Programs


Hubble Space Telescope

Honeywell supplied two key subsystems for theHubble Space Telescope: Reaction WheelAssemblies and an Antenna Pointing System.

To keep its sharp focus, the Hubble relied onHoneywell reaction wheel assemblies andisolation system for positioning and stability.To send images and data back to Earth, thegiant telescope linked with NASA’s Trackingand Data Relay Satellite System via aHoneywell antenna pointing system.

Honeywell supplied similar reaction wheel andpointing systems for the Solar Max andMagellan missions, as well as for missions likeTopex and Explorer Platform.

Two Axis GimbalAssembly (TAG)

Gimbal ElectronicsAssembly (GEA)


AMSR Honeywell provided mechanisms and momentumcontrols for Mitsubishi Electric Corporation’sAdvanced Microwave Scanning Radiometer(AMSR), an instrument used on NASA’s EarthObserving System satellite -- EOS-PM1.

SSO built and delivered an Antenna DriveAssembly and a Momentum Wheel Assembly tocontrol AMSR. The Antenna Drive Assembly, aspinning mechanism, is crafted to be the interfacebetween the AMSR instrument package and theEOS-PM1 satellite bus, providing signal andpower transfer and precision compensation for themomentum created by this rotation. Theseproducts demonstrate Honeywell’s heritage indesigning and building spinning mechanisms for anumber of successful satellite programs.


Galileo

When NASA’s Galileo spacecraftviewed Jupiter’s moon, Ganymede, theflyby was made possible in part byHoneywell Space Systems’ SpinBearing Assembly and Scan ActuatorSubsystem. Because the Galileospacecraft is stabilized by a spinningmotion of about 3 rpm, the spin bearingassembly was designed to “despin” andpoint an instrument platform carryingseveral sensitive scientific instruments.The result is precision pointing of theinstruments.

Honeywell’s scan actuator subsystemswere used to point another series ofinstruments during flyby encounterswith Jupiter and its satellites.

n Single axis gimbal for pointinginstruments on Galileo orbiter

n 200 circuit flex capsulen 0.5 N-m torque outputn 16 bit optical encodern Redundant motorsn ±105 deg angular traveln 0 to 1.0 deg/sec angular raten 19.5 Kg weight

n Single axis gimbal for pointinginstruments on Galileo orbiter

n 200 circuit flex capsulen 0.5 N-m torque outputn 16 bit optical encodern Redundant motorsn ±105 deg angular traveln 0 to 1.0 deg/sec angular raten 19.5 Kg weight


TOPEXHoneywell designed, developed and producedthe High Gain Antenna System (HGAS) forthe Ocean Topography experiment (TOPEX)satellite.

The system consisted of a deployment mast,gimbals and electronics and allowed theTOPEX spacecraft to maintain a two-waycommunications link between NASA’sTracking and Data Relay Satellite System andEarth.

Honeywell also provided four Reaction WheelAssemblies that stabilized and controlled thesatellite’s attitude.


SMM High Gain Antenna System (HGAS)

Solar Maximum Mission (SMM)High Gain Antenna System


EOS-AM Gimbal Assembly Description

n Azimuth/Elevation Rotary Actuatorn Redundant Absolute 14-bit Optical Encodersn Redundant Coaxial and Power/signal Cablesn Mechanical Stops: Az ± 202°, El -29° & + 97°n Titanium and Aluminum Structuren 36 lbs. Total Weightn 1.2 Deg/sec Slew Speedn Life Test– 10 Yr Duty Cyclen Delivered September 1995

n Azimuth/Elevation Rotary Actuatorn Redundant Absolute 14-bit Optical Encodersn Redundant Coaxial and Power/signal Cablesn Mechanical Stops: Az ± 202°, El -29° & + 97°n Titanium and Aluminum Structuren 36 lbs. Total Weightn 1.2 Deg/sec Slew Speedn Life Test– 10 Yr Duty Cyclen Delivered September 1995

Honeywell designed and built the Stepper-Gimbal Assembly for the Earth ObservingSystem Satellite (EOS) AM high gain antenna.

The two-axis gimbal pivot the craft’s antennadish and electronics, which gathered andtransmitted data.

EOS was among the first NASA spacecraftsusing Honeywell’s stepper-gimbals.


Advanced Gimbal System (AGS)n Control torquen Elevation: 34 N-mn Lateral: 34 N-mn Roll: 14 N-m

n Angular rangen Elevation: +100/-60 degn Lateral: ±60 degn Roll: ±60 deg

n Pointing accuracyn Using ideal inertial

sensor: 0.1 arcsecn Using gimbal resolvers:

27.7 arcmin


DMSP Scan Drive Assembly (SSMIS)

n 31.6 RPMn 7 year lifen 50 Slipringsn Redundant Optical

Encodern 2.9 ArcSec Accuracyn Redundant Motorsn 25 lbs


SeaWinds Scatterometer Antenna Subsystem

n Major Subassembliesn Spin Actuator Assemblyn Antenna Assemblyn Electronics Assemblyn Base Structure Assembly

n Selectable 18 or 20 rpm spinrates

n Redundant 15 bit encodern Redundant brushless DC

motorsn Dual Channel RF rotary

jointn 4.5 year design lifen Delivered 6/97 for ADEOS IIn Delivered 4/98 for QuikScat -

launched 6/99


ISS Assembly/Contingency Subsystem (ACS)Antenna Gimbals

Stepper Motor30:1 Anti-Backlash Spur Gear80:1 harmonic Drive-1 deg to +135 deg (Elev.)±236 deg (Azim.)0.018750 to 9 deg/sec9 in-lbs15,000 in-lbs/rad8.5” x 8.5” x 13.0”22 lbs8 lbs1 TS Quad1 Coaxial19.5 years18.9 (106) deg motion@ 0.06 deg/sec550 (106) deg motion@ 9 deg/sec190,000

Drive Config

Coverage

Output Step SizeAngular RateHolding TorqueTorsional StiffnessEnvelopeWeightPayload CapabilityConnections

Life

Direction Changes

Characteristics

Two-axis Pointing Gimbal forthe ISS High-gain Antenna

Application: Primary Communicationfor ISS to Ground


ISS Space-to-Ground Subsystem (SGS)Antenna Gimbals

Stepper Motor19:1 Anti-Backlash Spur Gear160:1 harmonic Drive±121 deg(Elev.)±48 deg (Cross Elev.)0.0050 to 5 deg/sec90 in-lbs375,000 in-lbs/rad12” x 12” x 25.0”70 lbs75 lbs1 Two Axis Rotary Joint14 bit Optical Encoder19.5 years18.9 (106) deg motion@ 0.06 deg/sec293 (106) deg motion@ 3 deg/sec400,000

Drive Config

Coverage

Output Step SizeAngular RateHolding TorqueTorsional StiffnessEnvelopeWeightPayload CapabilityConnections

Life

Direction Changes

Characteristics

Two-axis pointing gimbal for the ISS parabolic antenna


APS Antenna Gimbal Drive

n Redundant Brushless DCMotors

n Direct Driven 40 W Peak Powern 20 in.-Oz Output Torque

n Redundant Single-speed Resolversn ± 4 Arcmin Accuracyn Duplex Bearing Pairs - 1 Fixed, 1

Floatingn Flex Capsule for Power and

Telemetry Transfern Low Loss RF Rotary Couplern Lubrication Type Determines Life


Explorer Platform (EP) Modular AntennaPointing System (MAPS)

Antenna Gimbals with Deployed MastSteering Control Electronics (2) and

Remote Interface Units (2) on Mast Canister


Gimbal Torquer Drives (GTD)

n Roll and pitchdrives

n 3.8 ft-lb, 24 poleBDC, low ripplemotors

n Resolvercommutation

n Output torquen Roll: 74 ft-lbn Pitch: 243 ft-lb

n System weightn Roll: 28 lbn Pitch: 31 lb

Delivered for a Restricted Program


PMIRR

Honeywell designed, developed and builtthe Optical Chopper Assembly (OCA)for the Pressure Modulated InfraredRadiometer (PMIRR), a scientificinstrument that flew aboard the MarsObserver.

Honeywell’s OCA functioned as anoptical switch alternating beam pathsbetween detectors within the PMIRRinstrument.


Control Electronics Heritage

nAGS Yes Yesn SeaWinds Yes YesnAMSR Yes Yesn STAPS Yes NonHGAS/MAPS/TOPEX Yes YesnGalileo SAS/SBA Yes YesnDMSP SSMIS No NonQuikScat Yes Yesn EOS-AM No NonACS No Non SGS No No

Drive Electronics Control Electronics


Flex Capsule and Cable Wrap AssemblyHeritage

nGalileo SAS - 200 channel flexcapsuleassembly - +/- 100 degreesn ISS SGS - Two axis cable wrap including 6

coaxial cablesn ISS ACS - Two axis cable wrap, coaxial

cablesnAPGS - Optical fiber cable wraps


RF Rotary Joints

nDual Channel RotaryJoint (SeaWinds, &QuikScat @ 12 GHz)

n Single Channel RotaryJoint (STAPS, HGAS,TOPEX, & MAPS @ 3GHz)

Dual Channel RF Rotary Jointfrom SeaWinds

Honeywell worked with RF rotary joint suppliers to qualify the designHoneywell furnished the bearings and lubrication system


Deployment Systems Heritage

nControlled Deployment - Velocity controlled withan eddie current damper, latched into place(TOPEX)nDeploy/Retract Mechanisms - Controlled with a

redundant drive motor (HGAS & MAPS)nLaunch Retention - Several designs using pyro

devices, flangibolts, paraffin actuators (VISS,TOPEX, Polar Laboratory)


Position SensorsnSingle & Multi-Speed ResolversnCMG’s/HGAS/STAPS/AGS/TOPEX/APS

n InductisynsnAPGS

nOptical Encodersn Incrementaln Iridium/ACS

nAbsoluten Galileo/EOS-AM/SGS

Honeywell has experience with all types of sensors


Expanded Production Capabilityn State-of-the-art assembly,

integration & test area (Class100,000 and 100 flow hoods)nGrand Opening of enhanced

facility (March ‘99)

nAccommodates productionof various types of actuators(linear, rotary, solar arraydrives, and gimbals)


On-Line Work Instructionsn On-line database:

n Each work station has a monitor which has access to the electronic workinstructions

n Each necessary record is referenced in the work instructions and hyperlinked toan input table. All information is stored on a database by end item serial number.

n Paper back-up system is in placen Information is entered by keyboard or bar code.n All prints and Mspecs are accessible on line


Automated Test Equipment Console

n Automated Multi-channel test console inplace.

n Capable of testing 8 units simultaneously.n Lab View based operating systemn Modular hardware and software design

n Replaceable stepper motor drivers (3-phase or 2-phase)

n Same application software can be activated to test upto 8 units.n One application simplifies software change

process.n Minimizes possibility of errors

n Expandable to test power / signal data transfer assemblies(Solar Array Drives) - Planned for the future


Concurrent Data Reduction

n Real Time Data Reductionn Numerical print outn Graphical print outn Real time data evaluation (PASS /

FAIL criteria)

n Data Trending Capabilityn Currently being implementedn “In Family” data comparisonn Simplification of data packages for

internal and customer review

Program PTAG File Name:Test Name 5.1 Test Time: 8:00 amTest Paragraph 5.1 Test Date: 1/1/1999IT Document IT12345678 Software Rev. psXXXXXXX-XXXTester Rick Self Total Test Time

Part Number: 9999999-999 Pressure AmbientSerial Number: 123456789 Temperature Ambient

T e s t I n f o r m a t i o n

4525 - post vibe mechanical/electrical measurements at 23C (0-240 steps in 1 step increment)

P r e T e s t C o m m e n t s

Parameter Max Min Units Spec Max Spec Min Pass/Fail

Mechanical Output Position Error 0.0003 -0.0069 deg 0.035 -0.035 Pass

Fine Primary Potentiometer - Deviation 0.0113 -0.0145 volts 0.0782 -0.0782 Pass

Fine Secondary Potentiometer - Deviation 0.0196 -0.0042 volts 0.0782 -0.0782 Pass

Coarse Primary Potentiometer - Deviation 0.0000 -0.0018 volts 0.0316 -0.0316 PassCoarse Secondary Potentiometer - Deviation volts 0.0316 -0.0316 N/A

R e s u l t s

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Multiple Unit Test Capability

n Thermal Vacuum Testingn Multiple unit test capability

n 4 rotary actuators simultaneouslyn Quick set up test fixturesn Test console has been programmed

to perform standard test routines

UNITS BEING MOUNTED ON TEST FIXTURES

ONE SHIP SET OF ACTUATORS READY FOR THERMAL /VACUUM TESTING

ACTUATORS IN THERMAL VACUUM


Conclusions

nModular Product Designn Interchangeability of parts / Component and subassembly

performance characterization / Low part countn Multiple applications

nAdvances in Production Capabilityn On-line work instructions / Automated Test Console /

Expanded facilities

n Customer Emphasisn Customer tailored testing profiles and sequencing /

Expanded thermal operational range translates to a morereusable design (better suited for Hall thruster application)

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