Difference between revisions of "SatNOGS Rotator v3"

From SatNOGS Wiki
(Add notes for assembly instructions)
(Add more details to Counterweight for Antenna)
 
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== Intro ==
+
==Introduction==
  
 
v3 marks a major re-haul of the SatNOGS Rotator design, with learnings from [[SatNOGS Rotator v2|v2]] applied. You can see a lot of the thinking and background research that was conducted prior to v3 development in this [https://community.satnogs.org/t/satnogs-rotator-version-3/226 thread]. Also in this wiki page you can also find a "How to build the rotator", mechanical analysis and all documentation about the [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator SatNOGS rotator].
 
v3 marks a major re-haul of the SatNOGS Rotator design, with learnings from [[SatNOGS Rotator v2|v2]] applied. You can see a lot of the thinking and background research that was conducted prior to v3 development in this [https://community.satnogs.org/t/satnogs-rotator-version-3/226 thread]. Also in this wiki page you can also find a "How to build the rotator", mechanical analysis and all documentation about the [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator SatNOGS rotator].
Line 20: Line 20:
  
 
{| {{table}}
 
{| {{table}}
| align="center" style="background:#f0f0f0;" |
+
| style="background:#f0f0f0;" align="center" |
| align="center" style="background:#f0f0f0;" |'''SatNOGS v3 Rotator'''
+
| style="background:#f0f0f0;" align="center" |'''SatNOGS v3 Rotator'''
 
|-
 
|-
| Plastic Parts || 15
+
|Plastic Parts||15
 
|-
 
|-
| Non Printed Parts || 38
+
|Non Printed Parts||38
 
|-
 
|-
| Cost||~ $220
+
|Cost||~ $220
 
|-
 
|-
| Controller Electronics|| [[SatNOGS Rotator Controller]]
+
|Controller Electronics||[[SatNOGS Rotator Controller]]
 
|-
 
|-
| Type||AZ/EL (possible X/Y)
+
|Type||AZ/EL (possible X/Y)
 
|-
 
|-
| Motors||2x NEMA 17 Stepper or 2x DC Motors
+
|Motors||2x NEMA 17 Stepper or 2x DC Motors
 
|-
 
|-
| Frame Material|| Aluminum T-slot 20x20
+
|Frame Material||Aluminum T-slot 20x20
 
|-
 
|-
| Speed (deg/sec) || 7
+
|Speed (deg/sec)||7
 
|-
 
|-
| Torque (Nm) || ?, ~30
+
|Torque (Nm)||?, ~30
 
|-
 
|-
| Brake Torque (Nm) || ?
+
|Brake Torque (Nm)||?
 
|-
 
|-
| Dimensions (mm) || 280x140x140 (AZ/EL)
+
|Dimensions (mm)||280x140x140 (AZ/EL)
 
|-
 
|-
| Weight (kg) || ~5
+
|Weight (kg)||~5
|  
+
|
 
|}
 
|}
  
==== Design Goals ====
+
====Design Goals====
 
Considering the specifications as detailed in the [https://wiki.satnogs.org/SatNOGS_Rotator_v3#Mechanical_Analysis_.5BWIP.5D Mechanical Analysis], we would also like for the 3rd version of SatNOGS rotator to be:
 
Considering the specifications as detailed in the [https://wiki.satnogs.org/SatNOGS_Rotator_v3#Mechanical_Analysis_.5BWIP.5D Mechanical Analysis], we would also like for the 3rd version of SatNOGS rotator to be:
  
* inexpensive (less than €300, if possible)
+
*inexpensive (less than €300, if possible)
* lightweight and portable (~6Kg, size:~300x~150x~150mm)
+
*lightweight and portable (~6Kg, size:~300x~150x~150mm)
* rigid and durable
+
*rigid and durable
* easy to build and fix (try to use easily available materials)
+
*easy to build and fix (try to use easily available materials)
* weatherproof
+
*weatherproof
* electromagnetically shielded, so that noise in reception is reduced
+
*electromagnetically shielded, so that noise in reception is reduced
* accurate (<1deg, backlash reduction and use of encoders at the axis)
+
*accurate (<1deg, backlash reduction and use of encoders at the axis)
  
== Sourcing ==
+
==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.
 
'''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.
  
* [http://www.fabfoundation.org/fab-labs FabLabs]
+
*[http://www.fabfoundation.org/fab-labs FabLabs]
* [https://wiki.hackerspaces.org/List_of_Hacker_Spaces List of hacker spaces]
+
*[https://wiki.hackerspaces.org/List_of_Hacker_Spaces List of hacker spaces]
  
 
Most people building the rotator have had success builds with simple ABS material for the 3D printing parts.
 
Most people building the rotator have had success builds with simple ABS material for the 3D printing parts.
Line 83: Line 83:
 
'''Fixings / Pipe''' - eBay
 
'''Fixings / Pipe''' - eBay
  
==== Vendors Table ====
+
====Vendors Table====
  
 
Like the [https://reprap.org/wiki/RepRap_Buyers%27_Guide RepRap Buyers' Guide wiki], feel free to populate the table.  
 
Like the [https://reprap.org/wiki/RepRap_Buyers%27_Guide RepRap Buyers' Guide wiki], feel free to populate the table.  
Line 89: Line 89:
 
{| class="wikitable"
 
{| class="wikitable"
 
|-
 
|-
! Vendor
+
!Vendor
! Location
+
!Location
! Parts  
+
!Parts
! Notes
+
!Notes
 
|-
 
|-
| [https://www.pololu.com/ pololu]
+
|[https://www.pololu.com/ pololu]
| USA, Worldwide  
+
|USA, Worldwide
| Motors, electronics
+
|Motors, electronics
 
| -
 
| -
 
|-
 
|-
| [http://mouser.com/ mouser]
+
|[http://mouser.com/ mouser]
| Worldwide  
+
|Worldwide
| Motors, electronics
+
|Motors, electronics
 
| -
 
| -
 
|-
 
|-
| [https://www.ebay.com/ ebay]
+
|[https://www.ebay.com/ ebay]
| Worldwide  
+
|Worldwide
| Motors, electronics, Fasteners, T-Slots, pulleys, Tubes
+
|Motors, electronics, Fasteners, T-Slots, pulleys, Tubes
 
| -
 
| -
 
|-
 
|-
| [https://www.aliexpress.com/ aliexpress]
+
|[https://www.aliexpress.com/ aliexpress]
| Worldwide  
+
|Worldwide
| Motors, electronics, Fasteners, T-Slots, pulleys, Tubes
+
|Motors, electronics, Fasteners, T-Slots, pulleys, Tubes
 
| -
 
| -
 
|-
 
|-
| [https://grobotronics.com/ grobotronics]
+
|[https://grobotronics.com/ grobotronics]
| GR, EU
+
|GR, EU
| Motors, electronics, Fasteners, T-Slots, pulleys
+
|Motors, electronics, Fasteners, T-Slots, pulleys
 
| -
 
| -
 
|-
 
|-
| [https://www.motedis.com/shop/index.php motedis]
+
|[https://www.motedis.com/shop/index.php motedis]
| DE, EU
+
|DE, EU
| T-Slots, Tubes
+
|T-Slots, Tubes
 
| -
 
| -
 
|-
 
|-
| [https://uk.misumi-ec.com/ Misumi]
+
|[https://uk.misumi-ec.com/ Misumi]
| Worldwide
+
|Worldwide
| T-Slots, Tubes, Fasteners, Pulleys
+
|T-Slots, Tubes, Fasteners, Pulleys
 
| -
 
| -
 
|-
 
|-
| [https://www.omc-stepperonline.com/ omc-stepperonline]
+
|[https://www.omc-stepperonline.com/ omc-stepperonline]
| Worldwide
+
|Worldwide
| Stepper motors
+
|Stepper motors
 
| -
 
| -
 
|-
 
|-
| [https://www.fastenal.ca/ fastenal]
+
|[https://www.fastenal.ca/ fastenal]
| USA
+
|USA
| Fasteners
+
|Fasteners
 
| -
 
| -
 
|-
 
|-
| [https://www.mcmaster.com/ mcmaster]
+
|[https://www.mcmaster.com/ mcmaster]
| USA
+
|USA
| Fasteners
+
|Fasteners
 
| -
 
| -
 
|-
 
|-
| [http://www.rs-online.com/ rs]
+
|[http://www.rs-online.com/ rs]
| Worldwide
+
|Worldwide
| Electronics, fasteners, motors
+
|Electronics, fasteners, motors
 
| -
 
| -
 
|-
 
|-
| [https://8020.net/ 80/20]
+
|[https://8020.net/ 80/20]
| USA
+
|USA
| T-Slots
+
|T-Slots
 
| -
 
| -
 
|-
 
|-
| [https://www.pcbway.com/ pcbway]
+
|[https://www.pcbway.com/ pcbway]
| CN
+
|CN
| PCB fabrication
+
|PCB fabrication
 
| -
 
| -
 
|-
 
|-
| [https://www.servocity.com/ servocity]
+
|[https://www.servocity.com/ servocity]
| USA
+
|USA
| Motors, T-slots, fasteners
+
|Motors, T-slots, fasteners
| Most of parts are not metric
+
|Most of parts are not metric
 
|-
 
|-
  
 
|}
 
|}
  
== Build Sequence ==
+
==Build Sequence==
  
==== Tools & Consumables ====
+
====Tools & Consumables====
 
Here are presented tools and consumables about part fabrication, port-processing and assembly process.
 
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.  
 
Most of the tools are available in every hackerspace, makerspaces, FabLabs etc.  
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{| class="wikitable"
 
{| class="wikitable"
 
|-
 
|-
! Tool/Consumable
+
!Tool/Consumable
! Description
+
!Description
 
|-
 
|-
| Drill bits
+
|Drill bits
| 2mm for aluminum, 3mm, 4mm and 5mm for plastic
+
|2mm for aluminum, 3mm, 4mm and 5mm for plastic
 
|-
 
|-
| Drill driver
+
|Drill driver
| For aluminum tube drill hole, 3D printed part
+
|For aluminum tube drill hole, 3D printed part
 
|-
 
|-
| Sandpaper
+
|Sandpaper
| 80(dry), 120(dry), 240(dry) and 1000(wet) grit
+
|80(dry), 120(dry), 240(dry) and 1000(wet) grit
 
|-
 
|-
| Acetone
+
|Acetone
| For acetone vapor bath
+
|For acetone vapor bath
 
|-
 
|-
| Hacksaw
+
|Hacksaw
| For aluminum Tube
+
|For aluminum Tube
 
|-
 
|-
| Square File
+
|Square File
| For worm axis, for use on steel
+
|For worm axis, for use on steel
 
|-
 
|-
| Precision Knife
+
|Precision Knife
| For general use, especially in 3d-Printed parts
+
|For general use, especially in 3d-Printed parts
 
|-
 
|-
| Caliper
+
|Caliper
| Measuring Range 0-150mm
+
|Measuring Range 0-150mm
 
|-
 
|-
| Combination Wrenches
+
|Combination Wrenches
| 5.5mm, 7mm and 8mm
+
|5.5mm, 7mm and 8mm
 
|-
 
|-
| Thread-locker
+
|Thread-locker
| Like Loctite 271
+
|Like Loctite 271
 
|-
 
|-
| Cyano acrylic glue
+
|Cyano acrylic glue
| Like Loctite 401
+
|Like Loctite 401
 
|-
 
|-
| Screw driver
+
|Screw driver
| Number 1 Phillips
+
|Number 1 Phillips
 
|-
 
|-
| Heat Gun
+
|Heat Gun
| For Heat-shrinkables or use a lighter
+
|For Heat-shrinkables or use a lighter
 
|-
 
|-
| Ball-End L-Keys
+
|Ball-End L-Keys
| Hex 1.5mm, 2mm, 2.5mm, and 3mm
+
|Hex 1.5mm, 2mm, 2.5mm, and 3mm
 
|-
 
|-
| Soldering iron and consumables
+
|Soldering iron and consumables
| For cables
+
|For cables
 
|-
 
|-
| Wire Cutter
+
|Wire Cutter
| For cables
+
|For cables
 
|-
 
|-
| Long-Nose Plier
+
|Long-Nose Plier
| General purpose
+
|General purpose
 
|-
 
|-
 
|}
 
|}
  
==== Parts ====
+
====Parts====
 
Make sure you have all parts, according to [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator/blob/master/rotator-bom.ods BOM].
 
Make sure you have all parts, according to [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator/blob/master/rotator-bom.ods BOM].
  
Line 264: Line 264:
 
</gallery>
 
</gallery>
  
==== Assembly ====
+
====Assembly====
 
Follow the [https://ohai.satnogs.org/project/satnogs-rotator-v3-mechanical-assembly/hardware/ instructions for mechanical assembly] and also you can [https://www.youtube.com/watch?v=D6P9HK23Gmo watch timelapse]
 
Follow the [https://ohai.satnogs.org/project/satnogs-rotator-v3-mechanical-assembly/hardware/ instructions for mechanical assembly] and also you can [https://www.youtube.com/watch?v=D6P9HK23Gmo watch timelapse]
 
Also, exploded views and instructions are present here.
 
Also, exploded views and instructions are present here.
Line 272: Line 272:
  
 
Some notes for assembly:
 
Some notes for assembly:
* Resolve collision between of end-stop arm and C1042-1 end-stop mount, [https://community.libre.space/t/rotator-3-1-end-stop-switch-mounting/3463 community post]
+
 
* [https://community.libre.space/t/rotator-3-1-worm-gear-issues/1858/7 Running the worm gear] and [https://community.libre.space/t/rotator-3-1-worm-gear-issues/1858/9 lapping the worm gear] to get gear box running smooth
+
*Resolve collision between of end-stop arm and C1042-1 end-stop mount, [https://community.libre.space/t/rotator-3-1-end-stop-switch-mounting/3463 community post]
* [https://community.libre.space/t/stepper-motor-bolts-v3-1/3388 Collision between bolts and motor], this issue can be created by using wrong M4 screws(H1100-5) and washers(H1110-1)
+
*[https://community.libre.space/t/rotator-3-1-worm-gear-issues/1858/7 Running the worm gear] and [https://community.libre.space/t/rotator-3-1-worm-gear-issues/1858/9 lapping the worm gear] to get gear box running smooth
 +
*[https://community.libre.space/t/stepper-motor-bolts-v3-1/3388 Collision between bolts and motor], this issue can be created by using wrong M4 screws(H1100-5) and washers(H1110-1)
  
 
<gallery widths="180" heights="180" perrow="4">
 
<gallery widths="180" heights="180" perrow="4">
Line 291: Line 292:
 
</gallery>
 
</gallery>
  
==== Rotator Controller ====
+
====Rotator Controller====
Once mechanical assembly is ready, construct the [[SatNOGS Rotator Controller]].
+
The default way of controlling the rotator is to use the [[SatNOGS Rotator Controller]].This works for both stepper motor and DC motor set ups (Note: If you are uing the [https://wiki.satnogs.org/SatNOGS_Rotator_Controller#Encoders the rotary encoders] these will need to be set up). An alternative is to use the [[SatNOGS_Arduino_Uno/CNC_Shield_Based_Rotator_Controller]], whih has been used as a stand alone set up for use with GPredict.  
Also construct [https://wiki.satnogs.org/SatNOGS_Rotator_Controller#Encoders the rotary encoders] for DC motor set up.
 
  
==== Cover Box - Cabling ====
+
It's also possible to use a standard 3d printing RAMPs 1.4 board as an alternative, though note that these are designed for steppers which may cause extra RF noise. A RAMPs 1.4 [https://github.com/TheSkorm/satnogs-rotator-ramps14 firmware] has been developed.
 +
 
 +
====Cover Box - Cabling====
 
Prepare the cover box and install it to antenna rotator with rotator controller and cables.
 
Prepare the cover box and install it to antenna rotator with rotator controller and cables.
  
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</gallery>
 
</gallery>
  
==== Testing ====
+
====Testing====
 
You are ready! Proceed with [https://wiki.satnogs.org/SatNOGS_Rotator_Controller#Troubleshooting_hints testing].
 
You are ready! Proceed with [https://wiki.satnogs.org/SatNOGS_Rotator_Controller#Troubleshooting_hints testing].
  
==== Heading Calibration ====
+
====Heading Calibration====
 
The heading calibration is a manual process:
 
The heading calibration is a manual process:
  
* Power the rotator, it starts moving in order to find the home position, to find the end-stops
+
*Power the rotator, it starts moving in order to find the home position, to find the end-stops
* Remove the power from the rotator, the rotator is in home position
+
*Remove the power from the rotator, the rotator is in home position
* Install the rotator to vertical axis by using U-Bolt clamps
+
*Install the rotator to vertical axis by using U-Bolt clamps
* The azimuth axis it must be heading to the North, this is achieved by using a compass (e.g. from smart phone)
+
*The azimuth axis it must be heading to the North, this is achieved by using a compass (e.g. from smart phone)
* Secure the rotator in the vertical axis
+
*Secure the rotator in the vertical axis
* Install the elevation axis with the same process, now the zero elevation is achieved by using a pocket level
+
*Install the elevation axis with the same process, now the zero elevation is achieved by using a pocket level
* Secure the elevation axis
+
*Secure the elevation axis
* In the case of wrong rotation:
+
*In the case of wrong rotation:
** For stepper motors swap a pair of two stepper motor cables ([https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator-firmware/issues/15 it exists an open issue to be done by a command])
+
**For stepper motors swap a pair of two stepper motor cables ([https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator-firmware/issues/15 it exists an open issue to be done by a command])
** For DC motors, [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator-firmware/commit/961fb696536e35642f2b7064cc3c64676ebebb17 change the sign of encoder reading], it is a hacky method but it would be resolved by [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator-firmware/issues/15 this issue]
+
**For DC motors, [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator-firmware/commit/961fb696536e35642f2b7064cc3c64676ebebb17 change the sign of encoder reading], it is a hacky method but it would be resolved by [https://gitlab.com/librespacefoundation/satnogs/satnogs-rotator-firmware/issues/15 this issue]
 +
 
 +
====Counterweight for Antenna====
 +
It is necessary to balance the antenna in elevation and azimuth axis in order to not wear the gear box of rotator. In elevation axis would be done either by using back mounted antennas or by mounting the center of antenna mass in the mast. For a back mounted antenna, it is necessary to use counter-balance weights. An idea is to use weights that is used for training (it's cheap). The parts that used to mount weights to [https://www.wimo.com/en/x-quad X-quad antenna] are this [https://gitlab.com/librespacefoundation/satnogs/satnogs-hardware-misc/-/tree/master/mount-counterweight 3D printing part], a square aluminum profile 15x15 mm, weights with inner hole D28mm and M5 hex nuts DIN934 with M5 screws DIN912 L12 stainless steel to lock the weights in specific distance. Another way to [https://community.libre.space/t/quartapounds-satnogs-rotator-v3-1/3453/57 balance the antenna].
 +
 
 +
[[File:Counter-weight.jpg|thumb|center|800x420px|alt=|Counterweights]]
  
== Mechanical Analysis [WIP] ==
+
==Mechanical Analysis [WIP]==
  
==== Brake Torque ====
+
====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 [http://k7nv.com/notebook/topics/windload.html 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)
 
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 [http://k7nv.com/notebook/topics/windload.html 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)
  
 
{| class="wikitable"
 
{| class="wikitable"
 
|-
 
|-
! Method
+
!Method
! Wind Zone(km/h)
+
!Wind Zone(km/h)
! Height (m)  
+
!Height (m)
! Pressure(N/m^2)
+
!Pressure(N/m^2)
 
|-
 
|-
| EIA-222-C
+
|EIA-222-C
| 160
+
|160
| N/A
+
|N/A
| 1280
+
|1280
  
 
|-
 
|-
| EIA-222-F  
+
|EIA-222-F
| 128
+
|128
| 14
+
|14
| 1260
+
|1260
  
 
|-
 
|-
| EIA-222-F
+
|EIA-222-F
| 128
+
|128
| 21
+
|21
| 1390
+
|1390
  
 
|-
 
|-
| EIA-222-F  
+
|EIA-222-F
| 128
+
|128
| 30
+
|30
| 1500
+
|1500
  
 
|-
 
|-
| UBC'97
+
|UBC'97
| 128
+
|128
| 14
+
|14
| 1290
+
|1290
  
 
|-
 
|-
| UBC'97
+
|UBC'97
| 128
+
|128
| 21
+
|21
| 1160
+
|1160
  
 
|-
 
|-
| UBC'97
+
|UBC'97
| 128
+
|128
| 21
+
|21
| 1390
+
|1390
  
 
|-
 
|-
| UBC'97
+
|UBC'97
| 128
+
|128
| 30
+
|30
| 1260
+
|1260
  
 
|-
 
|-
| UBC'97
+
|UBC'97
| 128
+
|128
| 42
+
|42
| 990
+
|990
  
 
|-
 
|-
| UBC'97
+
|UBC'97
| 128
+
|128
| 42
+
|42
| 1360
+
|1360
  
 
|-
 
|-
| Generic Formula  
+
|Generic Formula
| 150
+
|150
| N/A
+
|N/A
| 1270
+
|1270
  
 
|}
 
|}
Line 414: Line 421:
  
  
==== Moment of inertia ====
+
====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.
 
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.
 
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
+
*M1: torque of Azimuth axis
* L: length of center of mass of antennas from azimuth axis (0.75m)
+
*L: length of center of mass of antennas from azimuth axis (0.75m)
* m: mass of antennas and of counterweight (3kg + 3kg = 6kg)
+
*m: mass of antennas and of counterweight (3kg + 3kg = 6kg)
* I: moment inertia
+
*I: moment inertia
* a: angular acceleration of azimuth axis 5deg/s^2
+
*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
+
*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
+
*M1 = I*a = 6.75kgm^2 * 0.087rad/s^2 = 0.58 Nm = 5.8 kgm = 58 kgcm
  
  
==== Angular velocity ====
+
====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.
 
(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.
  
Line 434: Line 441:
  
 
The equations that lead to maximum altitude at which we can track in relation to AZ angular velocity are
 
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
+
*ω : angular velocity of AZ DOF in rad/s
* R = ΑΕ : Radius of Earth, 6500 km
+
*H = ΑΕ + ΕΓ : Minimum Height of LEO, 160 km
* u : linear velocity of satellite that rotates in 160km height is 7.8 km/s
+
*R = ΑΕ : Radius of Earth, 6500 km
* ΒΔ = u / ω : ΒΔ in km
+
*u : linear velocity of satellite that rotates in 160km height is 7.8 km/s
* α = atan(ΒΔ / R)
+
*ΒΔ = u / ω : ΒΔ in km
* δ = π - α
+
*α = atan(ΒΔ / R)
* γ = asin( sqrt(R^2+ΒΔ^2) * sin(δ) / (H+R) )
+
*δ = π - α
* ά = π - δ - γ
+
*γ = asin( sqrt(R^2+ΒΔ^2) * sin(δ) / (H+R) )
* ΓΔ = (H+R) * sin(ά) / sin(δ)
+
*ά = π - δ - γ
* χ = atan(ΓΔ / ΒΔ)
+
*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.
 
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.
Line 452: Line 460:
 
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.
 
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.
  
==== Pulleys/Belts/Gearing ====
+
====Pulleys/Belts/Gearing====
 
Horizontal distance between pulleys (P1, P2) is 58mm.
 
Horizontal distance between pulleys (P1, P2) is 58mm.
 
Vertical distance between pulleys (P1, P2) is w = 9.5mm.
 
Vertical distance between pulleys (P1, P2) is w = 9.5mm.
Line 488: Line 496:
  
 
Belt gear selection:
 
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
+
*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)
 
To calculate Deflection force, (page T-31, sdp - design-guidelines)
* Y = 2.05, Tst = 1.3kg
+
 
* span length, t = 57.64mm
+
*Y = 2.05, Tst = 1.3kg
* Belt pitch length, L = 180mm
+
*span length, t = 57.64mm
* Fd,min =  
+
*Belt pitch length, L = 180mm
* Fd,max =  
+
*Fd,min =
* 2.8kg Working Tension [shapeoko - Belts and Pulleys](https://www.shapeoko.com/wiki/index.php/Belts_and_Pulleys#Tensile_Cord_Materials)
+
*Fd,max =
 +
*2.8kg Working Tension [shapeoko - Belts and Pulleys](https://www.shapeoko.com/wiki/index.php/Belts_and_Pulleys#Tensile_Cord_Materials)
  
  
Line 506: Line 516:
 
     P4-P5  <br />
 
     P4-P5  <br />
  
* Determination of design load  
+
*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.  
 
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
 
Select a service factor of 1.5 (service factors between 1.5 and 2.0 are generally recommended when
Line 512: Line 523:
 
Tpeak = SF*Tm = 1.5*0.6 = 0.9Nm  
 
Tpeak = SF*Tm = 1.5*0.6 = 0.9Nm  
  
* Choice of belt pitch
+
*Choice of belt pitch
 +
 
 
Due to backslash and accuracy in both directions of movements and volume constrains, we choose GT2, pitch 2mm.
 
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
+
*Check belt pitch selection based on individual graphs
 +
 
 
Due to Tpeak = 0.9Nm No-load speed,(Speed of fastest shaft) = 100RPM = 600deg/s  
 
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.  
 
GT2 pitch 2mm belt is the better solution for our application.  
  
* Determine speed ratio
+
*Determine speed ratio
 +
 
 
Speed ratio 1.8-2.25 according to specification of output rotation speed of 5deg/s.
 
Speed ratio 1.8-2.25 according to specification of output rotation speed of 5deg/s.
  
* Check belt speed
+
*Check belt speed
 +
 
 
V(m/s) = 0.0000524 x pulley PD (mm) x pulley rpm = 0.066548m/s  
 
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.  
 
Belt speeds up to 6,500 fpm (33.02 m/s) do not require special pulleys.  
  
* Determine belt length
+
*Determine belt length
 +
 
 
Table 'Belt calculation (according to calculator)'
 
Table 'Belt calculation (according to calculator)'
 
Teeth in mesh: 9
 
Teeth in mesh: 9
  
* Determine the belt width
+
*Determine the belt width
 +
 
 
From Table 43  
 
From Table 43  
 
torque = 0.17Nm  
 
torque = 0.17Nm  
Line 539: Line 556:
 
Tpeak = 0.9Nm, so belt width is nice for our application  
 
Tpeak = 0.9Nm, so belt width is nice for our application  
  
* Check the number of teeth in mesh
+
*Check the number of teeth in mesh
 +
 
 
Teeth in mesh: 9 according to calculator  
 
Teeth in mesh: 9 according to calculator  
  
* Determine proper belt installation tension
+
*Determine proper belt installation tension
 +
 
 
SECTION 10, on page T50, look at 'To calculate Deflection force, (page T-31, sdp - design-guidelines)'  
 
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
+
*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
  
* P2 timing pulley torque - Maximum radial load of timing belt ball bearing 625zz
 
 
Tpeak = 0.9Nm  
 
Tpeak = 0.9Nm  
 
TorqueP2 = 2*0.9Nm = 1.8Nm, PDp2 = 25.5mm  
 
TorqueP2 = 2*0.9Nm = 1.8Nm, PDp2 = 25.5mm  
Line 563: Line 584:
 
T-39
 
T-39
  
* Maximum thrust load of timing belt ball bearing 625zz
+
*Maximum thrust load of timing belt ball bearing 625zz
 +
 
 +
*Maximum radial and thrust load of output ball bearings 6008zz
  
* Maximum radial and thrust load of output ball bearings 6008zz
 
 
Calculate or evaluate correct loads for deep groove ball bearings
 
Calculate or evaluate correct loads for deep groove ball bearings
 
radial static load = 11.6kN  
 
radial static load = 11.6kN  
Line 574: Line 596:
 
whereas all the balls can withstand the thrust 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)
+
*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)
 
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  
+
*Nominal torque of drivable torque of gear box (according to more weak component) and maximum rotational speed of gear box
  
 
Notes:
 
Notes:
* [https://sdp-si.com/eStore/CenterDistanceDesigner sdp distance calculator]
 
* [http://www.ebay.com/itm/2GT-Timing-Belt-L-172-232-240-244-640-810-GT2-Belts-closed-loop-5pcs-lot-/221977955532?var=&hash=item33aeeacccc:m:me5GvSt_amrm6RWT03Ut4JA belt GT2-6mm wide, 172mm]
 
* [https://www.ebay.com/itm/2GT-GT2-synchronous-Timing-belt-Perimeter-98-194mm-width-6-9mm-Cogged-close-loop/222574382655?ssPageName=STRK%3AMEBIDX%3AIT&var=521434616407&_trksid=p2060353.m2749.l2649 belt GT2-6mm wide, 180mm]
 
* [http://www.ebay.com/itm/5pcs-Timing-Pulley-GT2-Idler-16-20T-gear-Bearing-Reprap-6mm-Belt-3-5mm-Bore-3D-/132195520937?var=&hash=item1ec77791a9:m:mljSYBViBlKOgXr3Gy-u0Tg idler pulley, no-teeth-ID3mm-OD18mm]
 
* [http://www.brecoflex.com/products/pulleys/design-guidelines/ brecoflex - design-guidelines]
 
* [http://www.shreegeeimpex.com/TECH_DATA_PAG/idlers_ten.htm shreegeeimpex - design-guidelines]
 
* [http://www.sdp-si.com/PDFS/Technical-Section-Timing.pdf sdp - design-guidelines]
 
  
==== Motor Specification ====
+
*[https://sdp-si.com/eStore/CenterDistanceDesigner sdp distance calculator]
 +
*[http://www.ebay.com/itm/2GT-Timing-Belt-L-172-232-240-244-640-810-GT2-Belts-closed-loop-5pcs-lot-/221977955532?var=&hash=item33aeeacccc:m:me5GvSt_amrm6RWT03Ut4JA belt GT2-6mm wide, 172mm]
 +
*[https://www.ebay.com/itm/2GT-GT2-synchronous-Timing-belt-Perimeter-98-194mm-width-6-9mm-Cogged-close-loop/222574382655?ssPageName=STRK%3AMEBIDX%3AIT&var=521434616407&_trksid=p2060353.m2749.l2649 belt GT2-6mm wide, 180mm]
 +
*[http://www.ebay.com/itm/5pcs-Timing-Pulley-GT2-Idler-16-20T-gear-Bearing-Reprap-6mm-Belt-3-5mm-Bore-3D-/132195520937?var=&hash=item1ec77791a9:m:mljSYBViBlKOgXr3Gy-u0Tg idler pulley, no-teeth-ID3mm-OD18mm]
 +
*[http://www.brecoflex.com/products/pulleys/design-guidelines/ brecoflex - design-guidelines]
 +
*[http://www.shreegeeimpex.com/TECH_DATA_PAG/idlers_ten.htm shreegeeimpex - design-guidelines]
 +
*[http://www.sdp-si.com/PDFS/Technical-Section-Timing.pdf sdp - design-guidelines]
 +
 
 +
====Motor Specification====
  
 
General Specification about motors. The voltage and current consumption also it depends from the motor controller which is (maybe) different
 
General Specification about motors. The voltage and current consumption also it depends from the motor controller which is (maybe) different
Line 595: Line 619:
 
{| class="wikitable"
 
{| class="wikitable"
 
|-
 
|-
! Specification
+
!Specification
! Value
+
!Value
 
|-
 
|-
| Min-Max Stall Torque (Nm)
+
|Min-Max Stall Torque (Nm)
| 0.4 - 1.5
+
|0.4 - 1.5
 
|-
 
|-
| Min-Max Speed (RPM)
+
|Min-Max Speed (RPM)
| 100 - 200
+
|100 - 200
 
|-
 
|-
| Size (mm) (LxWxH)
+
|Size (mm) (LxWxH)
| 47x42x64
+
|47x42x64
 
|-
 
|-
 
|}
 
|}
Line 614: Line 638:
 
</gallery>
 
</gallery>
  
==== Worm Gear Box Calculations ====
+
====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
  
* 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
 
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
 
  
 +
*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
 +
 +
[[Category:Build]]
 +
[[Category:Hardware]]
 
[[Category:Rotator]]
 
[[Category:Rotator]]

Latest revision as of 10:19, 15 September 2020

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


Introduction

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

Design Goals

Considering the specifications as detailed in the Mechanical Analysis, 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, backlash 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 [2].

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

Vendors Table

Like the RepRap Buyers' Guide wiki, feel free to populate the table.

Vendor Location Parts Notes
pololu USA, Worldwide Motors, electronics -
mouser Worldwide Motors, electronics -
ebay Worldwide Motors, electronics, Fasteners, T-Slots, pulleys, Tubes -
aliexpress Worldwide Motors, electronics, Fasteners, T-Slots, pulleys, Tubes -
grobotronics GR, EU Motors, electronics, Fasteners, T-Slots, pulleys -
motedis DE, EU T-Slots, Tubes -
Misumi Worldwide T-Slots, Tubes, Fasteners, Pulleys -
omc-stepperonline Worldwide Stepper motors -
fastenal USA Fasteners -
mcmaster USA Fasteners -
rs Worldwide Electronics, fasteners, motors -
80/20 USA T-Slots -
pcbway CN PCB fabrication -
servocity USA Motors, T-slots, fasteners Most of parts are not metric

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.

Assembly

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

Idea.png
Prior to Step 8, the rotary encoders must be ready and prior to Step 11 the motor must be mounted in A1070-1. For the rotary encoder assembly look at the next section Rotator_Controller.

Some notes for assembly:

Rotator Controller

The default way of controlling the rotator is to use the SatNOGS Rotator Controller.This works for both stepper motor and DC motor set ups (Note: If you are uing the the rotary encoders these will need to be set up). An alternative is to use the SatNOGS_Arduino_Uno/CNC_Shield_Based_Rotator_Controller, whih has been used as a stand alone set up for use with GPredict.

It's also possible to use a standard 3d printing RAMPs 1.4 board as an alternative, though note that these are designed for steppers which may cause extra RF noise. A RAMPs 1.4 firmware has been developed.

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.

Heading Calibration

The heading calibration is a manual process:

  • Power the rotator, it starts moving in order to find the home position, to find the end-stops
  • Remove the power from the rotator, the rotator is in home position
  • Install the rotator to vertical axis by using U-Bolt clamps
  • The azimuth axis it must be heading to the North, this is achieved by using a compass (e.g. from smart phone)
  • Secure the rotator in the vertical axis
  • Install the elevation axis with the same process, now the zero elevation is achieved by using a pocket level
  • Secure the elevation axis
  • In the case of wrong rotation:

Counterweight for Antenna

It is necessary to balance the antenna in elevation and azimuth axis in order to not wear the gear box of rotator. In elevation axis would be done either by using back mounted antennas or by mounting the center of antenna mass in the mast. For a back mounted antenna, it is necessary to use counter-balance weights. An idea is to use weights that is used for training (it's cheap). The parts that used to mount weights to X-quad antenna are this 3D printing part, a square aluminum profile 15x15 mm, weights with inner hole D28mm and M5 hex nuts DIN934 with M5 screws DIN912 L12 stainless steel to lock the weights in specific distance. Another way to balance the antenna.

Counterweights

Mechanical Analysis [WIP]

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.

Pulleys/Belts/Gearing

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)


  P3  
/ \
P1 P2
|
P4-P5
  • 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

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