ISO OEM precision metal stamping process
Pacific Antenna Systems (PAS) designs, processes and manufactures advanced antenna systems using 1-110Ghz radio frequency (RF). ISO OEM precision metal stamping process
Applications for these antenna systems include high-resolution radar, high-rate data communications for line-of-sight and satellite (SATCOM) communications, and high-power microwave systems for countermeasures against unmanned aerial vehicles (UAS).
The basic working principle of the antenna is to precisely locate the radio frequency beam on the target point. PAS employs a number of different electromechanical designs in the antenna depending on the specific application. A rotary position encoder is installed on each motion axis (gimbal joint) to meet accuracy and precision requirements. ISO OEM precision metal stamping process
The working environment of the airborne system is very harsh, for example, the temperature is lower than zero, the radio frequency noise is large, and the mechanical vibration is strong, which increases the difficulty of grating selection.
Previously, PAS antenna systems were plagued by grating performance issues, such as low accuracy, poor resistance to radio frequency interference, and weak resistance to vibration. ISO OEM precision metal stamping process
Renishaw encoder products have helped PAS improve the positioning accuracy and resolution of its servo control loop by more than two orders of magnitude.
challenge
In airborne applications, radar and radio frequency communication systems need to be light in weight, small in size, and powerful in power. In addition, it must be modular and easy to assemble. ISO OEM precision metal stamping process
Mr. AnthonyJ.Macri, vice president of PAS, introduced the challenges brought by the above requirements to the design: “What we value is: size, weight and power (Size, Weight and Power-SWAP). For each product in the airborne radar and communication fields, That said, SWAP is an extremely important parameter. Our challenge is to position the beam on the target. We use very narrow beams in RF systems, especially in the millimeter (mm) band. In the 95Ghz bandwidth, Beam widths can be as low as a few hundredths of a degree. Once the antenna is mounted on the platform, there is an error budget for the navigation data. If the accuracy and resolution of the grating mounted on the gimbal is poor, the RSS of the antenna system is pointing Errors will increase, resulting in failure to locate the target.”
PAS airborne communication systems are critical for high data rate communications in aircraft such as NASA’s WB57 experimental research aircraft. The gratings on each gimbal must operate at altitudes above 40,000 feet and temperatures below ~40F. High rotational speeds and accelerations are the basis for fast beam pointing and scanning operations. ISO OEM precision metal stamping process
In communications and radar applications, light grids are critical components that must guarantee high reliability, as any failure can be life-threatening.
solution
PAS uses different gimbal designs for single-station radar and communication systems, but these designs use RESOLUTE absolute encoders that are compatible with the BiSS-C serial protocol and have options of 26-bit or 32-bit resolution. ISO OEM precision metal stamping process
Mr. Macri said: “We have ingeniously used RESOLUTE gratings in radar, line-of-sight and satellite communication antennas as well as high power microwave systems. We chose this grating because of its high accuracy and resolution for our control loops. We used this grating on a UH60 Blackhawk helicopter as part of an anti-collision radar. The vibration environment on the UH60 is extremely harsh, and we found that the RESOLUTE grating is extremely resistant to vibration. If the grating vibrates and cannot count, it will Control cycles were detrimental. RESOLUTE encoders met our precision and robustness requirements.”
The PAS single-station radar system consists of many components, including the RF array feed at the bottom, and a series of lenses mounted on a two-axis gimbal and driven by a direct-drive motor. Each motor is mechanically coupled to a RESOLUTE Extended Temperature Range (ETR) grating system with a 75mmD cross-section RESA ring for feedback control of lens rotation. ISO OEM precision metal stamping process
Mr Macri added: “The grating is offset mounted and coupled directly to the drive system because the motor is very small. The motor consists of a rotor assembly and a stator assembly, and we couple the ring to the rotor assembly. When the motor rotates , while also precisely rotating the circular grating relative to the grating readhead located outside the entire mechanism. The advantage of this radar application is that the RF energy propagates in free space through the bore of each motor.”
RF communication systems use a similar design, but with more traditional slip rings, rotary joints, and coaxial media. In this case, the open bore of the Renishaw RESA ring provides the space and functionality required at the top of each axis of rotation. ISO OEM precision metal stamping process
result
Renishaw’s RESOLUTEETR encoders are compatible with the BiSS-C protocol, enabling PAS to design and build advanced antenna systems for a variety of applications.
Mr. Macri emphasized the advantages of choosing RESOLUTE gratings in the antenna system: “We appreciate the many characteristics of RESOLUTE, including ease of use, high accuracy and high resolution, as well as reliability and suitability in harsh environments. During assembly , our technicians can manually align the encoder readhead using a feeler gauge, which is a quick process. Also, RESOLUTE encoder’s advanced diagnostic and installation tools help quickly resolve any installation issues. The PAS uses a BiSS-C string for encoder signal output It is a good protocol because it has an open structure, is easy to use, and runs fast. Most importantly, the protocol has a long cyclic redundancy check (CRC) number of bits. In the event of a problem, the user can immediately know. Manufacturing speed and efficiency as well as delivery reliability are key when it comes to the product life cycle. RESOLUTE encoders help us do that.” ISO OEM precision metal stamping process
In a PAS radar system, the lens rotates at speeds in excess of 7,000 degrees per second and has accelerations in excess of 40,000 degrees per second. Due to the unique single-track design, RESOLUTE encoders are able to achieve ultra-high resolution at high operating speeds. This performance brings the PAS radar system’s target position measurement accuracy to a market-leading level.
Mr. Macri concluded: “We use 32-bit rasters, but only truncate about 18 bits. For us, the big advantage is that the precision values and the resolution are very close to the LSB (least significant bit). When the raster is set to With 18-bit BiSS, precision and resolution mesh perfectly. We need repeatability to within a thousandth of a degree. Due to the criticality of the application, all components on these assemblies must be tested. RESOLUTE goes well beyond our expected.”
Company Profile
Headquartered in California, Pacific Antenna Systems (PAS) uses advanced electromagnetic modeling and simulation tools to design aesthetically pleasing and affordable antenna systems for communications, satellite communications, radar, and high-energy microwave applications. PAS also specializes in solving complex antenna system problems for customers, providing rapid design and prototyping services. PAS’s range of services includes consulting, design, manufacturing and safety analysis. ISO OEM precision metal stamping process
About Renishaw
Renishaw is one of the world’s leading engineering technology companies with expertise in precision measurement and healthcare. The company provides products and services to a wide range of industries and fields – from aircraft engine and wind turbine manufacturing to medical devices for oral and brain surgery. Furthermore, it
It is also a global leader in additive manufacturing (also known as 3D printing), a company that designs and manufactures additive manufacturing equipment for industrial use that “prints” parts from metal powders. ISO OEM precision metal stamping process
The Renishaw Group currently has 79 branches in 37 countries and employs 4,400 people, of which more than 2,500 are based in the UK. Most of the company’s research and development and manufacturing is carried out in the UK, and in the 2020 financial year to June 2020, Renishaw achieved sales of £510 million, 94% of which came from exports. The company’s largest markets are China, the United States, Japan and Germany. ISO OEM precision metal stamping process
