PDF. - Pagnotta Engineering, Inc.

Transcription

MGSE
Design, Analysis,
and
dM
Manufacturing
f t i
PAGNOTTA ENGINEERING, INC. COMPANY BACKGROUND
OUR MISSION
MISSION:
To provide quality mechanical
design and analytical services
•
•
•
» Architectural/Civil since 1980
to our customers. We provide
» Aerospace Industry since 1982
creative solutions to complex
» Vehicle Simulation Structures since 1991
problems utilizing both our
unique experience and cutting
•
Since incorporation, PEI has completed over 400
projects in Architectural/Civil, Aerospace, Vehicle
Simulation, Medical and Consumer Products,
Power Generation, and other industries
•
Please visit www.pageng.com for more
information on our services,
services experience and
personnel
edge computer technology.
We strive to exceed our
customers expectations in
order to maintain our
outstanding reputation.
Incorporated in June of 1996
Based in Exton, PA
Company founders have extensive experience in:
Slide 2
PAGNOTTA ENGINEERING SERVICES AND CAPABILITIES
•
•
•
•
•
•
•
•
•
Stress Analysis and Optimization
Dynamic, Fatigue, and Fracture Analysis
Program and Vendor Management
Conceptual and Detailed Design Engineering
CAD Modeling (3-D Parametric Solid, Surface, and Wireframe)
Thermal and Non-Linear
Non Linear Structural Analysis
Mechanism Design and Analysis
Material Process and Testing Coordination
Manufacturing Detail and Assembly Drawings
PRIMARY ENGINEERING SOFTWARE TOOLS:
Design: Pro/Engineer, SolidWorks, AutoCAD Inventor
Analysis: NASTRAN, FEMAP, NASGRO
Slide 3
PAGNOTTA ENGINEERING: FOUR LEVELS OF SUPPORT
• Short-term overflow support
– Allows the customer to avoid severe peaks in manpower needs
– No long-term contract requirements as with job shops
• Long-term, fixed-price support
– For well-defined scope
– PEI takes ownership of the engineering, not just a “task doer”
• Turnkey solutions
– Design,
D i
analysis,
l i and
d coordination
di ti / managementt off manufacturing
f t i vendors
d
– Complete solution and delivery of hardware
• On
On-site
site engineering support
– Allows for regular interaction with customer personnel
Slide 4
PAGNOTTA ENGINEERING: INDUSTRIES SERVICED
Industries Serviced as a Percentage of Total Contract Awards
Industries Serviced: Percentage of Total Number of Contracts
Industries Serviced: Percentage of Total Number of Contracts
CIVIL STRUCTURES
5%
POWER GENERATION
5%
SPACE FLIGHT HARDWARE
20%
MGSE FOR SPACE FLIGHT MGSE
FOR SPACE FLIGHT
HDWR
13%
MISC*
4%
COMMERCIAL PRODUCTS
8%
CONSUMER PRODUCTS
3%
DEFENSE HARDWARE
2%
DER CONSULTING
13%
MISC*
CIVIL STRUCTURES
COMMERCIAL PRODUCTS
CONSUMER PRODUCTS
DEFENSE HARDWARE
DER CONSULTING
FLIGHT SIMULATION
GENERAL AVIATION
INDUSTRIAL PRODUCTS
MGSE FOR SPACE FLIGHT HDWR
INDUSTRIAL PRODUCTS
3%
GENERAL AVIATION FLIGHT SIMULATION
7%
17%
SPACE FLIGHT HARDWARE
POWER GENERATION
* MISC = UTILITIES, AUTOMOTIVE, MEDICAL, ENTERTAINMENT, RESEARCH
Slide 5
RECENT CLIENTS
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Lockheed Martin……………………….……..Orlando, FL; Newtown, PA; Valley Forge, PA
Orbital Sciences Corp……………….....……Dulles, VA; Greenbelt, MD
Alphaport, Inc………………………………….Cleveland, OH
Si
Sierra
Nevada
N
d Corporation………………….
C
ti
Hagerstown, MD
Rockwell Collins / STS……………………….Sterling, VA; Binghamton NY
Boeing…………………………………………..Ridley Park, PA
Northrop Grumman
Grumman……………………..…….Baltimore,
Baltimore MD
Keystone Helicopters……………………..….Coatesville, PA
NASA Langley…………………………….……Hampton, VA
PMC Engineering….….………………….……
g
g
Pottstown,, PA
Environmental Tectonics Corp.…………….Southampton, PA
JRL Ventures………………............................Cape Coral, FL
J.F. Taylor, Inc………………..………………...Lexington Park, MD
Eagle-Picher Technologies, LLC……………Joplin, MO
• Flight Safety International……….……..........St. Louis, MO; Austin, TX
• Fibertek, Inc……………………………………..Herndon, VA
Slide 6
ABBREVIATED LIST OF MGSE PROJECTS
• Spacecraft L-Fixture (LOCKHEED MARTIN)
• Payload Module Shipping Fixture (OSC)
• Analysis of B-SAT 3B Antenna L-Fixture
(LOCKHEED MARTIN)
• Analysis of Motorized Spacecraft Pivot
Shipping Fixture (OSC)
• Design and Analysis of TVAC Rail System (OSC)
• Design
D i and
dA
Analysis
l i off MUOS M
Mass M
Model
d l
(LOCKHEED MARTIN)
• Analysis of Range Fixture for JCSAT 12
(LOCKHEED MARTIN)
• Design
D i and
dA
Analysis
l i off St
Star 2
2.4+
4 IIntegration
t
ti D
Dolly
ll
(OSC)
• Design and Analysis of Falcon MGSE Hardware
including Multi-Use Dolly, L-Fixture, and Lifting
Beams (LOCKHEED MARTIN)
• Design and Analysis of STAR 2.4+ Core Shipping
Fixture (OSC)
• Design and Analysis of AMC-21 Payload Module
Shipping Fixture (OSC)
• Analysis of PIM Fixture, South Feed (LOCKHEED MARTIN)
• Analysis
y of Jitter Air Spring
p g Assembly
y ((LOCKHEED MARTIN))
• Analysis of Raymond Platform (LOCKHEED MARTIN)
• Structural Analysis of ECHO-X Tooling Fixtures
(LOCKHEED MARTIN)
• Design and Analysis of Single GPHS Test Stand
(ALPHAPORT)
• Design and Analysis of Motorized Spacecraft Pivot
Shipping Structure (OSC)
• Analysis of Lift Beam Extensions (OSC)
• Analysis of Various Hardware Support Equipment
(vibe plates, TVAC Plates, battery handling and
shipping fixtures) (LOCKHEED MARTIN)
• Analysis of Various Fixtures for GPSIII
(LOCKHEED MARTIN)
• Design and Fabrication of GPSIII Mass Models
(LOCKHEED MARTIN)
• Analysis of Sirius S4 Lifting Fixtures (LOCKHEED MARTIN)
Slide 7
EXAMPLES OF MGSE ENGINEERING SERVICES
Satellite L-Fixture for Lockheed Martin
PEI responsibilities: design
design, analyze
analyze, fabrication drawings
drawings,
manufacture, test, deliver finished product, FFMEA
WITH PROOF
WEIGHT
L-FIXTURE:
• 20 FEET LONG
• WEIGHT = 3500 LBS
WITH
SATELLITE
Slide 8
S t llit L-Fixture
Satellite
L Fi t
for
f Lockheed
L kh d Martin
M ti
PID 3 –
Vertical
I-Beams
PID 4 Horizontal
I-Beams
PID 5 Diagonal
I-Beams
S/C Mass Element
(61.38 in. offset for
L-Fixture interface plate)
Horn
Absorber
Mass
PID 2 - Lateral
I-Beams
Cold Plate
Mass Elements
PID 11 –
S/C Interface
Plate
PID 41 & 42 Detailed
I-Beam mesh
PID 12 & 13 Caster Interface
PID 21-23
Jack Interface
Longitudinal
I-Beams
PID 6 Jack Beam
Constraint
at caster axle
P1404-LFrame-CDR-05.MOD
Slide 9
Satellite L-Fixture for Lockheed Martin
Mike Pagnotta, President
Brian Dreibelbis, Staff Engineer
Slide 10
AMC-21 Payload Module Shipping Fixture for Orbital Sciences Corp. (OSC)
• OSC needs to safety ship their AMC-21 S/C Payload Module
(PM) tto Al
Alcatel
t l (E
(European customer)
t
) ffor equipment
i
t population.
l ti
• The populated PM must then be shipped back to OSC for
integration.
• PEI contracted to develop the shipping fixture
Design Requirements:
» Fit in standard 747 shipping container
» Meeting OSC MGSE strength requirements:
-
Sine-sweep response analysis
-
p
Random ((PSD)) spectrum
response analysis
-
Shock response analysis
-
Quasi-static load cases
+
=
Slide 11
AMC-21 Payload Module Shipping Fixture for Orbital Sciences Corp.
Sine Response, 1.3GY input, N101 (CG)
Sine Response, 1.3GY input, N101 (CG)
4 50
4.50
PEI
designed
the handling
frame too!
Payload module
being lowered
over shipping
fixture
Respo
onse [g's]
4.00
Fabricated
shipping
fixture
mounted to
shipping
container
base
MODE
NO.
1
2
3
4
5
6
FREQ
[Hz]
5 192
5.192
5.349
10.450
10.482
12.889
13.221
Sum =
RSS-mag
3.50
X-mag
3.00
Y-mag
Z-mag
2.50
Input
2 00
2.00
1.50
1.00
0.50
0.00
0.00
0
00
5.00
5
00
10.00
0 00
15.00
5 00
20.00
0 00
25.00
5 00
30.00
30
00
35.00
35
00
40.00
0 00
Frequency [Hz]
T1
0 498
0.498
0.014
0.000
0.000
0.488
0.000
1 000
1.000
MODAL EFFECTIVE MASS FRACTION
T2
T3
R1
R2
0 014
0.014
0 000
0.000
0 013
0.013
0 514
0.514
0.542
0.000
0.472
0.013
0.000
0.000
0.000
0.000
0.000
0.999
0.000
0.000
0.000
0.000
0.000
0.472
0.440
0.000
0.511
0.000
0 997
0.997
1 000
1.000
0 997
0.997
1 000
1.000
R3
0 000
0.000
0.000
0.997
0.000
0.000
0.000
0 998
0.998
Slide 12
Handling Frame with Payload Module
Slide 13
Fi it Element
Finite
El
t Analysis
A l i off Payload
P l d Handling
H dli Frame
F
for
f OSC
Detail of
stiffening
gusset
Rendered FE model of fixture
FE model
d l off fixture
fi t
with
ith payload
l d
Slide 14
Flotron Turnover Configuration
Slide 15
Handling Frame Supporting Payload Module at OSC Facility
Slide 16
Payload Module Handling Fixture on Flotron
Slide 17
Handling Frame Supporting Payload Module During Flotron Turn-over
Operations at OSC Facility
Slide 18
Finite Element Analysis of Payload Handling Frame for OSC, Turn-over
Configurations
56
56
123456
123456
3
1
151”
167”
56
45656
4
4
4
4
Y
Y
X
Z
X
Y
X
Z
Z
12
456
456
456
Slide 19
L Frame for Orbital Sciences Corporation (OSC)
L-Frame
• PEI developed fixture per OSC internal requirements.
• Created 3D design model and all manufacturing drawings
• Performed all stress analyses
L-Frame
Spacecraft
Fixture
Slide 20
LF
L-Frame
Welded
W ld d Assembly
A
bl
Slide 21
L-Frame Turn-over Configuration
Slide 22
LF
L-Frame
with
ith Payload
P l d
Slide 23
Thermal-Vacuum
Thermal
Vacuum (TVAC) Chamber Rail and Exterior Hoist Structure for Orbital
Sciences Corporation (OSC)
• Interior rail structure design to accommodate temperature extremes of TVAC
chamber using flexible titanium stand-offs
• Created 3D design models and all manufacturing drawings
• Managed fabrication vendors and installation
• Created FE models and p
performed all stress analyses
y
Payload fixture rolling into
C chamber
TVAC
Thermal-Vacuum Chamber
Rail and exterior hoist beam
structure
Slide 24
L-frame in Thermal-Vacuum Chamber at Lockheed Martin - Newtown, PA
Slide 25
A l i off Horizontal
Analysis
H i
l Range
R
Fixture
Fi
for
f Lockheed
kh d Martin,
M i Newtown,
N
PA
Rendered Finite
El
Element
t model
d l
shown
Slide 26
Design and Analysis of JCSAT
JCSAT-9
9 C-Band
C Band Support Fixture for
Lockheed Martin, Newtown, PA
First Stage of Assembly
Rendered View of C-band
Support Fixture
Finite Element Model
Pro-Engineer Model
Slide 27
C Band Assembly Finite Element Model
C-Band
First
Stage
Flotron components prior to
attachment of C-Band Assembly
2nd
Stage
Slide 28
Range Fixture Finite Element Model
Complete Range Assembly Finite
Element Model
Slide 29
Ka Band Antenna L-Fixture (Lockheed Martin)
PEI responsibilities:
design, analyze,
fabrication drawings,
manufacture, test, deliver
finished product, FFMEA
Reflector
Support Frame
Assembly
(20122178G1)
Tilt Table
T bl Assembly
A
bl
(20121912G1)
Reflector Interface
Fitting Assembly
(20122185G1) 3X
Tower Strong
Back Assembly
(20121911G1)
Ka-Band
Antenna L-Fixture
Assembly
(20121910G1)
Calculated Weight (less reflector and tower) = 575 lb
Slide 30
L-Fixture Lifting Configuration
L-Fixture
Lift Beam Assembly
Tower Strong Back/Flotron Configuration
Plate Assembly,
Flotron
Installation
Tower Strong
Back Lift Beam
A
Assembly
bl
Flotron
(to be
supplied
li d
by LMCSS)
Tower Strong Back
A
Assembly
bl
Slide 31
L-Fixture Finite Element Model
Vertical
Orientation
Horizontal
Orientation
Model: P1490-KaLFixture_06.MOD
Slide 32
L-Fixture Finite Element Model
PID 100003 & 100004 –
Tilt table support block
PID 100005 – Inner
I-Beam Support Blocks
PID 100002 – Tilt Table
standoff support block
PID 100006 &
100007 - I-Beam
PID 100008 I t f
Interface
Ring
Ri
PID 100009 &
100010 - Channel
PID 100011 –
Caster Mount Plate
PID 100001 – I-Beam
Support Blocks
Constraint at caster base
Slide 33
L-Fixture Turnover Configurations
Horizontal Turnover Configuration
45 Turnover Configuration
Vertical Turnover Configuration
Slide 34
Ka Band Antenna L-Fixture (Lockheed Martin)
Slide 35
Single Advanced Stirling Convertor (ASC) Test Stand for NASA
NASA-Glenn
Glenn
» Design and Analysis Requirements:
-
Develop a Test Stand with the required flexure assemblies at the test table to Test Stand and the Test Stand to
single ASC interfaces to ensure that the assembly meets the minimum frequency requirements
Perform Modal Analyses to determine the required stiffness at the interface between the single ASC and the Test
St d and
Stand
d the
th stiffness
tiff
and
d damping
d
i att the
th iinterface
t f
b
between
t
th
the T
Testt St
Stand
d and
d th
the ttestt ttable
bl
Run a Disturbance Analysis to predict the forces and accelerations at the load cells (SineVibe)
Provide an acceptance test plan and procedure for the testing and use of the single ASC Test Stand at NASA GRC
Single ASC
Load Cells
Test Stand
Test table interface
Slide 36
Stress Analysis of the STAR 2.4+ Core Structure transport fixture
For Orbital Sciences Corp. 2008
FE Model
Slide 37
MUOS
UOS Reflector
e ecto Mass
ass S
Simulators
u ato s for
o Lockheed
oc eed Martin
at
-
The mass simulators (shown below) are designed to comply with the mass properties and interface requirements
provided by LM. The simulators both accurately represent the mass, C.G. and interfaces of the flight hardware.
Installation procedure provided to LM
Static analysis
y of each simulator p
performed,, as well as bolted joint
j
analyses
y
at every
y connection
Complete a Functional Failure Modes and Effects Analysis (FFMEA)
MBA Mass Simulator
Legacy Mass Simulator
Slide 38
Motorized Pivot Structure Shipping Fixture (MPSSF) for STAR-2.7
STAR 2 7 Spacecraft for OSC
-
Designed to meet the OSC MGSE specifications in the General Environmental
Requirements and Test (GERT) Document
y
handling
g ((turnover)) loading
g conditions
Dynamic
Transportation loading conditions (quasi-static, random, sine sweep, and shock)
Various detailed connection analyses of both welded and bolted joints
Pivot
Frame
Base
Frame
Pivot
Arm
Actuators,
2x
MARS isolators
ANTONOV
isolators (exterior
positions, 8x)
(4x on +Z,
4x on –Z sides)
(interior positions, 8x)
(4x on +Z,
4x on –Z sides)
One isolator shown in
MARS and one shown
in ANTONOV
fi
ti
for
f clarity
l it
configurations
FEM: P1599_Turnover_45-MARS_020110.MOD
Slide 39
Falcon Hypersonic Vehicle for Lockheed Martin
• Lockheed Martin needs to assemble and test components of the
vehicle as well as the full vehicle assembly.
• The Falcon HVT-2 is a crewless, experimental hypersonic research
aircraft.
• PEI contracted to design, analyze, and manufacture several MGSE
components for testing of the LMSSC Falcon HTV-2 program.
Design Requirements:
» Meeting MGSE strength requirements:
-
Quasi-static and over-the-floor load cases
-
Lifting analysis
-
MGSE Proof Test Requirements
Slide 40
F l
Falcon
Hypersonic
H
i Vehicle
V hi l Multi-Use
M lti U D
Dolly
ll and
d L-Fixture
L Fi t
Slide 41
F l
Falcon
Hypersonic
H
i Vehicle
V hi l Multi-Use
M lti U D
Dolly
ll and
d L-Fixture
L Fi t
Slide 42
F l
Falcon
Hypersonic
H
i Vehicle
V hi l Proof
P
f Weights
W i ht
Slide 43
NAVSTAR Global Positioning System (GPS) III Phase B
• L
Lockheed
kh d M
Martin
ti needs
d tto safety
f t ttransportt and
d supportt components
t off the
th GPS III
satellite around the facility for various tests.
• PEI contracted to analyze several ground support and shipping equipment
Analysis Requirements:
» Meeting Lockheed Martin CIPS requirements:
-
Quasi-static
Quasi
static and over
over-the-floor
the floor load cases
-
Acoustic Vibration Testing
-
Thermal analysis
-
Proof Load Testing
Slide 44
NAVSTAR Global
Gl b l Positioning
P iti i System
S t
(GPS) III Phase
Ph
B
Absorber Hat Structure
• Static analysis for transportation on casters, mounted on jack stands, resting on foot plates
• Analyzed for the thermal environment and T-VAC testing
Constraint Set 1
Constraint Set 35
Slide 45
NAVSTAR Global
Gl b l Positioning
P iti i System
S t
(GPS) III Phase
Ph
B
Antenna Panel Acoustic Test Fixture
• Static analysis for transportation on casters, mounted on jack stands
• Analyzed for Acoustic Vibration Testing
• Analyzed for the Proof Load Assembly
Front Side of Assembly,
Antenna Panel and Antenna
Mass Elements Shown
Back Side of Assembly,
View of Antenna Mounting
Plate Support Beams
Slide 46
NAVSTAR Global
Gl b l Positioning
P iti i System
S t
(GPS) III Phase
Ph
B
V-Sensor Acoustic Vibe Fixture
• Static analysis for transportation on casters, mounted on jack stands
• Analyzed for Acoustic Vibration Testing
Slide 47
NAVSTAR Global
Gl b l Positioning
P iti i System
S t
(GPS) III Phase
Ph
B
V-Sensor T-Cycle Configuration
• Static analysis for transportation on casters for four configurations
• Analyzed for the thermal environment in each configuration
• Analyzed for the Proof Load Assembly for tall configurations
Slide 48
NAVSTAR Global Positioning System (GPS) III Phase B
Electronics Box Mass Simulators
• Created 3D design models and manufacturing drawings
• Managed fabrication vendors
Slide 49

PDF. - Pagnotta Engineering, Inc.

Transcription

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