Design, Analysis, d M f t i and Manufacturing

MGSE

Design, Analysis, d M f t iand Manufacturing

PAGNOTTA ENGINEERING, INC. COMPANY BACKGROUND

• Incorporated in June of 1996OUR MISSION • Based in Exton, PA

• Company founders have extensive experience in:» Architectural/Civil since 1980

» Aerospace Industry since 1982

OUR MISSION:To provide quality mechanical design and analytical services to our customers. We provide

» Aerospace Industry since 1982

» Vehicle Simulation Structures since 1991

• Since incorporation, PEI has completed over 400 projects in Architectural/Civil, Aerospace, Vehicle

creative solutions to complex problems utilizing both our

unique experience and cutting edge computer technology.

Simulation, Medical and Consumer Products, Power Generation, and other industries

• Please visit www.pageng.com for more information on our services experience and

We strive to exceed our customers expectations in

order to maintain our outstanding reputation. information on our services, experience and

personnel

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 Structural Analysis• Thermal and Non-Linear Structural Analysis• Mechanism Design and Analysis• Material Process and Testing Coordination• Manufacturing Detail and Assembly DrawingsManufacturing Detail and Assembly Drawings

PRIMARY ENGINEERING SOFTWARE TOOLS: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 solutionsD i l i d di ti / t f f t i d– Design, analysis, and coordination / management of manufacturing vendors

– Complete solution and delivery of hardware

• On-site engineering supportOn 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

MISC*4%

CIVIL STRUCTURES5%

COMMERCIAL PRODUCTS8%

POWER GENERATION5%

Industries Serviced: Percentage of Total Number of Contracts

MISC*

8%

CONSUMER PRODUCTS3%

DEFENSE HARDWARE2%

DER CONSULTINGMGSE FOR SPACE FLIGHT

SPACE FLIGHT HARDWARE20%

CIVIL STRUCTURES

COMMERCIAL PRODUCTS

CONSUMER PRODUCTS

DEFENSE HARDWARE

DER CONSULTING

FLIGHT SIMULATION

13%

FLIGHT SIMULATION17%

GENERAL AVIATION7%

INDUSTRIAL PRODUCTS3%

MGSE FOR SPACE FLIGHT HDWR13%

GENERAL AVIATION

INDUSTRIAL PRODUCTS

MGSE FOR SPACE FLIGHT HDWR

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 N d C ti• Sierra Nevada Corporation………………….Hagerstown, MD

• Rockwell Collins / STS……………………….Sterling, VA; Binghamton NY

• Boeing…………………………………………..Ridley Park, PA

• Northrop Grumman Baltimore MD• Northrop Grumman……………………..…….Baltimore, MD

• Keystone Helicopters……………………..….Coatesville, PA

• NASA Langley…………………………….……Hampton, VA

• PMC Engineering….….………………….……Pottstown, PAg g ,

• 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)

• Design and Analysis of AMC-21 Payload Module Shipping Fixture (OSC)

• Analysis of PIM Fixture, South Feed (LOCKHEED MARTIN)

• Analysis of Jitter Air Spring Assembly (LOCKHEED MARTIN)(LOCKHEED MARTIN)

• Analysis of Motorized Spacecraft Pivot Shipping Fixture (OSC)

• Design and Analysis of TVAC Rail System (OSC)

D i d A l i f MUOS M M d l

y p g y ( )

• Analysis of Raymond Platform (LOCKHEED MARTIN)

• Structural Analysis of ECHO-X Tooling Fixtures(LOCKHEED MARTIN)

• Design and Analysis of Single GPHS Test Stand• Design and Analysis of MUOS Mass Model(LOCKHEED MARTIN)

• Analysis of Range Fixture for JCSAT 12(LOCKHEED MARTIN)

D i d A l i f St 2 4 I t ti D ll

• 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)• Design and Analysis of Star 2.4+ Integration Dolly(OSC)

• Design and Analysis of Falcon MGSE Hardware including Multi-Use Dolly, L-Fixture, and Lifting Beams

• 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 GPSIIIBeams (LOCKHEED MARTIN)

• Design and Analysis of STAR 2.4+ Core Shipping Fixture (OSC)

• Analysis of Sirius S4 Lifting Fixtures (LOCKHEED MARTIN)

• Analysis of Various Fixtures for GPSIII(LOCKHEED MARTIN)

• Design and Fabrication of GPSIII Mass Models(LOCKHEED MARTIN)

Slide 7

EXAMPLES OF MGSE ENGINEERING SERVICES

PEI responsibilities: design analyze fabrication drawings

Satellite L-Fixture for Lockheed Martin

PEI responsibilities: design, analyze, fabrication drawings, manufacture, test, deliver finished product, FFMEA

L-FIXTURE:• 20 FEET LONG• WEIGHT = 3500 LBSWITH PROOF

WEIGHT

WITH SATELLITE

Slide 8


S t llit L Fi t f L kh d M ti

HornAbsorber

S/C Mass Element(61.38 in. offset forL-Fixture interface plate)

PID 3 –Vertical I-Beams


Mass PID 2 - Lateral I-Beams

Cold PlateMass Elements

PID 11

PID 4 -Horizontal I-Beams PID 11 –

S/C Interface Plate

I-Beams

PID 41 & 42 -Detailed I-Beam mesh

PID 12 & 13PID 12 & 13 -Caster Interface

Constraintat caster axle

PID 21-23 Jack Interface

PID 6 Jack Beam

PID 5 -Diagonal I-Beams

LongitudinalI-Beams

Slide 9

PID 6 Jack Beam P1404-LFrame-CDR-05.MOD



Mike Pagnotta, President Brian Dreibelbis, Staff Engineer

Slide 10


• OSC needs to safety ship their AMC-21 S/C Payload Module (PM) t Al t l (E t ) f i t l ti

AMC-21 Payload Module Shipping Fixture for Orbital Sciences Corp. (OSC)

(PM) to Alcatel (European customer) for equipment population.

• The populated PM must then be shipped back to OSC for integration.PEI contracted to develop the shipping fixture• PEI contracted to develop the shipping fixture

Design Requirements:» Fit in standard 747 shipping container» Fit in standard 747 shipping container

» Meeting OSC MGSE strength requirements:- Sine-sweep response analysis

- Random (PSD) spectrum ( ) presponse 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)

4 50

Sine Response, 1.3GY input, N101 (CG)

Fabricated 2 00

2.50

3.00

3.50

4.00

4.50

onse

[g's

]

RSS-magX-magY-magZ-magInput

shipping fixture mounted to shipping container base

0.00

0.50

1.00

1.50

2.00

0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00

Resp

o

PEI

MODE FREQNO. [Hz] T1 T2 T3 R1 R2 R3

1 5 192 0 498 0 014 0 000 0 013 0 514 0 000

MODAL EFFECTIVE MASS FRACTION

base 0 00 5 00 0 00 5 00 0 00 5 00 30 00 35 00 0 00

Frequency [Hz]designed the handling frame too!

1 5.192 0.498 0.014 0.000 0.013 0.514 0.0002 5.349 0.014 0.542 0.000 0.472 0.013 0.0003 10.450 0.000 0.000 0.000 0.000 0.000 0.9974 10.482 0.000 0.000 0.999 0.000 0.000 0.0005 12.889 0.488 0.000 0.000 0.000 0.472 0.0006 13.221 0.000 0.440 0.000 0.511 0.000 0.000

Sum = 1 000 0 997 1 000 0 997 1 000 0 998

Payload module being lowered over shipping

fixture

Slide 12

Sum 1.000 0.997 1.000 0.997 1.000 0.998


Handling Frame with Payload Module

Slide 13

Fi it El t A l i f P l d H dli F f OSC


Finite Element Analysis of Payload Handling Frame for OSC

Detail of stiffening gussetgusset

Rendered FE model of fixtureFE d l f fi t ith l d

Slide 14

FE model of fixture with payload


Flotron Turnover Configuration

Slide 15


Handling Frame Supporting Payload Module at OSC Facility

Slide 16

Payload Module Handling Fixture on Flotron


Payload Module Handling Fixture on Flotron

Slide 17


Handling Frame Supporting Payload Module During Flotron Turn-over Operations at OSC Facility

Slide 18


56 5656 56123456123456123456123456

31

Finite Element Analysis of Payload Handling Frame for OSC, Turn-over Configurations

151” 167”

4564565656

44444444444444444444444444

44444444444444444444444444

Y

X Y

Z

456456456456

12

X

Y

Z

X

Y

Z

Slide 19

L Frame for Orbital Sciences Corporation (OSC)


L-Frame for Orbital Sciences Corporation (OSC)

• PEI developed fixture per OSC internal requirements.

• Created 3D design model and all manufacturing drawingsCreated 3D design model and all manufacturing drawings

• Performed all stress analyses

L-Frame Spacecraft

Fixture

Slide 20

L F W ld d A bl


L-Frame Welded Assembly

Slide 21


L-Frame Turn-over Configuration

Slide 22

L F ith P l d


L-Frame with Payload

Slide 23

Thermal-Vacuum (TVAC) Chamber Rail and Exterior Hoist Structure for Orbital


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 performed all stress analysesp y

Thermal-Vacuum Chamber Rail and exterior hoist beam Payload fixture rolling into

C

Slide 24

structureTVAC chamber


L-frame in Thermal-Vacuum Chamber at Lockheed Martin - Newtown, PA

Slide 25

A l i f H i l R Fi f kh d M i N PA


Analysis of Horizontal Range Fixture for Lockheed Martin, Newtown, PA

Rendered Finite El t d lElement model

shown

Slide 26

Design and Analysis of JCSAT-9 C-Band Support Fixture for


Design and Analysis of JCSAT 9 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 Assembly Finite Element Model

First Stage

Flotron components prior to attachment of C-Band Assembly

2nd Stage

Slide 28

Stage


Complete Range Assembly Finite Element Model

Range Fixture Finite Element Model

Slide 29


Tilt T bl A blReflector

Ka Band Antenna L-Fixture (Lockheed Martin)

Tilt Table Assembly (20121912G1)

Reflector Support Frame

Assembly (20122178G1)PEI responsibilities:

design, analyze,Reflector Interface Fitting Assembly (20122185G1) 3X

design, analyze, fabrication drawings,

manufacture, test, deliver finished product, FFMEA

Ka-Band Antenna L-Fixture Assembly (20121910G1)

Tower Strong Back Assembly (20121911G1) (20121910G1)(20121911G1)

Calculated Weight (less reflector and tower) = 575 lb

Slide 30


Tower Strong Back/Flotron ConfigurationL-Fixture Lifting Configuration

Plate Assembly,Flotron

Installation Tower Strong Back Lift Beam

A bl

L-Fixture Lift Beam Assembly

Flotron (to be

li d

Assembly

supplied by LMCSS)

Tower Strong Back A blAssembly

Slide 31


L-Fixture Finite Element Model

Horizontal Orientation

Vertical Orientation

Slide 32

Model: P1490-KaLFixture_06.MOD


PID 100003 & 100004 –

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 Ri

standoff support block

Interface Ring

PID 100009 & 100010 - Channel

PID 100001 – I-Beam Support Blocks

Constraint at caster base

PID 100011 –Caster Mount Plate

Slide 33


L-Fixture Turnover Configurations

45 Turnover Configuration Vertical Turnover Configuration Horizontal Turnover Configuration

Slide 34


Ka Band Antenna L-Fixture (Lockheed Martin)

Slide 35

Single Advanced Stirling Convertor (ASC) Test Stand for NASA-Glenn


Single Advanced Stirling Convertor (ASC) Test Stand for NASA 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 d th tiff d d i t th i t f b t th T t St d d th t t t blStand and the stiffness and damping at the interface between the Test Stand and the test table

- 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

Slide 36

Test table interface


Stress Analysis of the STAR 2.4+ Core Structure transport fixture

For Orbital Sciences Corp. 2008

FE Model

Slide 37

MUOS Reflector Mass Simulators for Lockheed Martin


» Design and Analysis Requirements:- 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 of each simulator performed, as well as bolted joint analyses at every connection

UOS e ecto ass S u ato s o oc eed a t

y p , j y y- Complete a Functional Failure Modes and Effects Analysis (FFMEA)

MBA Mass Simulator

Slide 38

Legacy Mass Simulator

Motorized Pivot Structure Shipping Fixture (MPSSF) for STAR 2 7 Spacecraft for OSC


Motorized Pivot Structure Shipping Fixture (MPSSF) for STAR-2.7 Spacecraft for OSC» Design and Analysis Requirements:

- Designed to meet the OSC MGSE specifications in the General Environmental Requirements and Test (GERT) Document

- Dynamic handling (turnover) loading conditions

Pivot Frame

y g ( ) g- Transportation loading conditions (quasi-static, random, sine sweep, and shock)- Various detailed connection analyses of both welded and bolted joints

Base Frame

Actuators, 2x

Pivot Arm 2xArm

FEM: P1599_Turnover_45-MARS_020110.MODOne isolator shown in MARS and one shown

in ANTONOV fi ti f l it

MARS isolators (interior positions, 8x)

(4x on +Z, 4x on –Z sides)

ANTONOV isolators (exterior

positions, 8x)(4x on +Z,

4x on –Z sides)

Slide 39

configurations for clarity


• Lockheed Martin needs to assemble and test components of the

Falcon Hypersonic Vehicle for Lockheed Martin

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:Design Requirements:» Meeting MGSE strength requirements:

- Quasi-static and over-the-floor load cases

- Lifting analysisLifting analysis

- MGSE Proof Test Requirements

Slide 40

F l H i V hi l M lti U D ll d L Fi t


Falcon Hypersonic Vehicle Multi-Use Dolly and L-Fixture

Slide 41


F l H i V hi l M lti U D ll d L Fi tFalcon Hypersonic Vehicle Multi-Use Dolly and L-Fixture

Slide 42

F l H i V hi l P f W i ht


Falcon Hypersonic Vehicle Proof Weights

Slide 43


L kh d M ti d t f t t t d t t f th GPS III

NAVSTAR Global Positioning System (GPS) III Phase B

• Lockheed Martin needs to safety transport and support components of the 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 and over-the-floor load casesQuasi static and over the floor load cases

- Acoustic Vibration Testing- Thermal analysis

- Proof Load Testing

Slide 44

NAVSTAR Gl b l P iti i S t (GPS) III 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 35Constraint Set 1 Constraint Set 35

Slide 45



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



V-Sensor Acoustic Vibe Fixture

• Static analysis for transportation on casters, mounted on jack stands


• Analyzed for Acoustic Vibration Testing

Slide 47



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 thermal environment in each configuration

• Analyzed for the Proof Load Assembly for tall configurations

Slide 48



• Created 3D design models and manufacturing drawings

• Managed fabrication vendors

NAVSTAR Global Positioning System (GPS) III Phase BElectronics Box Mass Simulators

• Managed fabrication vendors

Slide 49

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