Computer Science – Performance
Scientific paper
Jul 2005
adsabs.harvard.edu/cgi-bin/nph-data_query?bibcode=2005esasp.591..185m&link_type=abstract
In: Proceedings of the 11th European Space Mechanisms and Tribology Symposium, ESMATS 2005, 21-23 September 2005, Lucerne, Switz
Computer Science
Performance
Pointing Mechanisms
Scientific paper
This paper describes the two axis Antenna Pointing Mechanism (APM) with dual frequency (X-Ka bands) Rotary Joint (RJ) developed by Kongsberg Defence and Aerospace and BAE Systems, in the frame of the ESA BepiColombo mission to the planet Mercury. The extreme environmental conditions induced by Mercury's proximity to the Sun (up to 14.500 W/m2 direct solar fluxes, up to 5000 W/m2 infrared flux and up to 1200 W/m2 albedo shine form the planet surface), have dictated the need for a specific high temperature development of the pointing mechanism and of its integrated RF Rotary Joint. Global thermal analysis of the antenna predicts qualification temperature for the elevation stage APM between 250°C and 295°C. In addition, the mechanism shall survive extreme cold temperatures during the interplanetary cruise phase. Beside the harsh environment, the stringent pointing accuracy required by the antenna high frequency operations, and the extreme dimensional stability demanded by a radio science experiment (which is using the antenna for range and range rate measurements), have introduced additional, specific challenges to the mechanism design. Innovative solutions have been deemed necessary at system architecture level, in the design of the mechanisms critical areas and in the selection of high temperature compatible materials and processes. The very high working temperature of the mechanism ruled out use of aluminium alloys, which is replaced by Titanium alloy and stainless steels. Special heat treatments of the steel are applied for minimum loss of hardness. The structures are optimised for minimum mass. To handle thermal stresses and distortion, a very compact design of the APM was performed integrating the bearings, position sensor and drive chain within minimum structural length. The Rotary Joint is a unique design tailored to the APM using a common main bearing support. Special manufacturing processes have been tested and applied for manufacture of the very compact RJ being the first of its kind (dual X-Ka band) in European space development. The twin channels are arranged concentrically, permitting continuous 360° rotation. Maximum use of waveguide has been made to minimise the loss in the Ka-band frequency channel and this leads to an unconventional design of the X-band channel. A specific effort and extensive test program at ESTL in the UK have been put in place to identify suitable high temperature solutions for the RJ and APM bearings lubrication. The high temperature demands the use of a dry lubrication system. High working loads due to thermal stresses puts extra challenge to the life duration of the dry film lubrication. Lead lubrication was initially the preferred concept, but has later in the program been substituted by MoS2 film. A design life of 20,000 cycles at 250°C and elevated load has been demonstrated for the bearings with MoS2. Special attention has been paid to the materials in the stepper motor using high temperature solder material and MoS2 dry lubrication in the bearings and gear train. The APM is designed for use of a high accuracy inductive based position sensor with remote signal and amplifier electronics. Electrical signal transfer is via a high temperature Twist Capsule. The activity has included the design, manufacturing and testing in a respresentative environment of a breadboard model of the APM and of its integrated radio frequency RJ. The breadboard does not include a position sensor or the Twist Capsule. The breadboard tests will include functional performance tests in air, vibration tests and thermal vacuum. The thermal vacuum test will include RF testing at high temperature combined with APM pointing performance.
Anderson Mike
Harper Richard
Mürer Johan A.
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