SatNOGS Rotator v3

SatNOGS Rotator v3
SatNOGS Rotator v3
Rotator Information
Type:	Az/El
Cost:	~220 USD
Release Information
Status:	Beta
Latest Release:	Torx Flathead (v3.0.1)
Repository:	[1]
Documentation:	[2]

Intro

v3 marks a major re-haul of the SatNOGS Rotator design, with learnings from v2 applied. You can see a lot of the thinking and background research that was conducted prior to v3 development in this thread. Also in this wiki page you can also find a "How to build the rotator", mechanical analysis and all documentation about the SatNOGS rotator.

Also in this list is presented different rotators, either commercial or DIY builds.

Specifications

	SatNOGS v3 Rotator
Plastic Parts	15
Non Printed Parts	38
Cost	~ $220
Controller Electronics	SatNOGS Rotator Controller
Type	AZ/EL (possible X/Y)
Motors	2x NEMA 17 Stepper or 2x DC Motors
Frame Material	Aluminum T-slot 20x20
Speed (deg/sec)	7
Torque (Nm)	30
Brake Torque (Nm)	?
Dimensions (mm)	280x140x140 (AZ/EL)
Weight (kg)	~5

Brake Torque

The greatest force the tracker needs to withstand is the force created by strong wind. The worst case is when one antenna is elevated at 90 degs, facing the direction of the wind. We based our calculations on an article found online after comparing it to others. We “translated” the second table in metric (because we don’t understand imperial and because we needed same units system in our calculations)

Method	Wind Zone(km/h)	Height (m)	Pressure(N/m^2)
EIA-222-C	160	N/A	1280
EIA-222-F	128	14	1260
EIA-222-F	128	21	1390
EIA-222-F	128	30	1500
UBC'97	128	14	1290
UBC'97	128	21	1160
UBC'97	128	21	1390
UBC'97	128	30	1260
UBC'97	128	42	990
UBC'97	128	42	1360
Generic Formula	150	N/A	1270

and we applied the worst case model (EIA-222-F) in 3 different antennas: in the biggest one of our designs, and in two others, for which we obtained data from yaesu G800 rotator manual at page 3. We assumed that antennas are mounted in 1m away from the azimuth axis. For our antenna with 2m length (actual, not wavelength), made by 2cm square tube, the generated torque was ≈600Kg*cm. For the 144MHz 10-elements Yagi from the article is ≈6000Kg*cm and for the third 430MHz, 12-elements Yagi is ≈1800Kg*cm

Moment of inertia

Now for the moment of inertia: (for all installation methods we assumed that antennas are counterbalanced in the elevation axis) the worst case scenario here is to use two 3kg (our designs are less than 1kg) back mounted yagis with 3kg counterbalances both mounted in 0.75m away from azimuth axis. The torque you need in order to accelerate this system from ω=0deg/s angular velocity to ω=5deg/s (the math about angular velocity is below) in one second is about 60kg*cm.

Note: we suppose that the mass of antennas is near to the altitude axis, so the torque of this axis that is needed to accelerate is approximately 0.

M1: torque of Azimuth axis
L: length of center of mass of antennas from azimuth axis (0.75m)
m: mass of antennas and of counterweight (3kg + 3kg = 6kg)
I: moment inertia
a: angular acceleration of azimuth axis 5deg/s^2
I = I1 + I2 = m*L^2 + m*L^2 = 2*m*L^2 = 6.75 kg*m^2
M1 = I*a = 6.75kgm^2 * 0.087rad/s^2 = 0.58 Nm = 5.8 kgm = 58 kgcm

Angular velocity

(How well do you remember trigonometry?)For the angular velocity max needed in altitude axis the things are straightforward. The closer is the satellite the larger the velocity. According to the wikipedia article about LEO, the lowest height limit is 160 km and the speed unit to orbit earth in this altitude is 7,8 km/s. As a result, maximum velocity in ALT axis is 2,8 deg/s. In ALT AZ rotator design there is a well known limitation: the closer something passes near zenith the biggest gets the velocity of the AZ axis. Therefore, we have analyzed this problem to figure out the optimal velocity and how high we are allowed to track a target in relation to AZ velocity. The picture below illustrates a ground station B which tracks a satellite Γ in X degrees altitude. The satellite velocity at this point is vertical to the screen (page) plane.

Angular Velocity

The equations that lead to maximum altitude at which we can track in relation to AZ angular velocity are

ω : angular velocity of AZ DOF in rad/s
H = ΑΕ + ΕΓ : Minimum Height of LEO, 160 km
R = ΑΕ : Radius of Earth, 6500 km
u : linear velocity of satellite that rotates in 160km height is 7.8 km/s
ΒΔ = u / ω : ΒΔ in km
α = atan(ΒΔ / R)
δ = π - α
γ = asin( sqrt(R^2+ΒΔ^2) * sin(δ) / (H+R) )
ά = π - δ - γ
ΓΔ = (H+R) * sin(ά) / sin(δ)
χ = atan(ΓΔ / ΒΔ)

Below you can see the plot of the equations mentioned above, where horizontal axis represents angular velocity (ω) in deg/s and vertical axis shows the max track altitude (χ) for lower bound of LEO.

Angular Velocity Plot

After studying this diagram, we came up to the conclusion that an angular velocity of 5 deg/s is adequate. For this decision, we took into consideration the main lobe of antenna (Δ3db) which in most situations is about 20 deg.

General Specifications

Together with the above mentioned specifications, we would also like for the 3rd version of SatNOGS rotator to be:

inexpensive (less than €300, if possible)
lightweight and portable (~6Kg, size:~300x~150x~150mm)
rigid and durable
easy to build and fix (try to use easily available materials)
weatherproof
electromagnetically shielded, so that noise in reception is reduced
accurate (<1deg, backslash reduction and use of encoders at the axis)

Sourcing

3d Printing at a Fab Lab or your local hackerspace: If you don't have your own 3d printer, then a local Fab Lab or hackerspace may be able to do it for you. Fab Labs and hackerspaces are places that have invested in the machinery and you can take the designs to them. Generally they need .stl files to import into the software that runs the machines, but this should be discussed with the Fab Lab or hackerspace. You then pay for the material, time or a combination of the two for each of the parts or any other agreement in place.

Most people building the rotator have had success builds with simple ABS material for the 3D printing parts.

T Slot - If you don't want to cut the pieces yourself, then you may be able to find a supplier that will do this for you. (Here's one in the United Kingdom.)

Hidden corner connectors - AliExpress gave the cheapest supplier

A good US source is MISUMI-USA; they will also cut to length. MISUMI has several other global locations [3].

Beware, the 20-series T-slot from 80/20 Inc. in the US has slots that are only 5.2mm wide. The hidden corner connectors from e.g. AliExpress will not fit.

Stepper Motors - eBay

Belts - eBay

Fixings / Pipe - eBay

Build Sequence

Tools & Consumables

Here are presented tools and consumables about part fabrication, port-processing and assembly process. Most of the tools are available in every hackerspace, makerspaces, FabLabs etc.

Tool/Consumable	Description
Drill bits	2mm for aluminum, 3mm, 4mm and 5mm for plastic
Drill driver	For aluminum tube drill hole, 3D printed part
Sandpaper	80(dry), 120(dry), 240(dry) and 1000(wet) grit
Acetone	For acetone vapor bath
Hacksaw	For aluminum Tube
Square File	For worm axis, for use on steel
Precision Knife	For general use, especially in 3d-Printed parts
Caliper	Measuring Range 0-150mm
Combination Wrenches	5.5mm, 7mm and 8mm
Thread-locker	Like Loctite 271
Cyano acrylic glue	Like Loctite 401
Screw driver	Number 1 Phillips
Heat Gun	For Heat-shrinkables or use a lighter
Ball-End L-Keys	Hex 1.5mm, 2mm, 2.5mm, and 3mm
Soldering iron and consumables	For cables
Wire Cutter	For cables
Long-Nose Plier	General purpose

Parts

Make sure you have all parts, according to BOM.

Most of the parts could be fabricated by a FDM 3D-printer. Some parts have only 2D geometry so could be fabricated by a laser cutter. Other parts have modifications of common(hardware) parts like threaded rods or aluminum pipes. Also you could find a lot of guides for post processing for FDM printed parts.

C1001, Aluminum Tube 6063 OD40mm TH1.5mm L240mm, 2 variants -1 and -3
C1010-3, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1011-3, laser cut in 3mm Acrylic Sheet or in FDM-3Dprinter with same fabrication parameters as C1010-3
C1020-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material, Smoothing the part with acetone vapor bath
C1021-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material, Smoothing the part with acetone vapor bath
C1022-3, laser cut in 3mm Acrylic Sheet or in FDM-3Dprinter with same fabrication parameters as C1010-3
C1030-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1040-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1041-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1042-1, laser cut in 3mm Acrylic Sheet or in FDM-3Dprinter with same fabrication parameters as C1010-3
C1043-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], Support material, Brim Width: 2 mm
C1050, Aluminum Profile 20x20 B-type slot 6, 2 variants -1 and -5
C1060-1, M5 Threaded rod A2 stainless steel(304)
C1061, 2 variants -3 and -4, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1062-1, It is recommended to build in laser sintering like Shapeways with White Versatile Plastic (cost ~10€) or like C1030-1 and Smoothing the part with acetone vapor bath
C1070-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1071-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material
C1072-1, FDM-3Dprinted, Material: ABS, Layer height: 0.4 mm, Perimeters: 2, Top/bottom solid layers: 3, Fill density: 20%, Fill pattern: Honeycomb, Fan speed: [35, 100], No support material

Assembly

Follow the instructions for mechanical assembly and also you can watch timelapse Also, exploded views and instructions are present here.

Step 1, Prepare the assembly of worm gear
Step 2, Prepare the assembly of worm gear mount, 2 variants -1 and -2 (mirror)
Step 3, Prepare the assembly of shaft collar for worm wheel
Step 4, Prepare the encoder gear
Step 5, Prepare the Motor mount
Step 6, In case of DC motor configuration
Step 7, Bearing side without encoder and end-stop mounts
Step 8, Bearing side with encoder and end-stop mounts
Step 9, Prepare symmetric and asymmetric axis, 2 variants -1 and -3
Step 10, Frame with worm gear mount and A1001-1 assembly
Step 11, Rotator module 2 Variants -1 and -3, symmetric and asymetric
Step 12, Final step of Antenna Rotator

Rotator Controller

Once mechanical assembly is ready, construct the SatNOGS Rotator Controller.

Cover Box - Cabling

Prepare the cover box and install it to antenna rotator with rotator controller and cables

Testing

You are ready! Proceed with testing.

Mechanical Analysis [WIP]

Horizontal distance between pulleys (P1, P2) is 58mm. Vertical distance between pulleys (P1, P2) is w = 9.5mm.

Pulleys and Belt are GT2, 2mm pitch. Belt width, 6mm. Belt thickness, 1.38mm (0.76 tooth).

Wrap angle in both pulleys is larger than 60deg. At least 6 teeth in contact with the pulley at any given time. In practice that means you want a minimum of a 12 tooth pulley, and usually try to get at least 18 teeth.

Outer Diameter of pulleys:

P(T) | OD(mm)
16 | 10.2
20 | 12.7
36 | 22.9
40 | 25.5

Belt calculation (according to calculator):

Ratio | P1(T) | P2(T) | Belt(T) | L(mm)
2.25|16|36|85/86|58.65/59.66
1.8|20|36|86/87/88|57.78/58.78/59.78
2.5|16|40|87/88|58.5/59.5
2|20|40|89/90|58.65/59.66

Motor Maximun no-load speed, 200RPM = 1200deg/s Motor Maximum stall-torue, 1.2Nm

Angular Velocity

Position of idler do not care, or min 1.3*P1, max 1.5*P1 (for 20T, ~16mm/~20mm).

Belt gear selection:

20/36 with 1.8 ratio and 86T/172mm belt without idler
20/40 with 2 ratio and 90T/190mm belt with idler

To calculate Deflection force, (page T-31, sdp - design-guidelines)

Y = 2.05, Tst = 1.3kg
span length, t = 57.64mm
Belt pitch length, L = 180mm
Fd,min =
Fd,max =
2.8kg Working Tension [shapeoko - Belts and Pulleys](https://www.shapeoko.com/wiki/index.php/Belts_and_Pulleys#Tensile_Cord_Materials)

Determination of design load

According to perfomance graph of DC motor, the optimal output power is Tm = 0.6Nm with efficiency of 0.2 and 100RPM = 600deg/s. Select a service factor of 1.5 (service factors between 1.5 and 2.0 are generally recommended when designing small pitch synchronous drives). Tpeak = SF*Tm = 1.5*0.6 = 0.9Nm

Choice of belt pitch

Due to backslash and accuracy in both directions of movements and volume constrains, we choose GT2, pitch 2mm.

Check belt pitch selection based on individual graphs

Due to Tpeak = 0.9Nm No-load speed,(Speed of fastest shaft) = 100RPM = 600deg/s GT2 pitch 2mm belt is the better solution for our application.

Determine speed ratio

Speed ratio 1.8-2.25 according to specification of output rotation speed of 5deg/s.

Check belt speed

V(m/s) = 0.0000524 x pulley PD (mm) x pulley rpm = 0.066548m/s Belt speeds up to 6,500 fpm (33.02 m/s) do not require special pulleys.

Determine belt length

Table 'Belt calculation (according to calculator)' Teeth in mesh: 9

Determine the belt width

From Table 43 torque = 0.17Nm Length Correction Factor = 0.9 width multiplier = 1.00 torque*Length Correction Factor*width multiplier = 0.17*0.9*1.00 = 0.153Nm Teeth in mesh: 9 Tpeak = 0.9Nm, so belt width is nice for our application

Check the number of teeth in mesh

Teeth in mesh: 9 according to calculator

Determine proper belt installation tension

SECTION 10, on page T50, look at 'To calculate Deflection force, (page T-31, sdp - design-guidelines)'

Y = 2.05, Tst = 0.812*DQ/d + mS^2 = 12.8lb + 0 = 5.8kg
DQ = Tpeak = 0.9Nm = 7.9lb-in
d = 12.7mm = 0.5in
S = (0.5*100/3.82)/1000 = 0.0131ft/min
m = 0.039
span length, t = sqrt(CD^2 - (PD-pd/2)^2) = 57.64mm
Belt pitch length, L = 180mm
t/L = 0.32
Fd,min = 0.8lb = 0.36kg
Fd,max = 0.9lb = 0.41kg

Safety factor 1.5

P2 timing pulley torque - Maximum radial load of timing belt ball bearing 625zz

Tpeak = 0.9Nm TorqueP2 = 2*0.9Nm = 1.8Nm, PDp2 = 25.5mm Radial static load of 625ZZ is 0.38kN T-39

Maximum thrust load of timing belt ball bearing 625zz

Maximum radial and thrust load of output ball bearings 6008zz

Calculate or evaluate correct loads for deep groove ball bearings radial static load = 11.6kN thrust static load = 0.7*11.6kN = 8.12kN This type of construction permits the bearings to support relatively high thrust load in either direction. In fact the thrust load capacity is about 70% of the radial load capacity. A ball bearing primarily designed to support radial load can also support high thrust load; because only few balls carry the radial load, whereas all the balls can withstand the thrust load.

Maximum self-locking or back-drivable torque of gear box (according to more weak component)

It necessary to achieve [specs](https://community.libre.space/t/satnogs-rotator-version-3/226), 60Nm (6Kg in 1 meter)

Nominal torque of drivable torque of gear box (according to more weak component) and maximum rotational speed of gear box

Notes:

Motor Specification

General Specification about motors. The voltage and current consumption also it depends from the motor controller which is (maybe) different from SatNOGS Rotator Controller.

Specification	Value
Min-Max Stall Torque (Nm)	0.4 - 1.5
Min-Max Speed (RPM)	100 - 200
Size (mm) (LxWxH)	47x42x64

Motor mount dimensions
Maximum Motor Height

Worm Gear Box Calculations

Gear ratio: i12 = 30
Angle between axis of gears: δ = 90 deg
Number of threads in worm: If i12 >= 30 then z1 = 1
Number of teeth in worm wheel: z2 = i12*z1 = 30
Center distance: initial case a = 45.5 mm
Worm reference diameter: AGMA d01>= 11.5*(a/25.4)^0.875 = 19.15 mm, so d01 = 19.5mm
Worm wheel reference: d02 = 2*a - d01 = 71.5 mm
Axial module: ms = d02/z2 = 2.38 , so ms = 2.5

Recalculate d02, a with new axial module

d02 = z2*ms = 75mm, a = (d02+d01)/2 = 47.25mm
Axial pitch: ts = π*ms = 7.854mm
Reference lead angle: γ0 = atan(d02/(i12*d01)) = 7.3 deg
Worm tip diameter: dk1 = d01 + 2*hk = 24.5mm
- Worm teeth reference addendum in axial section: hk = hk* *ms = 2.5mm
- Worm tooth reference addendum coefficient: hk* = 1
Worm root diameter: df1 = d01 - 2*hf = 13.5mm
- Worm tooth reference dedendum: hf = hf* _ms = 1.2_ms = 3mm
- Dedendum coefficient: hf* = 1.2
Worm length: L = 2.5_ms_sqrt(z2+2) = 35.36mm
Worm tooth thickness: smx1 = smx1* * ts = 3.927mm
- Tooth thickness coefficient: smx1* = 0.5
Normal pressure angle: aon = 20 deg
Worm wheel throat diameter: dk2 = d02+2*hk = 80mm
Worm wheel root diameter: df2 = d02 - 2*hf = 69mm
Worm wheel outside diameter: de2 = dk2 + 2*mx = 83.5mm
- Worm wheel tooth external addendum: mx = n*ms, 0.4<=n<=1.5
Effective worm wheel face width: b2H,max = sqrt((2_a - df2)^2 - (2_a - de2)^2) = 23mm

Test Sequence [WIP]

Test sequence needed