SPACE ROTARY JOINTS OVERVIEW & CAPABILITY BRIEF Prepared By: - - PowerPoint PPT Presentation

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Feb 15, 2024 284 likes •560 views

SPACE ROTARY JOINTS OVERVIEW & CAPABILITY BRIEF Prepared By: Charlie Lusher Diamond Antenna and Microwave Proprietary Document Director of Space Programs and Lead RF Design Engineer Approved for Global Viewing Diamond Antenna and

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Diamond Antenna and Microwave Proprietary Document Approved for Global Viewing

SPACE ROTARY JOINTS OVERVIEW & CAPABILITY BRIEF

Prepared By: Charlie Lusher Director of Space Programs and Lead RF Design Engineer Diamond Antenna and Microwave

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WHY USE A ROTARY JOINT IN SPACE?

PRODUCT/MISSION RELIABILITY

LONG LIFE DESIGN FLEXIBILTY EXCELLENT RF PERFORMANCE (MUCH BETTER THAN CABLE WRAPS) STABLE THERMAL & VACUUM PERFORMANCE HIGH MULTIPACTION MARGINS VERY LOW TORQUE NO ROTATION LIMITS (MORE ROBUST THAN FLEXIBLE WAVEGUIDE AND CABLE WRAPS) LOW OUTGASSING MATERIALS USED

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ROTARY JOINT MISCONCEPTIONS:

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

Diamond has delivered qualified products to multiple worldwide programs

POOR RELIABILITY

Diamond has never experienced a Space product test failure

HIGH TORQUE

Typical ambient temperature values are < 4 inch ounces

ROTATIONAL RF CHANGE

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

CABLE WRAPS or FLEXING A WAVEGUIDE IS A BETTER CHOICE

Why take the chance of a failure? Several customers have selected Rotary Joints after test failures of a cable wrap or flexible waveguide Diamond Antenna and Microwave Proprietary Document 3

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BEARING and LUBRICATION SELECTION:

BEARING SELECTION

Customers have final approval of bearings & lubricant selected Some customers choose to supply bearings as CFE (Customer Furnished Equipment) If required, Diamond personnel can be sent out for assembly and testing at the customer’s location

COMMON LUBRICANTS FOR SPACE BEARINGS

Penzane Rheolube Family Moly Disulfide (MOS2) Dry Film Braycote 601EF Customer Proprietary Lubricant

LUBRICANT LOSS

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

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DIAMOND ANTENNA SPACE ASSEMBLY AREA:

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Class 10,000 Clean Room Black Light Cleanliness Inspection RF Testing in Clean Room Class 100 Laminaire Flow Bench

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DIAMOND ROTARY JOINT DESIGN PROCESS: (Typical)

RF Modeling Design Mechanical Assembly Model Analysis Period Mechanical Manufacturing Package Final RF Modeling Verification Drawing Package Release

RF Modeling of Transient, Frequency, Thermal & Mechanical Deformation Solvers Available Design Cycle Repeated as Required Diamond Antenna and Microwave Proprietary Document 6

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RF DESIGN SOFTWARE (MICROWAVE STUDIO)

MODELING CAPABILITY

Virtual Prototypes Full RF Analysis High Power Thermal Analysis Mechanical Distortion Analysis Multipaction Analysis Ionization Analysis

Highly Accurate RF Prediction

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Diamond Antenna & Microwave Proprietary Document

RF MODELING ACCURACY: (WR-34 Waveguide Design)

EXAMPLE 1

No Tuning Needed

VSWR Model Prediction Initial Measured VSWR

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Initial Measured Actual VSWR

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Diamond Antenna & Microwave Proprietary Document

RF MODELING ACCURACY: (Coaxial Design)

EXAMPLE 2

No Tuning Needed

CST Predicted VSWR Initial Measured VSWR

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

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TYPICAL PROGRAM SDRLS:

Quality/Program Related: 1) MIP/KIP Plan 2) Quality Plan 3) PA Conformance Plan 4) PID Document 5) Configuration Control Plan 6) Cleanliness Control Plan 7) Critical Item List 8) Risk Management Plan 9) Risk Register 10) Schedules & WBS 11) Product Tree 12) Progress Reports Meetings: 1) Kickoff Meeting 2) Preliminary Design Review 3) Critical Design Review 4) Manufacturing Readiness Review 5) Test Readiness Review 6) Pre-Ship Review 7) Weekly Progress Meetings Documentation: 1) Materials/Process List 2) Log Books 3) Assembly Travelers 4) Photographic Inspection 5) Verification Test Plan 6) End Item Data Packages 7) Test Procedures 8) Test Reports SDRL’s and ANALYSES TYPICALLY COMPRISE NEARLY 50% OF A CONTRACT’S VALUE PROPER SELECTION CAN IMPROVE SCHEDULE & REDUCE COST

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TYPICAL RF & MECHANICAL ANALYSES:

RF Analyses: 1) RF Design Modeling 2) High Power Thermal 3) Multipaction 4) EMI 5) PIM 6) RF Data Trending 7) Worst Case Dimensional Mechanical Analyses: 1) Bearing 2) Structural (Vibration/Shock) 3) Thermal 4) Thread Engagement 5) FMEA 6) Reliability 7) Lubrication Loss 8) Life 9) Reliability

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TYPICAL FINITE ELEMENT ANALYSES

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Sinusoidal Vibration Random Vibration Shock Quasi-Static Thermal Loads Bearing & Life Bolted Joints Lubricant Loss

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TYPICAL RF ANALYSES

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RF Analysis Average Power Peak Power Multipaction Ionization Thermal Effects on RF Worst Case Analysis Distorted Geometry RF Leakage

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DIAMOND ANTENNA SPACE HERITAGE

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Customer Satisfaction:

Leading worldwide space rotary joint supplier
Exceptional customer service
Many repeat orders
Other vendor product refurbishment/legacy replacement

Design & Manufacturing Experience:

Performs 100% of the required activity (Prog Mgmt, QC, Design, Assy, Test, Shipment)
Core team has worked together for over 15 years

International Customer Base:

North America
Europe
Asia Pacific

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DIAMOND ANTENNA SPACE PROGRAM HERITAGE

15 Rotary Joint Heritage: (Pre 2013) Mars Observer: X-Band WR-90 Waveguide DSCS-3: X-Band WR-90 Waveguide Land Sat 5: X-Band Coaxial Land Sat 7: X-Band Coaxial CRSS: X-Band Coaxial Earthwatch: X-Band Coaxial Orbview: X-Band Coaxial Quickbird: X-Band Coaxial Stereo: X-Band Coaxial Rotary Joint Heritage: (2013 – Current) NASA Program: WR-34 Single Channel Waveguide NASA Program: WR-34 Single-Axis Military Program: WR-51 Multi-Axis Waveguide Military Program: X-Band Coaxial Single Channel WR-51 Program: WR-51 Dual Channel ESA Program: WR-112 & WR-28 Dual Channel, Dual-Axis Military Program: Coaxial Single Channel WR-51 Program: WR-51 Single Channel, Dual Axis Military Program: Dual Channel Coaxial Military Program: WR-51 & WR-22 Single Channel NASA Program: WR-34 Single Channel, Dual-Axis Military Program: WR-28 Single Channel, Dual Axis Military Program: Dual Channel Coaxial NASA Program: WR-112 Single Channel Mars 2020: X-Band Coaxial Single Channel Refurbishment Diamond Antenna and Microwave Proprietary Document

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Diamond Antenna & Microwave Proprietary Document

NEW IN-HOUSE TEST CAPABILITY THERMAL VACUUM CHAMBER

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Vacuum Chamber, 1 x 10-6 torr Feedthroughs for Waveguide, Coax, Thermocouples, and Wiring Servo Motor w/ Ferrofluidic Rotary Seal Torque Sensor, Vacuum Rated Rotary Joint Under Test Thermal Platen

150⁰C to + 150⁰C

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SPACE HERITAGE EXAMPLES

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

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+200o C / -80o C Temperature Range Very Severe Vibration & Shock Environment WR-112 Channel WR-28 Channel

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DUAL CHANNEL X-BAND COAXIAL:

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7.9 – 8.5 GHz (Both Channels)

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SINGLE CHANNEL WR-34:

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25.5 – 27.5 GHz

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SINGLE CHANNEL - DUAL AXIS, WR-34:

26.5 to 26.8 GHz

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SINGLE CHANNEL DUAL AXIS, WR-51:

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20.2 to 21.2 GHz

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DUAL CHANNEL COAXIAL:

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7.9 – 8.5 GHz (Both Channels)

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Diamond Antenna & Microwave Proprietary Document

SINGLE CHANNEL COAXIAL:

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7.9 – 8.5 GHz

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SINGLE CHANNEL WR-112:

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7.9 – 8.5 GHz

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PLEASE CONTACT:

Charlie Lusher

Director of Space Programs Diamond Antenna and Microwave clusher@diamondantenna.com sales@diamondantenna.com 978-486-0039 (Ext. 134)

DESIGN OR PROGRAM QUESTIONS?

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