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
Diamond Antenna and Microwave Proprietary Document
Approved for Global Viewing
SPACE ROTARY JOINTSOVERVIEW &
CAPABILITY BRIEF
Prepared By: Charlie LusherDirector of Space Programs and Lead RF Design EngineerDiamond Antenna and Microwave
WHY USE A ROTARY JOINT IN SPACE?
PRODUCT/MISSION RELIABILITY
LONG LIFE
DESIGN FLEXIBILTY
EXCELLENT RF PERFORMANCE (MUCH BETTER THAN CABLE WRAPS)
STABLE THERMAL & VACUUM PERFORMANCE
HIGH MULTIPACTION MARGINS
VERY LOW TORQUE
NO ROTATION LIMITS (MORE ROBUST THAN FLEXIBLE WAVEGUIDE AND CABLE WRAPS)
LOW OUTGASSING MATERIALS USED
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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
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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
DIAMOND ROTARY JOINT DESIGN PROCESS:
(Typical)
RF Modeling Design
Mechanical Assembly Model
AnalysisPeriod
Mechanical Manufacturing
Package
Final RF Modeling
VerificationDrawing Package
Release
RF Modeling of Transient, Frequency, Thermal &
Mechanical Deformation Solvers Available
Design Cycle Repeated as Required
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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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RF MODELING ACCURACY: (WR-34 Waveguide Design)
EXAMPLE 1No Tuning NeededVSWR Model
Prediction
Initial Measured
VSWR
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Initial Measured
Actual VSWR
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RF MODELING ACCURACY: (Coaxial Design)
EXAMPLE 2No Tuning Needed
CST Predicted
VSWR
Initial Measured
VSWR
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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
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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
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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
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 ChannelWR-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
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
DUAL CHANNEL COAXIAL:
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7.9 – 8.5 GHz
(Both Channels)
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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
PLEASE CONTACT:
Charlie Lusher
Director of Space ProgramsDiamond Antenna and Microwave
978-486-0039 (Ext. 134)
DESIGN OR PROGRAM QUESTIONS?
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