Activity Report of Space Mechanical Components

& Materials Subcommittee

Toshio HONDATokyo Electronic Systems Corporation

Chairman, Space Mechanical Components & Materials Subcommittee

19th Microelectronics WorkshopOctober 26, 2006 Tsukuba, Ibaraki, JAPAN

The subcommittee memberChairman: Toshio HONDA, TokyoElectronic Systems CorporationActing chairman: Mineo SUZUKI, JAXA

External memberTsunamitsu NAKAHARA, Tokyo Institute of TechnologyToshio OGATA., National Institute for Materials ScienceKatsuhiko AKIYAMA, Mitsubishi Heavy Industries, Ltd.Hideo OGUCHI, Ishikawajima-hHarima Heavy Industries

Co., Ltd.Masao AKIYAMA, IHI Aerospace Co., Ltd.Jun NAKAGAWA, Mitsubishi Electric CorporationAkira SASAKI, NEC TOSHIBA Space Systems, Ltd.Kazuo NATORI, Mitsubishi Precision Co., Ltd.Hisashi, KAWAMURA, NSK Ltd.Yoshihide KIYOSAWA, Harmonic Drive Systems Inc.Tomio NAKATA, Tamagawa Seiki Co., Ltd.Shohachiro YAMAGUCHI, Nippon Paint Co. Ltd.

JAXA memberRikio YOKOTAAkira KONNOKenji TOMIOKAKichiro IMAGAWAKen HIGUCHIKenichi KAJIWARAShingo OBARANoritsugu KAWASHIMATakashi TAMURA

JAXA Hiroshi MIYABA, Kenichi KUSHIKI, Yasuo TANAKA, Taiichi NAGATA, Yuichi ISHIDA

High-Reliability Engineering & Components CorporationYukio AMANO, Mikihiko URANO, Mieko MATSUDA

Secretariat

1. Committee on Space Component Technology – History-(a) Establishment of the Committee- In response to serious space component problems, such as decline in domestic production, withdrawal of some components from QPL, NASDA Committee on Space Component Technology was established to seek the solution.

- Under the Committee, Space Mechanical Components & Materials Subcommitteewas set up (September 2002).

- Secretariat was Office of Research & Development- The committee issued a report based on discussion in two sub-committees. In the

report 10 item recommendations were issued (June 2003).(b) Establishment of JAXA- Upon the merge of ISAS, NAL & NASDA into JAXA, JAXA Committee on Space Component Technology was established (October 2003)

- Secretariat was Space Component Engineering Center- The subjects of the Committee extended, including ISAS & NAL activeties.(c) JAXA Vision- JAXA Vision was released (March 2005).　(d) Re-organization of Institute of Aerospace Technology- R&D groups were re-organized into discipline engineering groups (October 2005)- Secretariat changed to Electronic, Mechanical Components and Materials Engineering Group.

2. Mechanical components to be developed by JAXA(1) Frontier components

Components which need innovative research to solve technologicalproblems, and to meet future space requirements.

(2) High priority componentsComponents which - have problems such as frequent failures, withdrawal from QPL, single source, ITAR, etc., and

- are required urgent development, and- are expect to be used in various applications for prolong period.

(3) Generic technologyStrategic technology which Japan should keep for steady and advanced space development. Through R&D activities, technology level will be kept, handed to next generations, and improved.

High priority components & Frontier components

•Strategic technology• Internationally competent •Contribute to higher reliability•Contribute to sustainment, succession, and progression of technological base

Technological view point

Development phase

No major research problem remained

Implementation of development （company）

• Bus equipment, crucial mission equipment (common technology)

• Break-downed from JAXA vision, and mid-term plan (Needs)

• Research output enabling unique system design (Seeds)

Usable for various applications Prolonged utilization of developed technology, and spin-off expected

Social circumstances

• Contribute to autonomous space activities• Solution to problems such as frequent failures, single source, ITAR, and high cost domestic production

Apparent advantages of research & development

Frontier components

Research phase

Solve problems through research

Applications

Development phase

Corporation with relevant organizations

Applied to projectsRemark: Gradation of in the figure shows

degree of emphasis for high priority component or frontier component

Hard research problems Limited research problems

～10 yeartime span

2～4 yeartime span

High priority components

3. JAXA vision, frontier & high priority component, generic technologyPresent After 5 year After 10 year After 15 year After 20 year

Research phase

MEMS・nano-tecnology・advanced materials ･･･

Brake-down of needed components

JAXA vision

Application of advanced commercial technology

mid-term plan mid-term plan mid-term plan

Space activity

plan

Frontier components Development

Need technological Innovation

DevelopmentResearch phase

3rd selectionHigh prioritycomponents

2nd selectionNeed urgent development

1st selection

Generictechnology

Enhance common technological base: tribology, evaluation ･･･Strategic technology

Function enhancement of Latching Valve

・Post Qualification test Review was done successfully. (August.11.2006)

・Function enhancement was accomplished in accordance with design strategy that is to take over the Pedigree design, drawings, production and inspection process.

・JAXA will carry out further evaluation tests in order to accumulate technical data.

・Now on sale!

High-priority components1st selection

Difference between Current valve and Enhanced valve

・Inheritance of Pedigree design, drawings, production and inspection process・Valve capability confirmation test (Mechanical environment, e,g, Shock, Random vibration)・Valve cost 15%OFF because of Development framework optimization

Special affairs

　JAXA／Moog Japan※Development efficiency improvement

　JAXA／IHI／　Moog Japan

Development Framework

　GHe　　GN2Test fluid of Internal leakage

　1.38MPa(nominal)　　　3.490mm2　（φ5.06mm）

Enhanced LV　Unregulated2.238mm2　(φ4.90mm）

Current LV

Reverse Cracking Pressure(ID of Outer nozzle)

Item

Schedule200720062005200420032002 200720062005200420032002

PQR

Pre-study, Trade-off study

Detailed Design

QT model manufacturing （4ea）

QT

Trial manufactures and Tests

MRR

20N-class Thruster valve High-priority components1st selection

・Critical Design Review is scheduled to be held in this October. The manufacturing documents are prepared.

・In order to create a “ROBUST” valve, the Japanese methodology of quality and reliability control engineering was applied from the beginning stage of development. (TOYOTA’s design method / TAGUCHI Method with CAE)

Typical performance specification

≦ 0.30kgWeight

Confirmation of High tmp capability

Confirmation of capability

65 ohm ± 10% @20degCCoil resistance

≧ 1,000,000 cycle @Wet&DryCycle life

4 ～ 149degC　@OperatingTemperature range

≦ 15msec @28Vdc,MEOP,20degC

Response（Opening）

23.5 ～ 32 VdcOperating Voltage

≦ 1×10-5scc/min @MEOP,GHeInternal leakage

≦ 0.172MPa @12.7g/sec H2OPressure drop

Test of surge pressure

7MPa / 10MPaProof／BurstPressure

2.80MPaMEOP

Remarks

N2H4,MMH,GHe,GN2,H2O,IPA

Development specificationCompatible fluid

Item

Schedule200720062005200420032002 200720062005200420032002

PQRCDR・MRRPreliminary design

Trial manufactures and tests

Detailed design

Design verification test

QT

QT valve manufacturing

EM valve manufacturing

Additional element test

High-priority components1st selectionResolver

・Post-Qualification Review & Final Revew was done successfully.

(July.24.2006)

Qualification test model

・Results of Accuracy qualification test・ Worst case is Low temp.condition (-30deg)・All data are within an accuracy　

requirement (±5arcsec)・ Now on sale!

CW : Clock-wiseCCW : Counter clock-wise

JFY 2003 2004 2005 2006ReviewPreliminary designBread board modelDetailed designManufactureQualification test

　　　PDR▼　　　　　 　CDR▼　　　　PQR▼

Description Resolver Optical encoder

Outer shape Diameter

Width

Bore Diameter

125 ｍｍ

67 ｍｍ

18 ｍｍ φ

137 ｍｍ

79 ｍｍ

－

Sensing method Electromagnetic induction Optical

Angular accuracy ＜±0.0015°(±5arcsec) ＜±0.0015°(±5arcsec)

Resolution 21 bit 18 bit

Mass ＜2.0kg（1.82kg） ＜2.2kg

Power ＜2.6W（1.2W） ＜5W

Input/Output Differential type（EIA RS422） Differential type（EIA RS422）

ＣＷ

ＣＣＷ

Requirement of upper limit : ＋５arcsec

Requirement of lower limit : -５arcsec

Angle(deg.)

Ang

le e

rror(

arcs

ec)

Harmonic Drive Gear High-priority components1st selection

・Under life testing (Long life type)

1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

1.0E+07

1 10 100 1000

Load Torque [Nm]

Tota

l Rev

olut

ion

Num

ber o

f Out

put S

haft

[rev

]

RequirementEM test

Estimaed Life in Vacuum

jig

Flexiblecupling

Acceleration transducerVibration test

Thermal vacuumtest

jig

– 10～ + 80℃– 30～ + 80℃– 10～ + 80℃Operating

temperature

＜　30arc-sec＜　60arc-sec＜　30arc-secAngletransfer rate

Solid lubricantSynthetic Hydro-Carbon oil, greaseLubricant

app.105 rev.100　rev.106 rev.Lifetime

370～300g103g221gMass

70φ×35.0L70φ×14.0L82φ×30.4LDimension

Existing productLight weight typeLong life typeItem

Light weight typeLong life type

2006200520042003 2006200520042003

PQRCDRPreliminary designBBM

Detailed designQalification test

PDR

High-priority components2nd selectionComponents to be developed

Two items were selected as having high priority to be developed. Now, cooperative research is under way.

Ring

Fiberbrush

Fiberbrush type slipring

A model for preliminarylaboratory test

(1) Slipring- Research status: Evaluation is under way to

select appropriate brush, ring & plating materials- Application: Solar array drive mechanism (SADM)- Purpose: Small, light-weight SADM- Point of development: High reliability & low cost　　(2) Low shock hold-down & release mechanism- Research status: Preliminary operation tests wereperfomed. International cost competition is a problem. Target cost is in consideration.

- Application: Hold-down & release mechanism for Solar array paddle (SAP)

- Purpose: Reduction of release shock for SAP - Point of development: Unique mechanism & high reliability　　　　　　　　

4. JAXA’s activities on space materials

A variety of materials have been used for space applications to meet the requirements of projects. New materials are sometimes adopted. Establishment of evaluation technology about space environment for many types of space materials is important.

(1) Present major activities- Evaluation of compatibility of materials to space environment* Modified thermal control films for superior durability & higher performance* Imported electric wire sheath materials (polymers)

　* Commercially available high performance paints, adhesives, etc.- Materials Database System

Obtained data are registered in a database (http://matdb.jaxa.jp)http://matdb.jaxa.jp), and open to public.

(2) Planned activities　- Continue evaluation of space compatibility for imported materials- R&D for advanced new materials, such as electrically conductive thermal control polymer films, superior durability & higher performance materials.

- Improve evaluation technique, compile characteristics of materials

5. Problems related to Space Mech. Comp. & Materials Subcommittee(1) Definition of Mechanical Components

The word “mechanical component” is interpreted in several ways: (a)mechanical parts such as springs, (b)mechanical element such as ball bearings, (c)mechanisms such as flywheels. The sub-committee covers all of (a)-(c) & related basic

Due to the merge of ISAS, NAL, NASDA into JAXA, components for ISAS’sscientific satellite, and basic research at NAL became the subjects discussed in the sub-committee.

(3) Requirements for mechanical componentsNeeded future mecahnical components should be extracted from JAXA Vision. To

set the requirements for the components, system design is mandatory. This task is insufficient.

(4) Enhanced secretariatFrom October 2005, a discipline engineering groups (Electronic, Mechanical

Components and Materials Engineering Group) became secretariat. The subjects of the sub-committee is far beyond the group’s activities. Participation of related groups in the sub-committee is needed.

technology such as tribology, without clarifing the definition of “component”.

(2) Subjects of the sub-committee expanded