Antenna Scan Mechanism for an Inter Satellite Link of a Constellation Program

For a constellation program, RF Inter Satellite Links between single satellites can support ranging and communication for uploading mission data or telecommands. These data shall be uploaded from one single ground station to the next reachable satellite and transmitted by the Inter Satellite Link to further dedicated satellites. For this function each satellite has to be equipped with 2 Antenna Scan Mechanisms (ASM) for data transfer in the K-Band.The main challenges for the mechanisms are the high speed position change requirement, low mass requirement and the design to cost approach. Furthermore a small envelope to accommodate the 2- axes antenna scan mechanism was provided. The maximum position change of +/- 180° needs to be reached within 3 seconds. All requirements shall be achieved by relying on the heritage design of our downlink antenna pointing mechanism product.The ASM design approach was based on our 2-axes steerable downlink antenna; however during the definition phase it turned out that some major changes have to be implemented due to mission requirements (high operation speed and long lifetime). Following the design to cost approach most components could be procured from industrial standard but had to be qualified in terms of functionality, performance and life. The following industrial components have been selected: - Bearings procured from an industrial supplier and modified (cage) by a supporting supplier - The selected actuator is a standard stepper motor equipped with redundant windings - The slip ring design was used from a previous project in order to keep the heritage - Suitable rotary joints for the RF link were provided by a small and flexible company However at the very beginning of the project some difficulties with the bearings selection and procurementhave been identified. Since the most suitable standard catalog bearings were not available in time, we were forced to use alternatives. In parallel due to envelope constrains the re-location of one actuator followed by additional design modifications became necessary. Finally this design modification impacts the bearing loads and consequently the selection of other bearings became necessary.The paper will show the error propagation generated by lead time issue of a main component and the test results of the final design including friction tests, and first measurements during the life test program.