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 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 2 Diamond Antenna and Microwave Proprietary Document
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 3 Diamond Antenna and Microwave Proprietary Document
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 4 Diamond Antenna and Microwave Proprietary Document
DIAMOND ANTENNA SPACE ASSEMBLY AREA: Class 10,000 Clean Room Class 100 Laminaire Flow Bench Black Light Cleanliness Inspection RF Testing in Clean Room Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 5 Proprietary Document
DIAMOND ROTARY JOINT DESIGN PROCESS: (Typical) RF Modeling of Transient, Frequency, Thermal & Mechanical Deformation Solvers Available RF Modeling Design Final RF Mechanical Drawing Package Modeling Assembly Model Release Verification Design Cycle Repeated as Required Mechanical Analysis Manufacturing Period Package 6 Diamond Antenna and Microwave Proprietary Document
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 7 Diamond Antenna & Microwave Proprietary Document
RF MODELING ACCURACY: (WR-34 Waveguide Design) EXAMPLE 1 VSWR Model No Tuning Needed Prediction Initial Measured Initial Measured VSWR Actual VSWR Diamond Antenna and Microwave Proprietary Document Diamond Antenna & Microwave 8 Proprietary Document
RF MODELING ACCURACY: (Coaxial Design) EXAMPLE 2 No Tuning Needed Initial Measured CST Predicted VSWR VSWR Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 3/5/2020 9 Proprietary Document
TYPICAL PROGRAM SDRLS: SDRL’s and ANALYSES TYPICALLY COMPRISE NEARLY 50% OF A CONTRACT’S VALUE PROPER SELECTION CAN IMPROVE SCHEDULE & REDUCE COST Quality/Program Related: Meetings: Documentation: 1) MIP/KIP Plan 1) Kickoff Meeting 1) Materials/Process List 2) Quality Plan 2) Preliminary Design Review 2) Log Books 3) PA Conformance Plan 3) Critical Design Review 3) Assembly Travelers 4) PID Document 4) Manufacturing Readiness Review 4) Photographic Inspection 5) Configuration Control Plan 5) Test Readiness Review 5) Verification Test Plan 6) Cleanliness Control Plan 6) Pre-Ship Review 6) End Item Data Packages 7) Critical Item List 7) Weekly Progress Meetings 7) Test Procedures 8) Risk Management Plan 8) Test Reports 9) Risk Register 10) Schedules & WBS 11) Product Tree 12) Progress Reports 10 Diamond Antenna and Microwave Proprietary Document
TYPICAL RF & MECHANICAL ANALYSES: Mechanical Analyses: RF Analyses: 1) Bearing 1) RF Design Modeling 2) Structural (Vibration/Shock) 2) High Power Thermal 3) Thermal 3) Multipaction 4) Thread Engagement 4) EMI 5) FMEA 5) PIM 6) Reliability 6) RF Data Trending 7) Lubrication Loss 7) Worst Case Dimensional 8) Life 9) Reliability 11 Diamond Antenna and Microwave Proprietary Document
TYPICAL FINITE ELEMENT ANALYSES Sinusoidal Vibration Random Vibration Shock Quasi-Static Thermal Loads Bearing & Life Bolted Joints Lubricant Loss Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 12 Proprietary Document
TYPICAL RF ANALYSES RF Analysis Average Power Peak Power Multipaction Ionization Thermal Effects on RF Worst Case Analysis Distorted Geometry RF Leakage Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 13 Proprietary Document
DIAMOND ANTENNA SPACE HERITAGE 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 Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 14 Proprietary Document
DIAMOND ANTENNA SPACE PROGRAM HERITAGE 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 & Microwave Diamond Antenna and Microwave Proprietary Document 15 Proprietary Document
NEW IN-HOUSE TEST CAPABILITY THERMAL VACUUM CHAMBER Servo Motor w/ Ferrofluidic Vacuum Chamber, Rotary Seal 1 x 10 -6 torr Torque Sensor, Vacuum Rated Feedthroughs for Waveguide, Coax, Thermocouples, and Wiring Thermal Platen -150 ⁰ C to + 150 ⁰ C Rotary Joint Under Test Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 16 Proprietary Document
Diamond Antenna and Microwave SPACE HERITAGE EXAMPLES Diamond Antenna and Microwave Proprietary Document Approved for Global Viewing 17
DUAL CHANNEL DUAL AXIS WR-112 / WR-28: +200 o C / -80 o C Temperature Range Very Severe Vibration & Shock Environment WR-28 Channel WR-112 Channel Diamond Antenna and Microwave Proprietary Document 18
DUAL CHANNEL X-BAND COAXIAL: 7.9 – 8.5 GHz (Both Channels) Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 19 Proprietary Document
SINGLE CHANNEL WR-34: 25.5 – 27.5 GHz Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 20 Proprietary Document
SINGLE CHANNEL - DUAL AXIS, WR-34: 26.5 to 26.8 GHz Diamond Antenna and Microwave Proprietary Document 21
SINGLE CHANNEL DUAL AXIS, WR-51: 20.2 to 21.2 GHz Diamond Antenna and Microwave Proprietary Document 22
DUAL CHANNEL COAXIAL: 7.9 – 8.5 GHz (Both Channels) Diamond Antenna and Microwave Proprietary Document 23
SINGLE CHANNEL COAXIAL: 7.9 – 8.5 GHz Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 24 Proprietary Document
SINGLE CHANNEL WR-112: 7.9 – 8.5 GHz Diamond Antenna & Microwave Diamond Antenna and Microwave Proprietary Document 25 Proprietary Document
DESIGN OR PROGRAM QUESTIONS? PLEASE CONTACT: Charlie Lusher Director of Space Programs Diamond Antenna and Microwave clusher@diamondantenna.com sales@diamondantenna.com 978-486-0039 (Ext. 134) 26 Diamond Antenna and Microwave Proprietary Document
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