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KAT7 Antenna DevelopmentWillem Esterhuyse
MeerKAT Project Manager
(Subsystem manager: Antenna Structures)
083 447 1615
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Introduction
• Introduction
• Technical focus (last year - XDM)
• Process/Strategy
• Touch on Progress
• Antenna Development Phases/Goals
• Basics (and did we follow them)
• XDM/KAT7 (one piece composite)
• Detail
• Progress
• Optimize performance/cost
• Conclusion
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Antenna Development Phases/Goals
XDM (Done)
Design Optimization(Done)
KAT7 – Manufacture started
MeerKAT
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GOAL
• Cost effective antenna for
MeerKAT
• Costed antenna option to
which we own the IP that
would be considered as an SKA
option
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Main Specifications and Design Goal XDM
KAT7Spec Achieved
Pointing Accuracy (deg) 0.04 25” RMS 25” RMS (target 15)
Surface Accuracy (mm rms) 4 1.8 1.5 (target 1)mm
Frequency Range (MHz) 700 - 1700 Up to 8 GHz Up to 8 GHz
Wind (Operational) km/h 20 36 36
Wind (Marginal Operation) km/h 36 45 45
Wind (Drive to Stow) km/h 36 55 55
Wind (Survival) km/h 160 160 160
Azimuth Rotation speed (deg/s) 1 2 2
Elevation speed (deg/s) 0.5 1 1
Diameter 15 15 12
F/D 0.5 0.5 0.38
Lowest Natural Frequency (Hz) 3 3+ 3+
Feed Mass (kg) 200kg with rotator 75kg no rotator
Mount Type All-Az Alt-Az
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Project Basics
• Development projects (any project) need
• Good Upper and Project Level Management
• Culture/support
• Good process (coupled with a healthy dose of common
sense)
• Apply to system and subsystems
• System Engineering tailored to your project/people
• Interfaces/Responsibilities clearly defined
• Good people (most important) – think marriage
• Any project need a Champion/Champions
• Attitude/Domain Specialist
• Experience (innovation vs. apply existing technologies/techniques)
• Design/Analyses and others
• Diligent
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Luck – “I’ll be lucky rather than good any day ”Gary Bevilacqua (Caterpillar)
“Better is the biggest enemy of good enough”Kobus Meiring (SALT)
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Applied to Antenna SS
Basics – Process
• Simple process – question is how well you execute it
• There will often be pressure not to follow this – tailor to your
system, but understand risk of omitting stages (and live with it)
• Things get tight – following is neglected
• Design Review and Acceptance testing
• System Integration/Operation hampered by unreliable subsystems
User requirements definition
User spec (reviewed/signed off)
System design & modeling (trade-offs)
System spec (reviewed/signed off)
Sub-system design & prototyping (trade-offs)
Sub-system spec (reviewed/signed)
Component spec
Operational testing
System int & test
Sub-system int & test
Detail design, design reviews, acceptance
testing definition, datapacks, manufacture
Component int & test
Verification
Verification
Verification
Validation
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Basics – Design Reviews
Why Design Reviews are critically important
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Basics – Acceptance Testing• Example of VCRM on XDM – 130 requirements that required testing
• Difficult to test all requirements for all possible events
Section in spec. Section
Test Level
Test Method Reference
Approval Note
Approval/
Date
aThe estimated mass of the structure is TBD kg (excluding the controls and drives). N/A N/A N/A N/A N/A N/A
b
The lowest natural frequency of the structure shall be more than 3 Hz, analyzed with the weight of the FPA (see 5.2.1.3) included and making provision for electrical and control cabling and cabling duct weights, the routing of which is TBD. System
Analysis, Test
5.15 (Control Test) and KAT7200PR1007-0037002
Issue 1 (FEA Analyses) Pass
FEA Analyses lowest frequency 4.2 Hz excluding servo's. Azimuth 2.4 Hz,
Elevation 3.5 Hz - this include drivetrain stiffnesses, but is
included as info.. 6.2.1.1.3Wind Loads and Deflections N/A N/A N/A N/A N/A N/A
aThe operating wind speed is given in Table 2 in section 5.3.2.1. Info Info Info Info Info Info
6.2.1.1.3.2
The wind loading as a result of this wind speed, combined with gravitational and thermal effects and manufacturing and alignment inaccuracies shall not cause reflecting surface inaccuracies of more than the value specified in section 6.2.1.8.2. Info Info
KAT7200TP2000-51002 Issue 1 par 3 / 6.2.1.8.1.g Info
6.2.1.1.4Tolerances N/A
6.2.1.1.4.1
The required accuracy of the reflecting surface shall be 4mm RMS (target of 2mm RMS) or better and 6mm maximum (target 3mm) - this shall include gravity, thermal and wind influences (operating wind speed - see section 5.3.2.1 - in any position) as well as manufacturing and alignment inaccuracies. Info
Analyses, Measure
KAT7200TP2000-51002 Issue 1 par 3 / 6.2.1.8.1.g/h Info
aThe survival conditions are given in Table 4 in section 5.3.2.3. Info Info Info Info Info Info
b
The surface errors shall be measured relative to the best fit parabola, y=(x2+z2)/(4*fd) where "fd" is the focal distance (7500mm), and the FPA displacement (see section 6.2.1.9) shall be calculated relative to this parabola. Info
Analyses, Measure
Measurements was done relative to best parabola with
variable focal length as discussed with Mike Gaylard. Info Info
cThe variations in surface accuracy shall not be systematic (variations shall be random). System Review KAT7200PR1003 Variation
Slight systematic variations, but that does not appear to impact on the performance. See NRF-XDM-0.0-TR0013.
6.2.1.1.5Lightning Protection N/A N/A N/A N/A N/A N/A
aThunderstorms occur on the site so the antenna must be equipped with a lightning protection system. System Inspection
MESA report - HartRAO XDM visit 18 July07 Pass
bA spike shall be placed at the FPA System InspectionMESA report Hartrao XDM 18
July 2008. Variation
Direct Strikes on XDM very unlikely (26m has not had one
and is much higher) - the MESA report therefore caters
mostly for indirect strikes.
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People
• Project Time pressure – subcontract structural design
manufacture
• Antenna Structure – tender (IST(BAE)) – XDM/KAT7• Dish – MMS
• EM design – EMSS• Feed into specification + design reviews
• Lightning/RFI – MESA (Prof HC Reader + students)• Feed into specification + design reviews
• HartRAO - Dr. Mike Gaylard/Dr. George Nicholson/Prof. Roy Booth
• Director Science/Engineering – Prof. Justin Jonas
• Experience
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People – Antenna Structures - IST
XDM
• IST Dynamics (now BAE)
• Prime contractor XDM – open Tender
• High tech electro-mechanical systems + software
• Military is biggest client
• Antennas – apply existing knowledge/expertise• Reduced risk
• Experience working with them?
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People – Antenna Structures - BAE
KAT7
• BAE (previously IST Dynamics) – open Tender
BAE GD SatCom Cobham/ Patriot
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People – Dishes - MMS
• MMS
• Subcontracted by IST/BAE
• Dish construction and design
• Exceptional experience in Composite
design and manufacture
• Existing for more than 20 years
• Antennas – apply existing
knowledge/process
• Reduced Risk *Work Ethic
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People – EM Design - EMSS
• Optical design (dish shape)
• Tolerances
• Feed leg shape/details
• Deflector
• It’s in the detail
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People – MESA
• Lightning/RFI – MESA (Prof Howard Reader)
• Fundamental Understanding – NB for flame sprayed dish
• Scale model – verify analyses results
• Build understanding/Confidence
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XDMVisual Recap – detail and lessons learned
shown under KAT7
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KAT7
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ANALYSES - CFD
• Detailed CFD (Computational Fluid Dynamics) analyses
to determine pressures on dish as result of wind
loading (for use in FEA analyses)
• Results compared to published results – good correlation
• Results compared with limited experimental data – good
correlation
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Analyses - FEA
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Mode
1:
4.51 Hz
Mode 2:
5.5 Hz
ANALYSES - MODAL
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ANALYSES - CADFEKO
• Lightning/RFI – MESA (Prof Howard Reader)
• Fundamental Understanding – NB for flame sprayed dish
• Scale model – verify analyses results
• Build understanding/Confidence
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Experiments – Pointing/Temp• Steel Pedestal
• Measure Existing steel
pedestal
• Paint heat performance
• Result – Paint selected +
Sunshield
• Temp sensors
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Integration before going to Site
• Industrialization version
• PTA in BAE parking lot
• Minimize time/integration on
site
• Control loops
• Cables
• Catch manufacturing issues
early
• Trial assembly
• Simulate dish influence
• 3x counterweight frames
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KAT7 Improvements (from XDM)• Mould
• Pattern Aluminium (KAT7) vs. Wood
(XDM)
• Mould Setup/Conditions
• Improved surface accuracy
• Analyses
• Thermal design improved (thin open
sections)
• FEA - Increased stiffness
• Dish surface error less
• Feed displacement less
• Better pointing
• EM design
• Dish shape optimized (for single pixel
feed)
• Cone Deflector improved detail
• Feed leg shape optimized (including
structural)
• RFI/Lightning protection design
improved
• Control system improved
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Mould
• Practical Lessons learnt
XDM
• Setup
• Dish off mould
• Process proven XDM
• KAT7 conditions more
controlled, more
accurate mould
• Result TBD, but
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HOT OFF THE
PRESS
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Control
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Pedestal Layout
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Conclusion• Development of low cost dish for KAT7
• Define sensible stages
• Good process
• SE, design reviews, testing
• Good people / detail orientated
• Dedicated, competent
• Analyses, Experiments, Scale models
• Common Sense prevailed (mostly )
• Low cost Poor performance (Improve XDM)
• Remaining work• Complete KAT7
• MeerKAT
• MeerKAT Detail design (changes from KAT7 )
• Another prototype might be required
• Manufacturing processes (optimize cost)
• MeerKAT (and SKA )