(Dspace Aero Iitb) 09D01006

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Design and Integration of Ground Station
Of Pratham

AE 219: Supervised Learning Project Report

Tushar Jadhav (09D01006)

Under the guidance of
Prof. P.M. Mujumdar

Department of Aerospace Engineering
Indian Institute of Technology Bombay
November 2010

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Acknowledgment
I would like to express my sincere gratitude towards my guide
Prof. P.M. Mujumdar and Prof. K.P. Ray for their invaluable
support and guidance. We would also like to thank SAMEER and
Aerospace Department personnel for the technical and non
technical support.


Introduction
In the 21st century, satellites have become an essential technology for
modern life. Among the important application of satellites are
telecommunication, earth and space observation, global resource monitoring,
military observation, global position (GPS), micro-gravity science and many
others.
Satellites are launched from earth by the space shuttle, from high-
flying air- planes, or from ground based rockets. Once lunched, the payloads
must reach proper elevation and escape velocity to to be boosted into orbit .Low
Earth Orbiting(LEO) satellites are visible for only a period of time from the point
of view of an observer on earth. They can dump data to the Ground Station when
they pass by a Ground Station area. Therefore, the Ground station plays a very
important role in the communication with the satellites in the orbit. They are
our only source of interaction with the satellite; and hence it is very important to
have a very good communication link between the ground station and the
satellite/space segment.
The Supervised Learning project aims at designing a Ground
Station(mechanical part) that allow automatic tracking of the satellites mainly
PRATHAM. The project is in the testing phase having undergone critical design
review at IIT Bombay. The report describes, in detail, the tasks completed as a
part of this project towards the design of the Ground station integration and
maintenance steps of it. We have design GS using standard process of design and
hence the report. The important topics in this design are
Need statement
Stakeholders
Requirements
Function Decomposition
Concept Generation

Concept Evaluation
Manufacturing or procuring of individual part
Integrating
Maintenance


Need Statement
Design and build a system (Mechanical Part) above Aerospace terrace
That will use the yagi antennae and rotor to track Pratham with
pointing error of <10 deg with the TEC Accuracy of 1 TECU

In this design we will be using four yagi antennae two of 145 MHz and
two of 437 MHz frequency as decided by the communication team depending on
the gain and other parameters and the rotor YAESU G-5500 to point antennae as
it can rotate in both the planes azimuthal and elevation angle and satisfies our
need. Aerospace department satisfies need of field of view of 30 deg elevation
throughout the 360 deg of azimuth and also it is closed to satellite laboratory
and we have easy access to it.


Stakeholder
People, group or organization that can affect the design or get affected
by decision of the design team are known as Stakeholders. Stakeholders are an
integral part of a project. They are the end-users or clients, the people from
whom requirements will be drawn, the people who will influence the design and,
ultimately, the people who will reap the benefits of your completed project.
1. Active Stakeholders
Satellite team
Other institute or organization like IPGP or NARL
Manufacturer or distributer of the parts
Aerospace Department
2. Passive Stakeholders
Estate office
Professor
Birds like Crows, pigeon
CASDE
Ground station will be only link between satellite and ground.
Ground station accuracy will affect output purity. The manufacturers of the
components that will get used for the GS will be stakeholders. The GS will be on
the aerospace terrace as and will have GS room in the department itself.
For GS we might need to take permission of Estate office. Professors
are the guide of the project hence their decision will directly affect the design.
Birds will use GS mainly antennae as place to sit causing unwanted bending in
the antenna elements.CASDE room is used as GS room. Change in the decision of
CASDE causes impact on the design.

Requirements
A requirement is a singular documented need of what a particular
product or service should perform or should not perform. Sets of requirements
are used as inputs into the design stages.Constraints, demands, necessities,
needs or parameters that must be met or satisfied by the system or the product.
Requirements of the individual part of the GS.
Primary requirements are the one who should be satisfied at any cost
1. Primary Requirements:-
a) Requirements of yagi antenna(other than electrical
requirements)
The antennae should remain parallel to each other (maximum offset
between any two antennae should be less than 10 degree)
The deviation of antennae from their parallel configuration should
be measurable after mounting
The elements should not bend in the plane due to mechanical stress
or load of wind
The distance between 2 antenna should be greater than
2D^2/lambda so that there won't be interference.
The antennae elements should not rotate out of the plane and the
rotation angle should be measurable with an accuracy of 1 degree
The soldering of the coaxial cables and baluns on the baluns on the
antenna needs to be robust and should be protected from rain and
shorting
The balun should be supported so that it doesnt hang from the
soldered joint
The antennae must not clash with the ground or the mounting
mechanism while rotating.
The antenna should be as far away from any radiating systems as
possible (at least 20m away)
The antenna assembly should be easy to assemble and disassemble

so that its location can shift if needed.
The clamps should allow for the change in spacing and rotation of
the antennas elements

In these requirements, electrical requirements (like length, diameter,
and material of the elements) are not included as they are fixed by the
simulations and testing. In this case as our payload is measuring TEC using
Faraday Rotation method that is by measuring change in the angle of wave from
the satellite. Antennas pointing accuracy will mainly determine the output
purity on the ground hence TEC measurement. And after the system is set up,
offset in the antenna should be measurable so that in the further calculation it
can be incorporated. Distance between the antennae and also radiating system
makes sure that there won't be any constructive interference and hence changes
in the gain pattern

b) Mount Requirement

The antenna mount should be durable and should not act as an
antenna director
The antennae should be mounted at 45 degrees to the beam on
which it is mounted
Mount is the structure on which antenna will be mounted. Mounting
antenna at 45 deg makes sure that the effect of the mount on the antenna will
equal on both the planes and hence get cancelled.

c) Base Requirement
The distance between the ground and mounts should be greater
than 2D^2/lambda.
The antennae must not clash with the ground or the mounting

mechanism while rotating.
The Ground station should be mounted on a structurally stable base.
Base supports the assembly of the antenna. To avoid the effect of the
ground reflection, base has height requirement.

d) System Requirement
The field of view of the antenna should be from 30 degree elevation
angle throughout 360 of azimuthal
The LNA and filter should be as close to the antenna as possible
(max distance between them should not exceed 1m)
There should be no obstructions close to the antennae that might
cause scattering. (i.e. No obstruction within 4-5m radius area)
The electrical connections of the LNA and rotor must be waterproof
and RF grounded.
There should not be any equipment that runs on a clock close to the
Antenna system e.g computer (distance >4-5m)

These are the requirement that system should satisfy even with the
other individual requirements of the sub parts. In the case of LEO satellite,
satellite pass starts from 0 elevation and some azimuthal to some maximum
elevation and again to 0.In our satellite we will be taking data only if elevation is
greater than 30 degree. Wire between antenna and filter or LNA adds noise to
the signal.

e) Systems other Requirements:-
There should be good RF grounding
The Coaxial cables should have minimum loss
The rotor should not experience any unbalanced moments while
tracking. When it is not tracking, it should be in the parking position
It should be possible to control the rotor manually or autonomously

Easily accessible for dismantling in case of emergency or up
gradation

2. Secondary requirements:-
a) System's Requirements
The GS components should not be very far away from the antenna
mounts (10m)
The distance between the ground and the mount should be
adjustable
The Ground station region should be demarked from the
surroundings using barricades so that someone doesnt fiddle with
the setup unknowingly.
The Coaxial cables should never be under mechanical stress
The connectors should be rugged and have good RF properties
shorting (low losses < 1dB)


Current Ground station

Problem with the Current Ground station
Main problem with the current ground station is does not satisfies
most of the primary requirements like height, pointing accuracy, over design,
overweight.


Function Decomposition
Function is the logical flow of energy (including static forces), material,
or information between objects or the change of state of an object caused by one
or more of the flows. It's the description of the steps that system has to follow
irrespective of the design.

1. Top level Functions:-
1) Rotate the antenna according to the pass of the satellite
2) Receive the data from the satellite and transfer it to computer.

1. Dividing in to Sub functions
(a) Rotate the antenna according to the pass of the satellite and
stresses and strains in the structure
1. Signals from nova to rotor controller
Input:-from the software NOVA to rotor controller
Function:-Converts it in to suitable form
Output:-Converted signal as input to rotor
2. Rotor rotates the rod accordingly
Input:-Converted signal to rotor
Function:-Rotor takes it as input and process it
Output:-Rotates the rotor
3. Force transfer in the mount.
4. Bending moment at the rotor screw.
Input:-Weight of the components and the bending moment at the
mount
Function:-Change in the position of the centre of the mass
Output:-Bending moment at the screws of the rotor

5. Force or stress in to the system

Input:-Weight of the components and the bending moment at the
mount
Function:-Force, weight or stress in the structure
Output:- Structure in the Stress or Strain
(b) Receive data from satellite and transfer it to computer
1. Transfer of wave to feed element
Input:-Wave from the satellite
Function:-Transfer of the wave to feed element from director and
reflector
Output:-Collection of wave at feed element
2. Conversion of wave in to voltage:
Input:-Wave from director and reflector
Function:-Sets up the wave at feed element
Output:-Converts it in to voltage
3. Processes on the data using AD8302
Input:- 2 inputs from yagi to AD8302 one from 145MHz yagi and
other from 437 MHz
Function:-Processes on it
Output:-Ratio of intensity
4. Data to the computer
Input:-Data from AD8302
Function:-Transmission through wire
Output:-Data in the computer


Concept Generation
Concept generation is the process where designing team generates
concept by either brain storming or literature survey or experts opinion. In this
concepts are generated and other feasible concepts but not consider for obvious
reasons like cement structure for the base or due to cost and time factors.
Here are the concepts of the important parts of the system.
A) Yagi Antenna (Material and dimensions of the antenna elements are fixed
by the simulation.)
Boom Materials:-We can use boom of wood, iron, aluminium.
Shape of the Boom:-We can make boom of the circular, square,
pentagonal etc

B) Attaching mechanism of elements to the boom
Coupler-One piece with elements passing through it and held
directly using screws. Three piece in which elements are held by
friction and holding parts with screws. Elements directly welded to
the coupler.
Welding the elements directly to the central boom
A homogeneous part with integrated coupler and elements
C) Base support for the antennae:-
Shapes of the support:-We can make the support of the shape
I,Z.M,E
Cross section of the rod:-Circular, square etc.
Materials:-PVC, aluminium, steel etc
D) Antenna mounting mechanism:-
Thread and bolt mechanism-Treading to the boom and using bolt.
Welding antenna to the rod.
Homogeneous antenna and mount rod

A socket to hold the antenna a) with the help of threads b)with the
help of weld c)with the help of screws d)homogeneous and to
mount that socket to central rod by the one of the methods.
Clamps like L or C between antenna and mount.
E) Base:(To mount rotor and support the system)
Shape: We can use table type structure ,tripod, Quadra-pod, solid
structure, on a single rod
If table or tripod then support of cross section L, C, square,
circular with the connecting mechanism of the parts by screws
or weld and plain or L shape or other shapes or Combinations
of this as mounting surface of the rotor.
If solid structure then of wood, steel, iron, aluminium
connected to each other by welding or screws.
Material:-We can use plastic, steel, aluminium, iron.


Concept Evaluation
A product concept evaluation is a type of evaluation in which the
product concept developed so far is reviewed by the user group. Generally,
product concept evaluations are aimed at selecting or optimizing product
concepts based on the preferences of the user group and other stakeholders.
In this Concepts are evaluated against requirements of the user.
A) Yagi antenna
a) Shape of boom
Selection criteria:
Ease of avaibility
Restriction on motion of the coupler
Ease of mounting on the base and offset after long time

Weightage Square Circular
Ease of Avaibility 3 3 4
Restriction on the
motion of the coupler
4 4 1
Ease of mounting and
error
5 4 3
Total 45 31

Clearly square boom has been selected for the boom which can stop
roll motion and can be easily mounted at 45 deg on the base in accordance to
requirement.
B) Attaching mechanism of the antenna to the boom
Selection criteria
Ease of manufacturing
Easily replacibility

Changes in the parameter like length

Weightage Coupler Welding
elements to the
boom
Homogeneous
piece
Ease of
manufacturing
3 3 4 1
Easily replacibility of
the elements
5 5 1 1
Change in the
parameters at the
time of
manufacturing or
later
5 4 1 5
Total 54 22 33

Clearly coupler has highest score in evaluation hence selected.
C) Base support for the antenna
1. Shape of the base rod
I shape is selected irrespective of the evaluation as it fits in to the rotor
and satisfies requirement posed by Payload team of having antennae of same
frequency at the opposite end of the square
2. Cross section of the rod:
Cross section of the rod selected to be is square for the same reason
by which we selected square rod for boom. Only the change is instead of coupler
it has an advantage in mounting antenna at a 45 degree angle.
D) Antenna mounting mechanism
Selection Criteria

Restriction on the motion of the antenna
Accuracy in maintenance of the plane of the antenna
Ease assembling and dissembling

Weightage Welding
antenna to
mount
Homogeneous
antenna and
mount
Plate or L 0r C
clamp or
combinations
Ease of
manufacturing
3 4 1 5
Restriction on
motion of the
antenna (roll)
5 5 5 5
Accuracy in
maintenance of
the plane of the
antenna
5 3 5 4
Ease of
assembling and
disassembling
4 0 0 5
Total 52 53 80

Clearly L or C or Plate to hold antenna to mount is selected.
E) Base to mount rotor and support the system
Selection criteria
Stability
Over design
Assembling and dissembling
Weight


Weightage Rod having
support
Table Solid Structure
Weight 4 5 4 3
Stability 5 3 4 5
Over design 4 3 3 2
Ease of
manufacturing
3 2 4 2
Assembling and
dissembling
3 4 4 3
Total 65 72 60

Table structure is used to support antenna and assembly.
F) Material selection
Evaluating concepts of the material for the most of the parts.
Weightage Aluminium PVC Wood Iron
Weight 5 4 5 5 2
Avaibility 3 5 2 3 5
Functional
period
4 5 3 3 4
Ease of
processing
3 4 4 4 3
Total 67 55 58 50
So the material for the most of the purpose is Aluminium


Concepts for the other requirements

To protect soldering from rain, it will be cover by the cap. To make it
strong and not to let hanged from the soldering; it will be tied to the
boom with lacing.
To avoid interference with radiating body, system will be kept 20m
from it.
With the permission of estate office RF grounding can be possible.
Coaxial cable RS 232 having loss of 1dB will serve our purpose.
Filter and LNA will be kept in waterproof box placed close to antenna.

Design

After following design process till concept evaluation, our system will have:

Antenna having square boom of aluminium and a coupler to hold
elements to the boom.
Elements will pass through and will be held by the srews.These
coupler will be fasten to the boom with the help of friction that is with
the screw touching to boom.
A socket at an angle of 45 degree to the mount to fix antenna to the
square boom.
Socket will be fixed to the mount with the help of screws.
Two parts of a flange (square shape) and Weber (square shape) will
be fasten with the help of L clamps, plates and screws.
Weber will have slave as an interface between rod and rotor.
Rotor will sit on the plate that is between midpoints of the opposite
sides of top square frame of the table and will be fixed to it with the
help of nut and bolts.

Square frame at the top and legs will be of I beam. Due to this
structure can easily be supported by trusses i.e. connecting trusses
will be easy
System will be more stabilized by adding square frame at the base of
2m side and connected to central vertical structure.

Wind Loading
Loading due to wind is called as wind loading. Maximum value of wind
in the Mumbai over the year is 10 m/s and maximum area that is exposed to the
wind is 1m^2.Hence there will not be appreciable force to take in to account. So
need to worry about wind loading.


Integration Sequence

The sequence in which system will be integrated.
To start integration initially we need all the components ready and
enough tools for it. All subparts should be at aerospace terrace and all should be
correctly holed and of correct length. Before starting integration make sure that
the all parts are in sufficient quantity especially socket so that we can measure
angle between flange and diagonal of socket after fixing and choose which are
close to the 90 degree.
Steps involve in the Integration
Assemble the antenna and characterise it for the 50 ohm.
Connect base to vertical legs.
Connect top square frame.
Connect L shape beam and plate between midpoints of the sides
having holes to fix rotor.
Connect trusses.
Fix the rotor by using some sort of stand to stand.
Connect sockets to half parts of the flange
Put the Weber beam in to the rotor and fix it in the middle with the
help of slave.
Connect half parts of the flange of the weber.
Connect the antennae in to the socket and filter, LNA on the weber.
Connect the wires
Use theodolite to measure the offset in the angels of the antenna.


Possible Errors
All antennae may not be parallel
Elements may not be in plane or may not be parallel
Uneven ground
Solder gets removed
Rotor starts vibrating or tumbling
Screw get removed
Co-axial wire or soldering get removed.

Maintenance
Ground station needs maintenance once in fifteen day. In this we will
use exact reverse process for the disintegration and change the faulty part. At
each time we will characterise the antennae and will reintegrate the system.


New Ground Station

(Dspace Aero Iitb) 09D01006

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